DEVELOPMENT DOCUMENT

                     for

EFFLUENT LIMITATIONS GUIDELINES AND STANDARDS

                   for the

 NONFERROUS METALS FORMING AND METAL POWDERS

            POINT SOURCE CATEGORY

                  VOLUME III

                Lee M. Thomas
                Administrator
             Lawrence J. Jensen
      Assistant Administrator for Water
           William A. Whittington
                  Director
  Office of Water Regulations and Standards
      Devereaux Barnes, Acting Director
       Industrial Technology Division
         Ernst P.  Hall, P.E., Chief
          Metals Industries Branch
              Janet K.  Goodwin
          Technical Project Officer
               September 1986
    U.S.  Environmental Protection Agency
               Office of Water
  Office  of Water Regulations and Standards
       Industrial Technology Division
           Washington, D.C.   20460

-------

-------
  iis document is divided into three volumes.   Volume I contains'Sections




I through IV.  Volume II contains Sections V and VI..  Volume III contains



Sections VII through XVI.
   SECTION I




   SECTION II




   SECTION III




   SECTION IV




   SECTION V




   SECTION VI




   SECTION VII




   SECTION VIII




   SECTION IX



   SECTION X



   SECTION XI




   SECTION XII




   SECTION XIII




   SECTION XIV




   SECTION XV




   SECTION XVI
SUMMARY AND CONCLUSIONS




RECOMMENDATIONS




INTRODUCTION




INDUSTRY SUBCATEGORIZATION




WATER USE AND WASTEWATER CHARACTERISTICS




SELECTION OF POLLUTANT PARAMETERS




CONTROL AND TREATMENT TECHNOLOGY




COST OF WASTEWATER TREATMENT AND CONTROL'




BEST PRACTICABLE CONTROL TECHNOLOGY CURRENTLY AVAILABLE




BEST AVAILABLE TECHNOLOGY ECONOMICALLY ACHIEVABLE




NEW SOURCE PERFORMANCE STANDARDS




PRETREATMENT STANDARDS




BEST CONVENTIONAL POLLUTANT CONTROL TECHNOLOGY




ACKNOWLEDGMENTS




GLOSSARY




REFERENCES

-------

-------
 Section
                             CONTENTS
 II
III
IV
V
VI
VII
SUMMARY AND CONCLUSIONS                     1
  Methodology
  Technology Basis for Limitations
    and Standards

RECOMMENDATIONS                             7
  BPT and BAT Mass Limitations
  New Source Performance Standards
  Pretreatment Standards for Existing
    and New Sources

INTRODUCTION                              319
  Legal Authority
  Data Collection and Utilization
  Description of the Nonferrous
    Metals Forming Category
•  Description of Nonferrous Metals
    Forming Processes

INDUSTRY SUBCATEGORIZATION                385
       Evaluation and Selection of
    Subcategorization Factors
  Production Normalizing Parameter
    Selection
  Description of Subcategories

WATER USE AND WASTEWATER CHARACTERISTICS  413
  Data Sources
  Water Use and Wastewater Characteristics

SELECTION OF POLLUTANT PARAMETERS        1119
  Rationale for Selection of Pollutant
    Parameters
  Description of Pollutant Parameters
  Pollutant Selection by Subcategory

CONTROL AND TREATMENT TECHNOLOGY         1311
  End-of-Pipe Treatment Technologies
    Major Technologies
    Major Technology Effectiveness
    Minor Technologies
  In-Process Pollution Control Techniques

-------
                      CONTENTS (Continued)
Section
VIII
                                          Page
IX
XI
COST OF WASTEWATER TREATMENT AND CONTROL  1461
  Summary of Cost Estimates
  Cost Estimation.Methodology
  Cost Estimates for Individual Treatment
    Technologies
  Compliance Cost Estimation
  Nonwater Quality Aspects

BEST PRACTICABLE CONTROL TECHNOLOGY       1553
  CURRENTLY AVAILABLE
    Technical Approach to BPT
    Lead-Tin-Bismuth Forming Subcategory
    Magnesium Forming Subcategory
    Nickel-Cobalt Forming Subcategory
    Precious Metals Forming Subcategory
    Refractory Metals Forming Subcategory
    Titanium Forming Subcategory
    Uranium Forming Subcategory
    Zinc Forming Subcategory           <
    Zirconium Hafnium Forming Subcategory
    Metal Powders Subcategory
    Application of Regulation in Permits

BEST AVAILABLE TECHNOLOGY ECONOMICALLY    1757
  ACHIEVABLE
    Technical Approach to BAT
    BAT Option Selection
    Regulated Pollutant Parameters
    Lead-Tin-Bismuth Forming Subcategory
    Magnesium Forming Subcategory
    Nickel-Cobalt Forming Subcategory  '
    Precious Metals Forming Subcategory
    Refractory Metals Forming Subcategory
    Titanium Forming Subcategory
    Uranium Forming Subcategory        ;
    Zinc Forming Subcategory
    Zirconium-Hafnium Forming Subcategory
    Metals Powders Subcategory

 NEW SOURCE PERFORMANCE STANDARDS         1915
   Technical Approach to NSPS
   NSPS Option Selection
   Regulated Pollutant Parameter
   New Source Performance Standards
                               11

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Section
XII
XIII


XIV

XV

XVI
                      CONTENTS (Continued)
PRETREATMENT STANDARDS
  Introduction of Nonferrous Metals
    Forming Wastewater into POTW
  Technical Approach to Pretreatment
  PSES and PSNS Option Selection
  Regulated Pollutant Parameters
  Pretreatment Standards

BEST CONVENTIONAL POLLUTANT CONTROL
  TECHNOLOGY

ACKNOWLEDGEMENTS

GLOSSARY

REFERENCES
Page

2013
2187


2189

2191

2211
                               111

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-------
                          LIST OF TABLES
 Table

 III-l




 III-2



 III-3


 III-4


 IV-1



 V-l


 V-2

 V-3



 V-4




 V-5




 V-6


V-7



V-8
  Title                              page

Metal  Types Not Formed on a            356
  Commercial  Scale, or for which
  Forming Operations Generate No
  Wastewater

Metal  Types Covered Under the          357
  Nonferrous  Metals Forming
  Category

Years  Since Nonferrous Forming         358
  Operations  Began at Plant

Nonferrous Metal Production by         359
  Product Formed in 1981

Number of Plants Discharging           411
  Nonferrous  Metals Forming
  Wastewater, By- Subcate'gory

Number of Samples Per Waste            478
  Stream, By  Subcategory

Sample Analysis Laboratories           483

Nonpriority Pollutants Analyzed        484
  for During  Sampling Effort
  Supporting  This Regulation

Results of Chemical Analyses of        486
  Sampled Lead and Nickel Extrusion
  Press and Solution Heat Treatment
  Contact Cooling Water

Results of Chemical Analyses of        487
  Sampled Lead, Nickel, and
  Precious Metals Rolling Spent
  Emulsions

Lead-Tin-Bismuth Rolling Spent         488
  Emulsions

Lead-Tin-Bismuth Rolling Spent         489
  Emulsions Raw Wastewater
  Sampling Data

Lead-Tin-Bismuth Rolling Spent         492
  Soap Solutions
                             v

-------
Table

V-9


V-10


V-ll


V-12



V-13



V-14




V-15


V-16


V-17


V-18



V-19



V-20



V-21
LIST OF TABLES (Continued)

      Title                             Page

   Lead-Tin-Bismuth Rolling Spent        493
     Neat 'Oils

   Lead-Tin-Bismuth Drawing Spent        494
     Emulsions

   Lead-Tin-Bismuth Drawing Spent        495
     Soap Solutions

   Lead-Tin-Bismuth Drawing Spent        496
     Soap Solutions Raw Wastewater
     Characteristics

   Lead-Tin-Bismuth Extrusion Press      497
     or Solution Heat Treatment  ;
     Contact Cooling Water

   Lead-Tin-Bismuth Extrusion Press      498
     Solution Heat Treatment Contact
     Cooling Water Raw Wastewater
     Characteristics

   Lead-Tin-Bismuth Extrusion Press      501
     Hydraulic Fluid Leakage

   Lead-Tin-Bismuth Swaging Spent        502
     Emulsions

   Lead-Tin-Bismuth Continuous Strip     503
     Casting Contact Cooling Water

   Lead-Tin-Bismuth Continuous Strip     504
     Casting Contact Cooling Water
     Raw Wastewater Characteristics

   Lead-Tin-Bismuth Semi-Continuous      506
     Ingot Casting Contact Cooling
     Water

   Lead-Tin-Bismuth Semi-Continuous      507
     Ingot Casting Contact Cooling
     Water Raw Wastewater Characteristics

   Lead-Tin-Bismuth Shot Casting Con-    510
     tact Cooling Water
                            VI

-------
                   LIST OF TABLES  (Continued)
Table

V-22




V-23


V-24


V-25




V-26


V-27




V-28

V-29

V-30


V-31


V-32


V-33


V-34


V-35

V-36
  Title                              Paqe
Lead-Tin-Bismuth Shot Casting         511
  Contact Cooling Water Raw
  Wastewater

Lead-Tin-Bismuth Shot Forming Wet     514
  Air Pollution Control Slowdown

Lead-Tin-Bismuth Alkaline Cleaning    515
  Spent Baths

Lead-Tin-Bismuth Alkaline Cleaning    516
  Spent Baths Raw Wastewater
  Sampling Data

Lead-Tin-Bismuth Alkaline Cleaning    519
  Rinse

Lead-Tin-Bismuth Alkaline Cleaning    520
  Rinse Raw Wastewater Sampling
  Data

Magnesium Rolling Spent Emulsions     524

Magnesium Forging Spent Lubricants    525

Magnesium Forging Contact Cooling     526
  Water

Magnesium Forging Equipment Cleaning  527
  Wastewater

Magnesium Direct Chill Casting Con-   528
  tact Cooling Water

Magnesium Surface Treatment Spent     529
  Baths

Magnesium Surface Treatment Spent     530
  Baths Raw Wastewater Sampling Data

Magnesium Surface Treatment Rinse     535

Magnesium Surface Treatment Rinse     536
  Raw Wastewater Sampling Data
                            vn

-------
                    LIST OF TABLES  (Continued)
 Table

 V-37


 V-38


 V-39



 V-40


 V-41

 V-42


 V-43


 V-44


 V-45


 V-46




 V-47


 V-48

 V-49


V-50


V-51
 Title                                 page

 Magnesium Sawing or Grinding Spent     548
   Emulsions

 Magnesium Wet Air Pollution Control     549
   Slowdown

 Magnesium Wet Air Pollution Control     550
   Slowdown Raw Wastewater  Sampling
   Data

 Nickel-Cobalt Rolling  Spent Neat        552
   Oils                         :

 Nickel-Cobalt Rolling  Spent Emulsions   553

 Nickel-Cobalt Rolling  Spent Emulsions   554
   Raw Wastewater  Sampling  Data

 Nickel-Cobalt Rolling  Contact Cooling   558
   Water

 Nickel-Cobalt Rolling  Contact Cooling   559
   Water Raw Wastewater Sampling Data

 Nickel-Cobalt Tube  Reducing Spent       566
   Lubricants

 Nickel-Cobalt Tube  Reducing Spent       567
   Lubricants  Raw  Wastewater Sampling
   Data

 Nickel-Cobalt  Drawing  Spent Neat        570
   Oils

 Nickel-Cobalt  Drawing Spent Emulsions   571

 Nickel-Cobalt  Drawing Spent  Emulsions   572
   Raw Wastewater  Sampling Data

 Nickel-Cobalt  Extrusion Spent  >         574
   Lubricants

Nickel-Cobalt Extrusion Press and       575
   Solution Heat Treatment Contact
  Cooling Water
                            Vlll

-------
                    LIST  OF  TABLES  (Continued)
 Table


 V-52





 V-53


 V-54



 V-55


 V-56


 V-57



 V-58


 V-59


 V-60



 V-61



V-62





V-63


V-64
 Title                               Page


Nickel-Cobalt Extrusion Press and     576
  Solution Heat Treatment Contact
  Cooling Water Raw Wastewater
  Sampling Data

Nickel-Cobalt Extrusion Press         579
  Hydraulic Fluid Leakage

Nickel-Cobalt Extrusion Press         580
  Hydraulic Fluid Leakage Raw
  Wastewater Sampling Data

Nickel-Cobalt Forging Spent           584
  Lubricants

Nickel-Cobalt Forging Contact         585
  Cooling Water

Nickel-Cobalt Forging Contact         586
  Cooling Water Raw Wastewater
  Sampling Data

Nickel-Cobalt Forging Equipment       590
  Cleaning Wastewater

Nickel-Cobalt Forging Press           591
  Hydraulic Fluid Leakage

Nickel-Cobalt Forging Press           592
  Hydraulic Fluid Leakage Raw
  Wastewater Sampling Data

Nickel-Cobalt Metal Powder            595
  Production Atomization
  Wastewater

Nickel-Cobalt Metal Powder            596
  Production Atomization
  Wastewater Raw Wastewater
  Sampling Data

Nickel-Cobalt Stationary Casting      601
  Contact Cooling Water

Nickel-Cobalt Vacuum Melting          602
  Steam Condensate
                             IX

-------
 Table


 V-65



 V-66



 V-67




 V-68


 V-69



 V-70


 V-71



 V-72

 V-73


 V-74


 V-75



 V-76


V-77



V-78

V-79
LIST OF TABLES (Continued)

  Title                                 Page


   Nickel-Cobalt Vacuum Melting          603
     Steam Condensate Raw Wastewater
     Sampling Data

   Nickel-Cobalt Annealing and           60S
     Solution Heat Treatment
     Contact Cooling Water        i

   Nickel-Cobalt Annealing and           607
     Solution Heat Treatment
     Contact Cooling Water Raw    :
     Wastewater Sampling Data     '

   Nickel-Cobalt Surface Treatment        611
    • Spent Baths

   Nickel-Cobalt Surface Treatment        612
     Spent Baths Raw Wastewater
     Sampling Data

   Nickel-Cobalt Surface Treatment        620
     Rinse

   Nickel-Cobalt  Surface Treatment        621
     Rinse Raw Wastewater Sampling
     Data

   Nickel-Cobalt  Ammonia Rinse            635

   Nickel-Cobalt  Ammonia Rinse  Raw        636
     Wastewater  Sampling Data

   Nickel-Cobalt  Alkaline Cleaning        639
     Spent  Baths

   Nickel-Cobalt  Alkaline Cleaning        640
     Spent  Baths  Raw Wastewater
     Sampling  Data

   Nickel-Cobalt  Alkaline  Cleaning        646
    Rinse

   Nickel-Cobalt  Alkaline  Cleaning        647
    Rinse Raw Wastewater  Sampling
    Data                          '

   Nickel-Cobalt Molten  Salt Rinse       654

   Nickel-Cobalt Molten  Salt Rinse       655
     Raw Wastewater Sampling Data

-------
Table
LIST OF TABLES (Continued)

    Title
Paqe
V-80


V-81



V-82


V-83


V-84




V-85


V-86



V-87


V-88



V-89

V-90


V-91


V-92



V-93


V-94
    Nickel-Cobalt Sawing or Grinding     661
      Spent Emulsions

   Nickel-Cobalt Sawing or Grinding      662
     Spent Emulsions Raw Wastewater
     Sampling Data

   Nickel-Cobalt Sawing or Grinding      685
     Rinse

   Nickel-Cobalt Steam Cleaning          686
     Condensate

   Nickel-Cobalt Hydrostatic Tube        687
     Testing and Ultrasonic Testing
     Wastewater

   Nickel-Cobalt Dye Penetrant Testing   688
     Wastewater

   Nickel-Cobalt Dye Penetrant Testing   689
     Wastewater Raw Wastewater Sampling
     Data

   Nickel-Cobalt Wet Air Pollution       691
     Control Slowdown

   Nickel-Cobalt Wet Air Pollution       692
     Control Slowdown Raw Wastewater
     Sampling Data

   Nickel-Cobalt Electrocoating Rinse    697

   Precious Metals Rolling Spent Neat    698
     Oils

   Precious Metals Rolling Spent         699
     Emulsions

   Precious Metals Rolling Spent         700
     Emulsions Raw Wastewater
     Sampling Data

   Precious Metals Drawing Spent         705
     Neat Oils

   Precious Mstals Drawing Spent         706
     Emulsions
                             XI

-------
                   LIST OF TABLES (Continued)
V-96


V-97



V-98


V-99


V-100



V-101


V-102



V-103



V-104


V-105


V-106


V-107



V-108
                       Title                        •       Paqe
Precious Metals Drawing Spent         707
  Emulsions Raw Wastewater
  Sampling Data

Precious Metals Drawing Spent Soap    710
  Solutions

Precious Metals Metal Powder          711
  Production Atomization
  Wastewater

Precious Metals Direct Chill Casting  712
  Contact Cooling

Precious Metals Shot Casting Contact  713
  Cooling Water

Precious Metals Shot Casting Contact  714
  Cooling Water Raw Wastewater
  Sampling Data

Precious Metals Stationary Casting    717
  Contact Cooling Water

Precious Metals Semi-Continuous and   718
  Continuous Casting Contact Cooling
  Water                       :

Precious Metals Semi-Continuous and   719
  Continuous Casting Contact Cooling
  Water Raw Wastewater Sampling Data

Precious Metals Heat Treatment' Con-   723
  tact Cooling Water

Precious Metals Surface Treatment     724
  Spent Baths

Precious Metals Surface Treatment     725
  Rinse

Precious Metals Surface Treatment     726
  Rinse Raw Wastewater Sampling
  Data

Precious Metals Alkaline Cleaning     732
  Spent Baths
                           xii

-------
                    LIST OF TABLES (Continued)
 Table



 V-109



 V-110



 V-lll




 V-112



 V-113




 V-114



 V-115



 V-116




 V-117



 V-118




 V-119



 V-120




 V-121



 V-122



V-123
 Title                                Paqe
 Precious Metals Alkaline Cleaning     733
   Rinse

 Precious Metals Alkaline Cleaning     734
   Prebonding Wastewater

 Precious Metals Alkaline Cleaning     735
   Prebonding Wastewater  Raw
   Wastewater Sampling  Data

 Precious Metals Tumbling or           740
   Burnishing Wastewater

 Precious Metals Tumbling or           741
   Burnishing Wastewater  Raw
   Wastewater Sampling  Data

 Precious Metals Sawing or Grinding     745
   Spent  Neat Oils

 Precious Metals Sawing or Grinding     746
   Spent  Emulsions

 Precious Metals Sawing or Grinding     747
   Spent  Emulsions Raw  Wastewater
   Sampling Data

 Precious Metals Pressure Bonding       750
   Contact Cooling Water

 Precious Metals Pressure Bonding       751
   Contact Cooling Water Raw
   Wastewater  Sampling  Data

 Precious Metals  Wet Air Pollution  -    754
   Control Slowdown

 Refractory Metals Rolling Spent        755
   Neat Oils and  Graphite-Based
   Lubricants

Refractory Metals Rolling Spent        756
   Emulsions

Refractory Metals Drawing Spent        757
   Lubricants

Refractory Metals Extrusion Spent      758
  Lubricants
                           Xlll

-------
Table
LIST OF TABLES (Continued)

  Title
                                                           Page
V-124


V-125



V-126


V-127


V-128


V-129


V-130


V-131


V-132



V-133


V-134


V-135


V-136



V-137


V-138

V-139
   Refractory Metals Extrusion Press     759
     Hydraulic Fluid Leakage

   Refractory Metals Extrusion Press     760
     Hydraulic Fluid Leakage Raw
     Wastewater Sampling Data

   Refractory Metals Forging Spent       762
     Lubricants

   Refractory Metals Forging Contact     763
     Cooling Water

  •Refractory Metals Metal Powder        764
     Production Wastewater

   Refractory Metals Metal Powder        765
     Production Floor Wash Wastewater

   Refractory Metals Metal Powder        766
     Pressing Spent Lubricants

   Refractory Metals Surface Treatment   767
     Spent Baths

   Refractory Metals Surface Treatment   768
     Spent Baths Raw Wastewater
     Sampling Data

   Refractory Metals Surface Treatment   771
     Rinse

   Refractory Metals Surface Treatment   772
     Rinse Raw Wastewater Sampling^ Data

   Refractory Metals Alkaline Cleaning   778
     Spent Baths

   Refractory Metals Alkaline Cleaning   779
     Spent Baths Raw Wastewater Sampling
     Data

   Refractory Metals Alkaline Cleaning   781
     Rinse

   Refractory Metals Molten Salt Rinse   782

   Refractory Metals Molten Salt Rinse   783
     Raw Wastewater Sampling Data
                            xiv

-------
                    LIST OF TABLES (Continued)
 Table
   Title
                                                            Paqe
 V-140



 V-141




 V-142



 V-143



 V-144




 V-145



 V-146




 V-147



 V-148



 V-149




 V-150



 V-151




 V-152



V-153
 Refractory  Metals  Tumbling  or          789
   Burnishing  Wastewater

 Refractory  Metals  Tumbling  or          790
   Burnishing  Wastewater Raw
   Wastewater  Sampling  Data

 Refractory  Metals  Sawing or Grinding   796
   Spent Neat  Oils

 Refractory  Metals  Sawing or Grinding   797
   Spent Emulsions

 Refractory  Metals  Sawing or Grinding   798
   Spent Emulsions  Raw  Wastewater
   Sampling  Data

 Refractory  Metals  Sawing or Grinding   800
   Contact Cooling  Water

 Refractory  Metals  Sawing or Grinding   801
   Contact Cooling  Water Raw
   Wastewater  Sampling  Data

 Refractory  Metals  Sawing or Grinding   805
   Rinse

 Refractory  Metals  Dye  Penetrant        806
   Testing Wastewater

 Refractory  Metals  Dye  Penetrant        807
   Testing Wastewater Raw
   Wastewater  Sampling  Data

 Refractory Metals  Equipment Cleaning   810
  Wastewater

 Refractory Metals  Equipment Cleaning   811
  Wastewater Raw Wastewater Sampling
  Data

Refractory Metals Miscellaneous        813
  Wastewater Sources

Refractory Metals Wet Air Pollution    814
  Control Slowdown
                            xv

-------
                    LIST OF TABLES (Continued)
 Table
    Title
                                                            Paqe
 V-154



 V-155

 V-156


 V-157

 V-158

 V-159

 V-160


 V-161



 V-162

 V-163


 V-164


 V-165


 V-166


 V-167



 V-168


 V-169



V-170
 Refractory Metals  Wet  Air  Pollution    815
   Control Slowdown Raw Wastewater
   Sampling Data

 Titanium Rolling Spent Neat Oils       819

 Titanium Rolling Contact Cooling       820
   Water

 Titanium Drawing Spent Neat Oils       821

 Titanium Extrusion Spent Neat Oils     822

 Titanium Extrusion Spent Emulsions     823

 Titanium Extrusion Press Hydraulic     824
   Fluid Leakage

 Titanium Extrusion Press Hydraulic     825
   Fluid Leakage Raw Wastewater
   Sampling Data

 Titanium Forging Spent  Lubricants      826

 Titanium Forging Contact Cooling       827
  Water

 Titanium Forging Equipment Cleaning    828
  Wastewater

 Titanium Forging Press  Hydraulic       829
  Fluid Leakage

 Titanium Tube Reducing  Spent           830
  Lubricants

 Titanium Tube Reducing  Spent           831
  Lubricants Raw Wastewater   '.
  Sampling Data

 Titanium Heat Treatment Contact        832
  Cooling Water

Titanium Heat Treatment Contact        833
  Cooling Water Raw Wastewater
  Sampling Data

Titanium Surface Treatment Spent      836
  Baths
                            xvi

-------
                    LIST  OF  TABLES  (Continued)
 Table
   Title
                                                            Page
V-171




V-172

V-173


V-174


V-175




V-176

V-177



V-178

V-179

V-180


V-181


V-182


V-183




V-184


V-185




V-186
Titanium Surface Treatment Spent      837
  Baths Raw Wastewater Sampling
  Data

Titanium Surface Treatment Rinse      841

Titanium Surface Treatment Rinse      842
  Raw Wastewater Sampling Data

Titanium Alkaline Cleaning Spent      847
  Baths

Titanium Alkaline Cleaning Spent      848
  Baths Raw Wastewater Sampling
  Data

Titanium Alkaline Cleaning Rinse      850

Titanium Alkaline Cleaning Rinse      851
  Raw Wastewater Sampling Data

Titanium Molten Salt Rinse            853

Titanium Tumbling Wastewater          ,854

Titanium Tumbling Wastewater Raw      855
  Wastewater Sampling Data

Titanium Sawing or Grinding Spent     858
  Neat Oils

Titanium Sawing or Grinding Spent     859
  Emulsions

Titanium Sawing or Grinding Spent     860
  Emulsions Raw Wastewater Sampling
  Data

Titanium Sawing or Grinding Contact   865
  Cooling Water

Titanium Sawing or Grinding Contact   866
  Cooling Water Raw Wastewater
  Sampling Data

Titanium Dye Penetrant Testing        867
  Wastewater
                           xvii

-------
                    LIST OF TABLES (Continued)
 Table
  Title
                                                            Paqe
 V-187

 V-188



 V-189




 V-190

 V-191



 V-192

 V-193



 V-194




 V-195



 V-196




 V-197

 V-198



 V-199



 V-200




 V-201



V-202

V-203
 Titanium  Hydrotesting Wastewater      868

 Titanium  Wet Air  Pollution Control    869
   Slowdown

 Titanium  Wet Air  Pollution Control    870
   Slowdown Raw Wastewater Sampling
   Data

 Uranium Extrusion Spent Lubricants    873

 Uranium Extrusion Tool Contact        874
   Cooling Water

 Uranium Forging Spent Lubricants      875

 Uranium Heat Treatment Contact        876
   Cooling Water

 Uranium Heat Treatment Contact        877
   Cooling Water Raw Wastewater
   Sampling Data

 Uranium Surface Treatment Spent       884
   Baths

 Uranium Surface Treatment Spent       885
   Baths Raw Wastewater Sampling
   Data

 Uranium Surface Treatment Rinse       888

 Uranium Surface Treatment Rinse       889
   Raw Wastewater  Sampling Data

 Uranium Sawing or Grinding Spent      894
   Emulsions

 Uranium Sawing or Grinding Spent      895
   Emulsions Raw Wastewater
   Sampling Data

 Uranium Sawing or Grinding Contact    898
   Cooling Water

Uranium Sawing or Grinding Rinse      899

Uranium Area Cleaning Washwater       900
                            xviii

-------
                   LIST OF TABLES (Continued)
Table
   Title
Paqe
V-204


V-205


V-206



V-207

V-208


V-209

V-210


V-211

V-212

V-213


V-214

V-215


V-216


V-217


V-218


V-219

V-220
Uranium Area Cleaning Washwater       901
  Raw Wastewater Sampling Data

Uranium Wet Air Pollution Control     908
  Slowdown

Uranium Wet Air Pollution Control     909
  Slowdown Raw Wastewater Sampling
  Data

Uranium Drum Washwater                911

Uranium Drum Washwater Raw            913
  Wastewater Sampling Data

Uranium Laundry Washwater             917

Uranium Laundry Washwater Raw         918
  Wastewater Sampling. Data

Zinc Rolling Spent Neat Oils          921

Zinc Rolling Spent Emulsions          922

Zinc Rolling Contact Cooling          923
  Water

Zinc Drawing Spent Emulsions          924

Zinc Direct Chill Casting             925
  Contact Cooling Water

Zinc Stationary Casting Contact       926
  ..Cooling Water

Zinc Heat Treatment Contact           927
  Cooling Water

Zinc Surface Treatment Spent          928
  Baths

Zinc Surface Treatment Rinse          929

Zinc Surface Treatment Rinse          930
  Raw Wastewater Sampling
  Data
                            xix

-------
                    LIST OF TABLE,:,
                teemed)
V-222

V-223


V-224


V-225

V-226


V-227


V-228


V-229


V-230



V-231


V-232


V-233


V-234



V-235


V-236
                       Title
Zinc Alkaline Cleaning Spent          935
  Baths

Zinc Alkaline Cleaning Rinse          936

Zinc Alkaline Cleaning Rinse          937
  Raw Wastewater Sampling Data

Zinc Sawing or Grinding Spent         942
  Emulsions

Zinc Electrocoating Rinse             943

Zirconium-Hafnium Rolling Spent       944
  Neat Oils

Zirconium-Hafnium Drawing Spent       945
  Lubricants

Zirconium-Hafnium Extrusion Spent     946
  Lubricants

Zirconium-Hafnium Extrusion Press     947
  Hydraulic Fluid Leakage

Zirconium-Hafnium Extrusion Press     948
  Hydraulic Fluid Leakage Raw
  Wastewater Sampling Data

Zirconium-Hafnium Swaging Spent       949
  Neat Oils

Zirconium-Hafnium Tube Reducing       950
  Spent Lubricants

Zirconium-Hafnium Heat Treatment      951
  Contact, Cooling Water

Zirconium-Hafnium Heat Treatment      952
  Contact Cooling Water Raw
  Wastewater Sampling Data

Zirconium-Hafnium Surface Treatment   955
  Spent Baths

Zirconium-Hafnium Surface Treatment   956
  Spent Baths Raw Wastewater
  Sampling Data
                            xx

-------
                    LIST OF TABLES (Continued)
 Table
Title
V-237
V-238
V-239
V-240
V-241
V-242
V-243
V-244
V-245
V-246
V-247
V-248
V-249
V-250
V-251
Zirconium-Hafnium Surface Treatment
Rinse
Zirconium-Hafnium Alkaline Cleaning
Spent Baths
Zirconium-Hafnium Alkaline Cleaning
Rinse
Zirconium-Hafnium Molten Salt Rinse
Zirconium-Hafnium Sawing or Grinding
Spent Neat Oils
Zirconium-Hafnium Sawing or Grinding
Spent Emulsions
Zirconium-Hafnium Sawing or Grinding
Contact Cooling Water
Zirconium-Hafnium Sawing or Grinding
Rinse
Zirconium-Hafnium Inspection and
Testing Wastewater
Zirconium-Hafnium Inspection and
Testing Wastewater Raw Wastewater
Sampling Data
Zirconium-Hafnium Degreasing Spent
Solvents
Zirconium-Hafnium Degreasing Rinse
Zirconium-Hafnium Wet Air Pollution
Control Slowdown
Metal Powders Metal Powder Production
Atomization Wastewater
Metal Powders Metal Powder Production
j^gi-jc
962
963
964
965
966
967
968
969
970
971
974
975
976
977
978
V-252
   Atomization Wastewater Raw
   Wastewater Sampling Data

 Metal Powders Tumbling, Burnishing or
   Cleaning Wastewater
                                                            980
                            xxi

-------
                    LIST OF TABLES  (Continued)
Table
 Title
                                                            Page
V-253



V-254


V-255


V-256



V-257


V-258



V-259


V-260

V-261


V-262



V-263


V-264


V-265



V-266
Metal Powders Tumbling, Burnishing or 982
  Cleaning Wastewater Raw Wastewater
  Sampling Data

Metal Powders Sawing or Grinding      987
  Spent Neat Oils

Metal Powders Sawing or Grinding      988
  Spent Emulsions             ;

Metal Powders Sawing or Grinding      989
  Spent Emulsions Raw Wastewater
  Sampling Data

Metal Powders Sawing or Grinding      993
 • Contact Cooling Water

Metal Powders Sawing or Grinding      994
  Contact Cooling Water Raw   ;
  Wastewater Sampling Data

Metal Powders Sizing Spent Neat       995
  Oils

Metal Powders Sizing Spent Emulsions  996

Metal Powders Steam Treatment Wet     997
  Air Pollution Control Slowdown

Metal Powders Steam Treatment Wet     998
  Air Pollution Control Slowdown
  Raw Wastewater Sampling Data:

Metal Powders Oil-Resin              1001
  Impregnation Spent Neat Oils         •

Metal Powders Hot Pressing Contact   1002
  Cooling Water

Metal Powders Hot Pressing Contact   1003
  Cooling Water Raw Wastewater
  Sampling Data

Metal Powders Mixing Wet Air         1004
  Pollution Control Slowdown
                            xxn

-------
                   LIST OF TABLES  (Continued)
Table


V-267




V-268


V-269


V-270


V-271


V-272


V-273


V-274


V-275


V-276


V-277


V-278


V-279


V-280


V-281


V-282
Title                                Paqe
Metal Powders Mixing Wet Air         1005
  Pollution Control Slowdown
  Raw Wastewater Sampling Data

Wastewater Treatment Performance     1006
  Data - Plant A

Wastewater Treatment Performance     1009
  Data - Plant B

Wastewater Treatment Performance     1013
  Data - Plant D

Wastewater Treatment Performance     1017
  Data - Plant E

Wastewater Treatment Performance     1025
  Data - Plant F

Wastewater Treatment Performance     1032
  Data - Plant I

Wastewater Treatment Performance     1038
  Data - Plant J

Wastewater Treatment Performance     1041
  Data - Plant M

Wastewater Treatment Performance     1051
  Data - Plant Q

Wastewater Treatment Performance     1060
  Data - Plant R

Wastewater Treatment Performance     1062
  Data - Plant S

Wastewater Treatment Performance     1064
  Data - Plant T

Wastewater Treatment Performance     1065
  Data - Plant U

Wastewater Treatment Performance     1072
  Data - Plant V

Wastewater Treatment Performance     1080
  Data - Plant W
                          XXlll

-------
                    LIST OF TABLES (Continued)
                                                            Paqe
 VI-1

 VI-2


 VI-3



 VI-4


 VI-5


 VI-6



 VI-7



 VI-8


 VI-9


 VI-10


 VI-11



VI-12
 Wastewater Treatment Performance     1084
   Data - Plant X

 Wastewater Treatment Performance     1089
   Data - Plant Y

 Wastewater Treatment Performance     1094
   Data - Plant Z

 List of 129 Priority Pollutants       1245

 Analytical Quantification and        1251
   Treatment Effectiveness Values

 Priority Pollutant  Disposition:       1255
   Lead-Tin-Bismuth  Forming
   Subcategory

 Priority Pollutant  Disposition        1259
   Magnesium Forming Subcategory

 Priority Pollutant  Disposition        1263
   Nickel-Cobalt  Forming Subcategory

 Priority Pollutant  Disposition        1273
   Precious  Metals Forming
   Subcategory

 Priority Pollutant  Disposition        1280
   Refractory Metals  Forming
   Subcategory

 Priority Pollutant  Disposition        1287
   Titanium  Forming  Subcategory;

 Priority  Pollutant Disposition        1294
   Uranium Forming Subcategory

 Priority  Pollutant Disposition        1298
   Zinc Forming Subcategory

 Priority  Pollutant Disposition        1302
   Zirconium-Hafnium Forming
   Subcategory

Priority Pollutant Disposition        130"6
  Metal Powders Subcategory
                               xxiv

-------
                    LIST  OF  TABLES  (Continued)
 Table



 VII-1



 VII-2



 VII-3



 VII-4




 VII-5




 VIII-6



 VII-7

 VII-8

 VII-9

 VII-10



 VII-11

 VII-12

 VII-13

 VII-14



 VII-15



 VII-16



VII-17
Title                     .           Page


pH Control  Effect on Metals          1400
  Removal

Effectiveness of Sodium Hydroxide    1400
  for Metals Removal

Effectiveness of Lime and Sodium     1401
  Hydroxide for Metals Removal

Theoretical Solubilities of          1401
  Hydroxides and Sulfide of
  Selected Metals in Pure Water

Sampling Data From Sulfide           1402
  Precipitation-Sedimentation
  Systems

Sulfide Precipitation-Sedimentation  1403
  Performance

Ferrite Co-Precipitation Performance 1404

Concentration of Total Cyanide       1404

Multimedia Filter Performance        1405

Performance of Selected Settling.    1405
  Systems

Skimming Performance                 1406

Selected Partition Coefficients      1407

Trace Organic Removal by Skimming    1408

Combined Metals Data Effluent        1408
  Values

L & S Performance Additional         1409
  Pollutants

Combined Metals Data Set -           1409
  Untreated Wastewater

Maximum Pollutant Level in           1410
  Untreated Wastewater Additional
  Pollutants
                         XXV

-------
                    LIST  OF  TABLES  (Continued)
Table
  Title
                                                           Paqe
VII-18


VII-19


VII-20


VII-21

VII-22



VII-23


VII-24


VII-25


VII-26

VII-27


VII-28

VII-29

VII-30


VIII-1



VIII-2



VIII-3
Precipitation-Settling-Filtration    1411
   (LS&F) Performance Plant A

Precipitation-Settling-Filtration    1412
   (LS&F) Performance Plant B  ,

Precipitation-Settling-Filtration    1413
   (LS&F) Performance Plant C

Summary of Treatment Effectiveness   1414

Summary of Treatment Effectiveness   1415
   for Selected Nonconventional
   Pollutants

Treatability Rating of Priority      1416
   Pollutants

Classes of Organic Compounds         1417
   Adsorbed on Carbon

Activated Carbon Performance         1418
   (Mercury)

Ion Exchange Performance      .       1418

Membrane Filtration System           1419
   Effluent

Peat Adsorption Performance          1419

Ultrafiltration Performance          1420

Chemical Emulsion Breaking           1421
   Efficiencies

BPT Costs of Compliance for          1508
   the Nonferrous Metals
  Forming Category

BAT Costs of Compliance for the      1509
  Nonferrous Metals Forming
  Category

PSES Costs of Compliance for the     1510
  Nonferrous Metals Forming
  Category
                           xxvi

-------
                    LIST OF TABLES (Continued)
 Table
   Title
                                                            Page
 VIII-4
 VIII-5
 VIII-6
 VIII-7
 Nonferrous Metals Forming Category   1511
   Cost Equations for Recommended
   Treatment and Control Technologies
 Components of Total  Capital
   Investment

 Components of Total  Annualized
   Investment

 Wastewater Sampling  Frequency
                                                            1518
                                                            1519
                                                            1520
VIII-8


VIII-9

VIII-10

VIII-11


VIII-12


VIII-13


VIII-14

VIII-15


VIII-16


IX-1



IX-2
 Pollutant  Parameter  Important  to   •   1521
   Treatment  System Design

 Sludge  to  Influent Flow Ratios        1522

 Key  to  Cost  Curves.and Equations      1523

 Cost Equations Used  in Cost Curve     1524
   Method

 Number  of  Plants for Which Costs      1525
   Were  Scaled From Similar Plants

 Flow Reduction Recycle Ratio and      1526
   Association Cost Assumptions

 Segregation Cost Basis                1528

 Nonferrous Metals Forming Solid       1529
   Waste Generation

 Nonferrous Metals Forming Energy      1530
   Consumption

Potential Preliminary Treatment       1626
  Requirements Lead-Tin-Bismuth
  Forming Subcategory

Potential Preliminary Treatment       1627
  Requirements Magnesium Forming
  Subcategory
                         xxvn

-------
                   LIST OF TABLES  (Continued)
Table
 Title
Pac
IX-3



IX-4



IX-5



IX-6



IX-7



IX-8



IX-9



IX-10



IX-11



IX-12


IX-13



IX-14
Potential Preliminary Treatment      1628
  Requirements Nickel-Cobalt
  Forming Subcategory

Potential Preliminary Treatment      1630
  Requirements Precious Metals
  Forming Subcategory

Potential Preliminary Treatment      1631
  Requirements Refractory Metals
  Forming Subcategory

Potential Preliminary Treatment      1633
  Requirements Titanium Forming
  Subcategory

Potential Preliminary Treatment      1635
  Requirements Uranium Forming
  Subcategory

Potential Preliminary Treatment      1636
  Requirements Zinc Forming
  Subcategory

Potential Preliminary Treatment      1637
  Requirements Zirconium-Hafnium
  Forming Subcategory

Potential Preliminary Treatment      1638
  Requirements Metal Powders
  Subcategory

BPT Regulatory Flows for Production  1639
  Operations - Lead-Tin-Bismuth
  Forming Subcategory       ;

Lead-Tin-Bismuth Forming Subcategory 1641
  BPT Effluent Limitations

BPT Regulatory Flows for Production  1648
  Operations - Magnesium Forming
  Subcategory

Magnesium Forming Subcategory BPT    1649
  Effluent Limitations
                               xxviii

-------
                   LIST OF TABLES  (Continued)
IX-16


IX-17



IX-18


IX-19



IX-20


IX-21



IX-22


IX-23


IX-24


IX-25



IX-26


IX-27



IX-28
                      Title
BPT Regulatory Flows for Production  1653
  Operations - Nickel-Cobalt
  Forming Subcategory

Nickel-Cobalt Forming Subcategory    1656
  BPT Effluent Limitations

BPT Regulatory Flows for Production  1670
  Operations - Precious Metals
  Forming Subcategory

Precious Metals Forming Subcategory  1672
  BPT Effluent Limitations

BPT Regulatory Flows for Production  1682
  Operations - Refractory Metals
  Forming Subcategory

Refractory Metals Forming Subcate-   1684
  gory BPT Effluent Limitations

BPT Regulatory Flows for Production  1701
  Operations - Titanium Forming
  Subcategory

Titanium Forming Subcategory  BPT     1703
  Effluent Limitations

BPT Regulatory Flows for Production  1715
  Operations - Uranium  Forming

Uranium Forming  Subcategory BPT      1717
  Effluent Limitations

BPT Regulatory Flows for Production  1724
  Operations  - Zinc Forming
   Subcategory

 Zinc  Forming  Subcategory BPT         1725
   Effluent  Limitations

 BPT Regulatory Flows for  Production   1731
   Operations  -  Zirconium-Hafnium
   Forming  Subcategory

 Zirconium-Hafnium Forming  Subcate-   1733
   gory BPT Effluent Limitations
                              xxix

-------
                   LIST OF TABLES  (Continued)
IX-30


IX-31



IX-32




IX-33
                      Title                                Page
BPT Regulatory Flows for Production  1741
  Operations - Metal Powders
  Subcategory

Metal Powders Subcategory BPT    \    1742
  Effluent Limitations

Allowable Discharge Calculations for 1748
  Refractory Metals Forming Plant X
  in Example 1 (Nickel)

Allowable Discharge Calculations for 1749
  Lead-Tin-Bismuth Forming Plant Y
  in Example 2 (Total Suspended
  'Solids)

Allowable Discharge Calculations for 1751
  Nickel-Cobalt and Titanium Forming
  Plant  Z in Example 3  (Nickel)
IX-34



X-l


X-2


X-3




X-4




X-5
Allowable Discharge Calculations  for  1753
  Nickel-Cobalt and Titanium Forming
  Plant  Z in Example  3  (Cyanide)

Capital  and Annual Cost  Estimates    1794
  for  BAT  (PSES)  Total  Subcategory

Capital  and Annual Cost  Estimates    1795
  for  BAT Direct  Dischargers

Nonferrous Metals Forming  Pollutant   1796
  Reduction Benefit Estimates  Lead-
  Tin-Bismuth  Forming Subcategory
  Total  Subcategory

Nonferrous Metals Forming  Pollutant   1797
  Reduction Benefit Estimates
  Magnesium Forming Subcategory
  Total  Subcategory

Nonferrous Metals Forming  Pollutant   1798
  Reduction Benefit Estimates
  Nickel-Cobalt Forming Subcategory
  Total  Subcategory
                           XXX

-------
                   LIST OF TABLES (Continued)
X-7
X-8
X-9
X-10
X-ll
X-12
X-13
X-14
                      Title
Nonferrous Metals Forming Pollutant  1799
  Reduction Benefit Estimates Precious
  Metals Forming Subcategory Total
  Subcategory

Nonferrous Metals Forming Pollutant  1800
  Reduction Benefit Estimates
  Refractory Metals Forming
  Subcategory Total Subcategory

Nonferrous Metals Forming Pollutant  1801
  Reduction Benefit Estimates
  Titanium Forming Subcategory Total
  Subcategory

Nonferrous Metals Forming Pollutant • 1802
  Reduction Benefit Estimates
  Uranium Forming Subcategory Total
  Subcategory

Nonferrous Metals Forming Pollutant  1803
  Reduction Benefit Estimates Zinc
  Forming Subcategory Total
  Subcategory

Nonferrous Metals Forming Pollutant  1804
  Reduction Benefit Estimates
  Zirconium-Hafnium Forming
  Subcategory Total Subcategory

Nonferrous Metals Forming Pollutant  1805
  Reduction Benefit Estimates Metal
  Powders Subcategory Total
  Subcategory

Nonferrous Metals Forming Pollutant  1806
  Reduction Benefit Estimates Lead-
  Tin-Bismuth Forming Subcategory
  Direct  Dischargers

Nonferrous Metals Forming Pollutant   1807
  Reduction Benefit Estimates
  Magnesium Forming Subcategory
  D5 rect  Dischargers
                           xxxi

-------
                   LIST OF TABLES  (Continued)
X-16




X-17




X-18




X-19




X-20



X-21



X-22



X-23


X-24
                       Title
Nonferrous Metals Forming Pollutant  1808
  Reduction Benefit Estimates Nickel-
  Cobalt Forming Subcategory Direct
  Dischargers

Nonferrous Metals Forming Pollutant  1809
  Reduction Benefit Estimates
  Precious Metals Forming Subcategory
  Direct Dischargers

Nonferrous Metals Forming Pollutant  1810
  Reduction Benefit Estimates
  Refractory Metals Forming
  Subcategory Direct Dischargers

Nonferrous Metals Forming Pollutant  1811
  Reduction Benefit Estimates
  Titanium Forming Subcategory
  Direct Dischargers

Nonferrous Metals Forming Pollutant  1812
  Reduction Benefit Estimates Uranium
  Forming Subcategory Direct
  Dischargers
Nonferrous Metals Forming Pollutant
  Reduction Benefit Estimates Zinc
  Forming Subcategory
1813
Nonferrous Metals Forming Pollutant  1814
  Reduction Estimates Zirconium- ,
  Hafnium Forming Direct Dischargers

Nonferrous Metals Forming Pollutant  1815
  Reduction Estimates Metal Powders
  Subcategory Direct Dischargers

Options Selected as the Technology   1816
  Basis for BAT

BAT Regulatory Flows for the Produc- 1817
  tion Operations - Lead-Tin-Bismuth
  Forming Subcategory
                           xxxii

-------
                    LIST OF TABLES (Continued)
                        Title
                                                            Pac
 X-27


 X-28




 X-29


 X-30



 X-31


 X-32




 X-33


X-34




X-35


X-36
                       Lead-Tin-Bismuth Forming Subcategory 1819
                         BAT Effluent Limitations

                       BAT_Regulatory Flows for the Produc- 1824
                         tipn Operations - Magnesium Forming
                         Subcategory
 Magnesium Forming  Subcategory BAT
   Effluent Limitations
1825
 BAT  Regulatory  Flows  for  the  Produc^-  1829
   tion  Operations  - Nickel-Cobalt
   Forming  Subcategory

 Nickel-Cobalt Forming Subcategory     1832
   BAT Effluent  Limitations

 BAT  Regulatory  Flows  for  the          1845
   Production Operations - Precious
     Metal  Forming  Subcategory

 Precious Metals Forming Subcategory   1847
   BAT Effluent  Limitations

 BAT  Regulatory  Flows  for  the          1856
   Production Operations - Refractory
   Metals Forming Subcategory

 Refractory Metals  Forming Subcate-    1858
   gory BAT Effluent Limitations

 BAT Regulatory Flows  for  the          1869
   Production Operations -
   Titanium Forming Subcategory

Titanium Forming Subcategory BAT      1871
   Effluent Limitations

BAT Regulatory Flows for the          1882
  Production Operations - Uranium
  Forming Subcategory
                         xxxni

-------
                   LIST OF TABLES  (Continued)
Table
Title
Paqe
X-37


X-38



X-39


X-40




X-41



X-42



X-43


XI-1


XI-2


XI-3


XI-4


XI-5


XI-6


XI-7
Uranium Forming Subcategory BAT      1884
  Effluent Limitations

BAT Regulatory Flows for the  '       1889
  Production Operations - Zinc
  Forming Subcategory

Zinc Forming Subcategory BAT         1890
  Effluent Limitations

BAT Regulatory Flows for the         1896
  Production Operations -
  Zirconium-Hafnium Forming
  Subcategory

Zirconium-Hafnium Forming            1898
  Subcategory BAT Effluent
  Limitations

BAT Regulatory Flows for the         1906
  Production Operations - Metal
  Powders Subcategory

Metal Powders Subcategory BAT        1907
  Effluent Limitations

Options Selected as the Bases        1919
  for NSPS

Lead-Tin-Bismuth Forming Subcategory 1920
  New Source Performance Standards

Magnesium Forming Subcategory New    1927
  Source Performance Standards

Nickel-Cobalt Forming Subcategory    1931
  New Source Performance Standards

Precious Metals Forming Subcategory  1946
  New Source Performance Standards

Refractory Metals Forming Subcate-   1956
  gory New Source Performance Standards
Titanium Forming Subcategory New
  Source Performance Standards
1973
                            XXXIV

-------
                   LIST OF TABLES  (Continued)
Table
Title
XI-8
XI-9
XI-10
XI-11
XII-1
XII-2
XII-3
X1I-4
XII-5
XII-6
XII-7
Uranium Forming Subcategory New
  Source Performance Standards

Zinc Forming Subcategory New
  Source Performance Standards
                                                           1986
                                                           1993
Zirconium-Hafnium Forming Subcate-   1999
  gory New Source Performance Standards

Metal Powders Subcategory New Source 2006
  Performance Standards

POTW Removals of the Toxic Pollu-    2019
  tants Found in Nonferrous Metals
  Forming Wastewater

Pollutant Removal Percentages for    2021
  BAT or PSES Model Technology By
  Subcategory

Option Selected as the Model         2022
  Technology Basis for PSES and
  PSNS

Capital and Annual Cost Estimates    2023
  for PSES Options Indirect
  Dischargers

Nonferrous Metals Forming Pollutant  2025
  Reduction Benefit Estimates Lead-
  Tin-Bismuth Forming Subcategory
  Indire'ct Dischargers

Nonferrous Metals Forming Pollutant  2026
  Reduction Benefit Estimates Magnesium
  Forming Subcategory Indirect
  Dischargers

Nonferrous Metals Forming Pollutant  2027
  Reduction Benefit Estimates Nickel-
  Cobalt Forming Subcategory Indirect
  Dischargers
                         xxxv

-------
                    LIST OF TABLES (Continued)
 Table
  Title
 XII-8
 XII-9
 XII-10
 XII-11
XII-12
XII-13
XII-14
XII-15
XII-16
XII-17
 Nonferrous Metals Forming Pollutant  2028
   Reduction Benefit Estimates Precious
   Metals Forming Subcategory Indirect
   Dischargers

 Nonferrous Metals Forming Pollutant  2029
   Reduction Benefit Estimates Refractory
   Metals Forming Subcategory Indirect
   Dischargers

 Nonferrous Metals Forming Pollutant  2030
   Reduction Benefit Estimates Titanium
   Forming Subcategory  Indirect
   Dischargers

 Nonferrous Metals Forming Pollutant  2031
   Reduction Benefit Estimates
   Zirconium-Hafnium Forming  Subcategory
   Indirect Dischargers

 Nonferrous Metals Forming Pollutant  2032
   Reduction Benefit Estimates Metal
   Powders  Subcategory Indirect
 .  Dischargers

 Lead-Tin-Bismuth  Forming  Subcategory  2033
   Pretreatment Standards  for
   Existing Sources

 Magnesium  Forming  Subcategory         2038
   Pretreatment Standards  for
   Existing Sources

 Nickel-Cobalt Forming Subcategory     2042
   Pretreatment Standards  for
   Existing  Sources

Precious Metals Forming Subcategory   2055
   Pretreatment Standards  for
   Existing  Sources

Refractory Metals Forming Subcate-    2064
  gory Pretreatment Standards for
  Existing  Sources              :
                          xxxvi

-------
                   LIST OF TABLES  (Continued)
Table
 Title
                                                           Page
XII-18
XI1-19
XII-20
XII-21
XII-22
Titanium Forming Subcategory
  Pretreatment Standards for
  Existing Sources

Uranium Forming Subcategory
  Pretreatment Standards for
  Existing Sources
                                                           2075
                                                           2085
Zinc Forming Subcategory Pretreat-^   2091
  ment Standards for Existing Sources
Zirconium-Hafnium Forming Subcate-
  gory Pretreatment Standards for
  Existing Sources
                                                           2097
Metal Powders Subcategory Pretreat-  2105
  ment Standards for "Existing Sources
XII-23
XII-24
XII-25
XII-26
XII-27
XII-28
Lead-Tin-Bismuth Forming Subcategory 2110
  Pretreatment Standards for
  New Sources

Magnesium Forming Subcategory        2115
  Pretreatment Standards for New
  Sources

Nickel-Cobalt Forming Subcategory    2119
  Pretreatment Standards for
  New Sources

Precious Metals Forming Subcategory  2132
  Pretreatment Standards for
  New Sources

Refractory Metals Forming Subcate-   2141
  gory Pretreatment Standards for
  New Sources

Titanium Forming Subcategory         2152
  Pretreatment Standards for
  New Sources
                          xxxvii

-------
                   LIST OF TABLES (Continued)
Table
Title
Paqe
XII-29



XII-30


XII-31



XII-32
Uranium Forming Subcategory          2162
  Pretreatment Standards for
  New Sources

Zinc Forming Subcategory Pretreat-   2168
  ment Standards for New Sources

Zirconium-Hafnium Forming Subcate-   2174
  gory Pretreatment Standards for New
  Sources

Metal Powders Subcategory Pretreat-  2182
  ment Standards for New Sources
                          XXXVlll

-------
                         LIST OF FIGURES
Figure

III-l


III-2


III-3

III-4

III-5

III-6

III-7

III-8

III-9

111-10

III-ll

111-12

111-13

111-14

111-15

111-16

111-17

111-18

111-19

111-20

111-21

111-22

111-23

111-24
 Title                               ,,   Page

Geographical Distribution of Nonferrous   360
  Forming Plants

Sequence of Nonferrous Metals Forming     361
  Operations

Common Rolling Mill Configurations .       362

Reversing Hot Strip Mill                  363

4-High Cold Rolling Mill                '  364

Tube Drawing                              365

Hydraulic Draw Bench                      366

Direct Extrusion                          367

Extrusion Press             "              368

Extrusion Tooling and Setup               369

Forging                                   370

Ring Rolling                              371

Impacting                                 372

Some Clad Configurations                  373

Atomization                               374

Powder Metallurgy Die Compaction          375

Direct Chill Casting                      376

Direct Chill (D.C.) Casting, Unit          377

Continuous Sheet Casting                  373

Continuous Strip Casting                  379

Shot Casting                              380

Roller Hearth Annealing Furnace           381

Bulk Pickling Tank                        382

Continuous Pickling Line                  383
                              xxxix

-------
 Figure
 111-25
 V-l
 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
 V-l 5
 V-l 6
 V-17
 V-18
 V-l 9
V-20
V-21
     LIST OF FIGURES  (Continued)
Title    ,
Vapor Degreaser
Wastewater Sources at Plant A
Wastewater Sources at Plant B
Wastewater Sources at Plant C
Wastewater Sources at Plant D
Wastewater Sources at Plant E
Wastewater Sources at Plant F
Wastewater Sources at Plant G
Wastewater Sources at Plant I
Wastewater Sources at Plant J
Wastewater Sources at Plant K
Wastewater Sources at Plant L
Wastewater Sources at Plant M
Wastewater Sources at Plant N
Wastewater Sources at Plant O
Wastewater Sources at Plant P
Wastewater Sources at Plant Q
Wastewater Sources at Plant R
Wastewater Sources at Plant S
Wastewater Sources at Plant T
Wastewater Sources at Plant V
Wastewater Sources at Plant Z
Page
 384
1098
1099
1100
1101
1102
1103
1104
1105
1106
1107
1108
1109
1110
1111
1112
1113
1114
1115
1116
1117
1118
                               xl

-------
                    LIST OF  FIGURES  (Continued)
 Figure

 VII-1




 VII-2

 VII-3


 VII-4


 VII-5


 VII-6



 VII-7


 VII-8


 VII-9 •


 VII-10


 VII-11


 VII-12



 VII-13


 VII-14

VII-15

VII-16

VII-17

VII-18
 Title                                   page

 Comparative Solubilities of Metal       1422
   Hydroxides and Sulfide as a
   Function of pH

 Lead Solubility in Three Alkalies       1423

 Effluent Zinc Concentrations vs.         1424
   Minimum Effluent pH

 Hydroxide Precipitation Sedimentation   1425
   Effectiveness - Cadmium

 Hydroxide Precipitation Sedimentation   1426
   Effectiveness - Chromium

 Hydroxide Precipitation Sedimentation   1427
   Effectiveness - Copper

 Hydroxide Precipitation Sedimentation   1428
   Effectiveness - Lead

.Hydroxide Precipitation Sedimentation   1429
   Effectiveness - Nickel and Aluminum

 Hydroxide Precipitation Sedimentation   1430
   Effectiveness - Zinc

 Hydroxide Precipitation Sedimentation   1431
   Effectiveness - Iron

 Hydroxide Precipitation Sedimentation   1432
   Effectiveness - Manganese

 Hydroxide Precipitation Sedimentation   1433
   Effectiveness - TSS

 Hexavalent Chromium Reduction with       1434
   Sulfur  Dioxide

 Granular  Bed Filtration                 1435

 Pressure  Filtration                     1436

 Representative  Types of Sedimentation   1437

 Activated Carbon Adsorption Column       1438

 Centrifugation                           1439
                               xli

-------
LIST OF FIGURES (Continued)
Figure .
VII-19
VII-20
VII-21
VII-22
VII-23
VII-24
VII-25
VII-26
VII-27
VII-28
VII-29
VII-30
VII-31
VII-32
VII-33
VII-34
VII-35
VII-36
VII-37
VII-38

Title
Treatment of Cyanide Waste by Alkaline
Chlorination
Typical Ozone Plant for Waste Treatment
UV/Ozonation
Types of Evaporation Equipment
Dissolved Air Flotation
Gravity Thickening
Ion Exchange with Regeneration
Simplified Reverse Osmosis Schematic
Reverse Osmosis Membrane Configurations
Sludge Drying Bed
Simplified Ultraf iltration Flow
Schematic
Vacuum Filtration
Flow Diagram for Emulsion Breaking with
Chemicals
Filter Configurations
Gravity Oil/Water Separator
Flow Diagram for a Batch Treatment
Ultraf iltration System
Flow Diagram of Activated Carbon
Adsorption with Regeneration
Flow Diagram for Recycling with a
Coolint Tower
Countercurrent Rinsing (Tanks)
Effect of Added Rinse Stages on Water
Use
xlii
Page
1440
1441
1442
1443
1444
1445
1446
1447
1448
1449
1450
1451
1452
1453
1454
1455
1456
1457
1458
1459


-------
                    LIST OF FIGURES  (Continued)
 Figure

 VIII-1



 VIII-2



 VIII-3



 VIII-4



 VIII-5



 VIII-6



 VIII-7



 VIII-8


 VIII-9



 VIII-10



 VIII-11



 VIII-12

 VIII-13

 VIII-14



VIII-15


VIII-16



VIII-17
Title                  ' •        '        Page

  General Logic Diagram of Computer     1531
    Cost Model

  Logic Diagram of Module Design        1532
    Procedure

  Logic Diagram of the Cost             1533
    Estimation Routine

  Capital Cost of a Spray Rinsing       1534
    System

  Capital and Annual Costs of Aerated   1535
    Rectangular Fiberglass Tanks

  Capital and Annual Costs of Centri-   1536
    fugal Pumps

  Capital and Annual Costs of Cooling   1537
    Towers and Holding Tank -

  Capital and Annual Costs of Holding   1538
    Tanks and Recycle Piping

  Capital and Annual Costs of           1539
    Equalization

  Capital and Annual Costs of Cyanide   1540
    Precipitation

  Capital and Annual Costs of Chromium  1541
    Reduction

  Capital Costs of Iron Coprecipitation  1542

  Annual Costs of Iron Coprecipitation  1543

  Capital and Annual Costs of Chemical  1544
    Emulsion  Breaking

  Capital and Annual Costs of Ammonia   1545
    Steam Stripping

  Capital and Annual Costs of Chemical  1546
    Precipitation

  Capital Costs for Carbon Steel Vacuum  1547
    Filters
                             xliii

-------
 Figure

 VIII-18


 VIII-19

 VIII-20


 VIII-21

 XI-1


 X-l



X-2
    LIST OF FIGURES (Continued)

Title                                  page

  Capital Costs for Stainless Steel    1548
    Vacuum Filters

  Annual Costs for Vacuum Filters      1549

  Capital and Annual Costs for Multi-  1550
    media and Cartridge Filtration

  Annual Costs for Contract Hauling    1551

  BPT Treatment Train for the Non-     1755
    ferrous Metals Forming Category

  BAT Option 1 and 2 Treatment Train    1912
    for  the Nonferrous Metals Forming
    Category

  BAT Option 3 Treatment  Train for     1913
    the  Nonferrous Metals Forming
    Category
                              xliv

-------
                           SECTION VII
                CONTROL AND TREATMENT TECHNOLOGY
This section describes the treatment techniques currently used or
available to remove or  recover  wastewater .pollutants  normally
generated   by  the  nonferrous metals forming and metal  powders
industrial  point  source  category  (hereafter  referred  to  as
nonferrous  metals  forming).    Included  are   discussions   of
individual  end-of-pipe treatment   technologies   and   in-plant
technologies.    These treatment  technologies  are  widely  used
in    many     industrial   categories, •     and     data     and
information    to   support, their .effectiveness has  been  drawn
from  a  similarly  wide  range  of sources and data bases.
               END-OF-PIPE TREATMENT TECHNOLOGIES
Individual  recovery  and  treatment  technologies  are described
which are used or are suitable for  use  in  treating  wastewater
discharges    from   nonferrous  metals  forming  plants.    Each
description includes a functional description and discussion   of
application   and   performance,   advantages  and   limitations,
operational' factors  (reliability,    maintainability,     solid
waste    aspects),    and demonstration  status.   The  treatment
processes   described   include  both   technologies •"   presently
demonstrated    within   the   category,     and     technologies
demonstrated  in treatment of similar wastes in other industries.-

Nonferrous  metals forming wastewaters characteristically may  be
acid  or   alkaline;    may   contain   substantial   levels   of
dissolved  or particulate metals  including  cadmium,   chromium,
copper,    lead,    nickel,   -silver,   and  zinc;  may  contain
substantial levels of cyanide,,  ammonia and fluoride; may contain
only small or trace amounts of toxic organics; and are  generally
free   from   strong  chelating   agents.   The  toxic  inorganic
pollutants  constitute the most significant wastewater pollutants
in this category.   Oils and emulsions are also present in  waste
streams   emanating- from  forming ' operations  using  neat   and
emulsified  oil  lubricants.   Ammonia is present  in  wastewater
discharges associated with some surface treatment operations.

In   general,    these    pollutants    are    removed    by  oil
removal   (skimming   and  emulsion  breaking),   ammonia   steam
stripping, hexavalent chromium reduction,  chemical precipitation
and sedimentation or filtration.  Most of them may be effectively
removed  by  precipitation of  metal  hydroxides   or  carbonates
utilizing  the reaction with lime,  sodium hydroxide,  or  sodium
carbonate.   For  some, improved removal's, are provided by the use
of  sodium  sulfide  or  ferrous  sulfide  to   precipitate   the
pollutants as sulfide compounds with very low" solubilities.
                               13-11 •

-------
Discussion  of end-of-pipe treatment technologies is divided into
three parts: the major technologies; the effectiveness  of  major
technologies; and minor end-of-pipe technologies.

MAJOR TECHNOLOGIES

In  Sections  IX,  X,  XI,  and  XII  the rationale for selecting
treatment systems is discussed.  The individual technologies used
in  the  system  are  described  here.   The  major   end-of-pipe
technologies  for treating nonferrous metals forming  wastewaters
are:   (1)   chemical  reduction  of  chromium,   (2)    chemical
precipitation,   (3)  cyanide  precipitation,   (4)  granular  bed
filtration,  (5) pressure  filtration,   (6)  settling,  and  (7)
skimming.     In practice,  precipitation  of metals and settling
of  the  resulting  precipitates  is often  a  unified   two-step
operation.     Suspended   solids   originally  present  in   raw
wastewaters  are  not appreciably affected by  the  precipitation
operation  and are removed with  the precipitated    metals    in
the  settling  operations.   Settling operations can be evaluated
independently  of  hydroxide  or  other chemical    precipitation
operations,   but  hydroxide  and  other chemical   precipitation
operations   can   only   be  evaluated  in  combination  with  a
solids removal operation.

1.   Chemical Reduction of Chromium

Description  of_  the Process.  Reduction is a chemical reaction in
which electrons'  are transferred to  the  chemical  being  reduced
from  the  chemical initiating the transfer  (the reducing agent).
Sulfur  dioxide,  sodium  bisulfite,  sodium  metabisulfite,  and
ferrous  sulfate  form strong reducing agents in aqueous solution
and are often used in industrial waste treatment  facilities  for
the  reduction of hexavalent chromium to the trivalent form.  The
reduction allows removal  of chromium from solution in conjunction
with other metallic salts by alkaline precipitation.   Hexavalent
chromium  is  not  precipitated as the hydroxide.

Gaseous   sulfur  dioxide  is  a  widely  used  reducing agent and
provides  a   good example of  the  chemical  reduction  process.
Reduction  using other   reagents   is  chemically  similar.   The
reactions  involved may be illustrated as follows:


   3  S02 +  3  H20  	>  3 H2S03

   3  H2S03  +

   3H2S032  H2Cr04 	>  Cr2  (S04)3 + 5 H20          ,

The  above reaction  is  favored  by  low  pH.  A  pH of  from  2  to 3   is
-normal  for  situations  requiring complete reduction.   At pH  levels
above   5,   the   reduction rate  is  slow.  Oxidizing agents such  as
dissolved oxygen and  ferric  iron   interfere  with   the  reduction
process  by consuming  the reducing  agent.
                                1312

-------
A  typical  treatment  consists  of  45  minutes  r  ^ncion
reaction tank.  The reaction tank  has  an  electronic  recorder-
controller  device  to control process conditions with respect to
pH and  oxidation  reduction  potential  (ORP).    Gaseous  sulfur
dioxide  is  metered  to  the  reaction  tank to maintain the ORP
within the range of-250 to  300  millivolts.   Sulfuric  acid  is
added  to  maintain  a pH level of from 1.8 to 2.0.
tank is equipped with a propeller agitator
approximately   one  turnover per minute.
continuous chromium reduction system.
         The reaction
designed  to  provide
Figure VII-13 shows a
Application and  Performance.    Chromium  reduction  is -used  in
nonferrous  metals  forming  for  treating  chromium   containing
wastewaters  such as surface treatment baths and rinses.  A study
of  an operational waste  treatment facility chemically
hexavalent  chromium  has shown that a 99.7   percent
efficiency  is  easily achieved.   Final concentrations
mg/1   are   readily   attained,    and concentrations
             reducing
            reduction
             of  0.05
            of   0.01
                  and
mg/1  are considered to be attainable by.properly maintained
operated equipment.

Advantages and Limitations.    The  major  advantage  of  chemical
reduction  to  reduce  hexavalent  chromium is that it is a fully
proven technology based on many years of  experience.   Operation
at  ambient conditions results in minimal energy consumption, and
the process, especially when using sulfur dioxide, is well suited
to automatic control.   Furthermore,  the  equipment  is  readily
obtainable from many suppliers, and operation is straightforward.

One  limitation  of  chemical reduction of hexavalent chromium is
that for high concentrations of chromium,  the cost  of  treatment
chemicals  may be prohibitive.  When this situation occurs, other
treatment techniques are likely to be more economical.   Chemical
interference  by oxidizing agents is possible in the treatment of
mixed wastes, and the treatment itself may  introduce  pollutants
if  not  properly  controlled.   Storage  and  handling of sulfur
dioxide is somewhat hazardous.

Operational  Factors.   Reliability:   Maintenance  consists   of
periodic  removal  of sludge, the frequency of removal depends on
the input concentrations of  detrimental constituents.

Solid Waste Aspects:  Pretreatment to eliminate substances  which
will  interfere  with  the  process may.often be necessary.  This
process produces trivalent chromium which can  be  controlled  by
further  treatment.   However,  small  amounts  of  sludge may be
collected as the result of minor shifts in the solubility of  the
contaminants.   This  sludge  can be processed by the main sludge
treatment equipment.

Demonstration Status.  The reduction of chromium waste by  sulfur
dioxide  or  sodium bisulfite is a classic process and is used by
numerous plants  which  have  hexavalent  chromium  compounds  in'
wastewaters  from  operations  such  as electroplating conversion
                               1313

-------
coating  and noncontact cooling.   Six nonferrous metals  forming
plants reported the use of hexavalent chromium reduction to treat
chromium containing wastewaters.

2.   Chemical Precipitation

Dissolved toxic metal ions and certain anions may  be  chemically
precipitated for removal by physical means such as sedimentation,
filtration,  or  centrifugation.   Several  reagents are commonly
used to effect this precipitation:

1) Alkaline compounds such as lime or  sodium  hydroxide  may  be
used  to  precipitate  many toxic metal ions as metal hydroxides.
Lime  also  may  precipitate  phosphates  as  insoluble   calcium
phosphate,  fluorides as calcium fluoride, and arsenic as calcium
arsenate.

2) Both "soluble" sulfides such as  hydrogen  sulfide  or  sodium
sulfide  and  "insoluble" sulfides such as ferrous sulfide may be
used to precipitate many heavy metal ions as metal sulfides.

3) Ferrous sulfate, zinc sulfate or both (as is required) may  be
used  to  precipitate  cyanide  as  a  ferro or zinc ferricyanide
complex.

4) Carbonate precipitates may be used to remove metals either  by
direct  precipitation  using  a carbonate reagent such as calcium
carbonate or  by  converting  hydroxides  into  carbonates  using
carbon dioxide.

These  treatment chemicals may be added to a flash mixer or rapid
mix tank, to a presettling tank, or directly to  a  clarifier  or
other  settling device.  Because metal hydroxides tend to be col-
loidal in nature, coagulating agents may also be added  to  faci-
litate  settling.   After  the solids have been removed, final pH
adjustment may be required to reduce the high pH created  by  the
alkaline treatment chemicals.

Chemical  precipitation  as  a mechanism for removing metals from
wastewater is a complex process of at  least  two  steps  -  pre-
cipitation of the unwanted metals and removal of the precipitate.
Some  very  small  amount  of  metal will remain dissolved in the
wastewater  after  precipitation  is  complete.   The  amount  of
residual dissolved  metal  depends  on  the  treatment  chemicals
used and related factors.   The effectiveness of this  method  of
removing  any   specific  metal depends on the  fraction  of  the
specific  metal  in   the   raw   waste   (and   hence   in   the
precipitate)   and   the effectiveness   of   suspended    solids
removal.    In  specific instances, a sacrifical ion such as iron
or  aluminum  may  be added to aid in  the   removal   of   toxic
metals  by  co-precipitation.

Application and Performance.  Chemical precipitation is  used  in
nonferrous metals forming for precipitation of dissolved  metals.
It  can  be  used  to remove  metal  ions   such   as   antimony,


                               1314

-------
arsenic,   beryllium,     cadmium,  '  chremium,   copper,   lead,
mercury,  nickel,  selenium,  silver,    zinc,  alum.' .  .,  cob^'" .
columbium,   gold,   hafnium,   iron,     manganese,   molybdenu.-u,
tantalum,  tin,  tungsten,  vanadium and zirconium.   The process
is    also   applicable   to   any   substance   that   can    be
transformed into an insoluble form such as fluorides, phosphates,
soaps, sulfides and others.  Because it is simple and  effective,
chemical  precipitation
treatment.
is extensively used for industrial waste
The performance of  chemical  precipitation  depends  on  several
variables.   The  more  important factors -affecting precipitation
effectiveness are:

1. Maintenance of an appropriate '{usually alkaline) pH throughout
   the precipitation reaction and subsequent settling;

2. Addition of a sufficient excess of treatment ions to drive the
   precipitation reaction to completion;

3. Addition of an adequate supply of  sacrifical  ions  (such  as
   iron  or  aluminum)  to ensure precipitation  and  removal  of
   specific    target ions; and

4.  Effective  removal  of  precipitated  solids (see appropriate
    solids removal technologies).

Control of_ pH.  Irrespective of  the  solids  removal  technology
employed,  proper  control  of  pH  is  absolutely  essential for
favorable     performance  .   of      precipitation-sedimentation
technologies.   This  is clearly illustrated by solubility curve.s
for selected metals hydroxides and sulfides shown in Figure VII-1
and  by  plotting effluent zinc concentrations   against  pH   as
shown   in   Figure   VII-3.    Figure VII-3  was  obtained  from
Development   Document  for  the  Proposed  Effluent  Limitations
Guidelines   and  New Source Performance Standards for  the  Zinc
Segment   of   Nonferrous  Metals  Manufacturing  Point    Source
Category,  U.S. E.P.A., EPA 440/1-74/033, November, 1974.   Figure
VII-3 was plotted from the sampling data from several  facilities
with  metal finishing operations.  It is partially illustrated by
data obtained from 3 consecutive days of sampling  at  one  metal
processing   plant  (47432) as displayed  in  Table  VII-1.  Flow
through  this  system  is  approximately  49,263   1/hr   (13,000
gal/hr).                        '                        •

This  treatment  system  uses  lime precipitation (pH adjustment)
followed by coagulant addition and sedimentation.   Samples  were
taken before (in) and after (out) the treatment system.  The best
treatment for removal of copper and zinc was achieved on day one,
when  the pH was maintained at a satisfactory level.  The poorest
treatment was found on the second day, when the pH slipped to  an
unacceptably  low level; intermediate values were achieved on the
third day, when pH values were 1e^s than desirable but in between
those for the first and second days.
                               1315

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 Sodium   hydroxide  is  used  by  another  facility   (plant   439)   for
 pH   adjustment   and    chemical   precipitation,     followed    by
 settling (sedimentation and a polishing lagoon)  of  precipitated
 solids.   Samples   were   taken  prior to  caustic   addition   and
 following the polishing lagoon.    Flow  through  the   system   is
 approximately 22,700   1/hr  (6,000 gal/hr).   These data displayed
 in   Table VII-2   indicate  that  the   system   was    operated
 efficiently. Effluent   pH  was controlled within the range of  8.6
 to  9.3,  and, while raw waste loadings were  not  unusually  high,
 most toxic metals were removed to very low concentrations.

 Lime and sodium  hydroxide  (combined)  are  sometimes  used to
 precipitate metals.  Data developed from plant 40063, a facility
 with a metal bearing wastewater, exemplify efficient operation of
 a   chemical precipitation and settling system.  Table VII-3 shows
 sampling  data  from this system,  which  uses  lime and  sodium
 hydroxide   for   pH   adjustment,    chemical    precipitation,
 polyelectrolyte flocculant addition, and sedimentation.   Samples
 were taken  of  the   raw waste influent to the system  and of  the
 clarifier effluent.  Flow through  the  system  is   approximately
 19,000 1/hr (5,000 gal/hr).

 At   this   plant,  effluent  TSS levels were below 15 mg/1 on each
 day, despite average raw waste TSS concentrations  of   over  3500
 mg/1.    Effluent  pH  was  maintained  at  approximately  8, lime
 addition  was sufficient to precipitate the dissolved metal  ions,
 and  the   flocculant  addition  and clarifier retention served  to
 remove effectively the precipitated solids.

 Sulfide precipitation  is sometimes  used  to  precipitate  metals
 resulting  in  improved metals removals.   Most metal sulfides are
 less soluble than hydroxides, and the precipitates are  frequently
 more dependably removed from water.   Solubilities   for  selected
 metal  hydroxide, carbonate and sulfide precipitates are shown  in
 Table  VII-4.      (Source:     Lange's  Handbook   of  Chemistry).
 Sulfide   precipitation  is  particularly effective  in  removing
 specific  metals such as silver  and   mercury.    Sampling  data
 from   three   industrial   plants  using  sulfide  precipitation
 appear in Table VII-5.    In  all  cases   except  iron,  effluent
 concentrations   are   below  0.1  mg/1 and in many  cases  below
 0.01 mg/1 for  the three plants studied.

 Sampling data  from several  chlorine-caustic manufacturing  plants
 using   sulfide   precipitation   demonstrate   effluent  mercury
 concentrations varying between 0.009  and  0.03 mg/1.   As shown  in
 Figure  yil-l,  the  solubilities  of  PbS and Ag2S are lower
 at alkaline pH levels than  either the  corresponding   hydroxides
 or   other   sulfide   compounds.     This  implies  that  removal
performance for lead and silver  sulfides  should be comparable  to
 or  better than that for the metal hydroxides.   Bench scale tests
on   several  types   of   metal    finishing  and   manufacturing
wastewater  indicate that metals  removal  to levels of  less  than
 0.05  mg/1 and in  some cases  less  than  0.01  mg/1 are  common
 in systems using sulfide precipitation followed by clarification.


                               1316

-------
Some  of the bench scale data,  particularly in the    c- of
do  not support  such  low effluent   concentrations     Howe-,.
lead  is  consistently removed to very low  levels   (less   than
0.02    mg/1)   in   systems   using  hydroxide   and   carbonate
precipitation and sedimentation.

Of  particular  interest is the ability of sulfide to precipitate
hexavalent chromium (Cr+6) without prior reduction  to  the  tri-
valent  state  as  is  required  in  the hydroxide process.  When
ferrous sulfide is used as the precipitant, iron and sulfide  act
as  reducing  agents for the hexavalent chromium according to the
reaction:                                            ,
FeS
              3H20 ---- > Fe(OH)3 ;+ Cr(OH)3
The sludge produced in this reaction consists  mainly  of  ferric
hydroxides,  chromic  hydroxides,  and various metallic sulfides.
Some excess hydroxyl ions are generated in this process, possibly
requiring a downward re-adjustment of pH.

Based  on the available data,  Table VII-6    shows  the  minimum
reliably    attainable   effluent  concentrations   for   sulfide
precipitation-sedimentation systems.  These values  are- used  to
calculate   performance  predictions  of  sulfide  precipitation-
sedimentation systems.

Carbonate precipitation is sometimes used to precipitate  metals,
especially  where precipitated metals values are to be recovered.
The solubility of most metal carbonates is  intermediate  between
hydroxide  and sulfide solubilities; in addition, carbonates form
easily filtered precipitates.

Carbonate ions appear to be particularly useful in  precipitating
lead  and  antimony.   Sodium  carbonate  has been observed being
added at treatment to improve lead precipitation and  removal  in
some  industrial  plants.   The lead hydroxide and lead carbonate
solubility  curves  displayed in Figure VII-2     ("Heavy  Metals
Removal,"        by        Kenneth       Lanovette,      Chemical
Engineer ing/Deskbook  Issue,  October  17,  1977)  explain   this
phenomenon.

Co-precipitation   With   Iron.   The  presence  of   substantial
quantites of iron in metal bearing wastewaters  before  treatment
has  been  shown to improve the removal of toxic metals.  In some
cases this iron is an integral part of the industrial wastewater;
in  other  cases  iron  is deliberately added  as  a  preliminary
treatment  or first  step of  treatment.   The iron functions  to
improve  toxic  metal removal by three mechanisms:  the iron  co-
precipitates  with   toxic  metals forming a  stable  precipitate
which  desolubilizes  the toxic metal;  the  iron   improves  the
settleability  of the precipitate;  and the large amount of  iron
reduces the fraction of toxic metal  in  the  precipitate.    Co-
precipitation   with  iron  has  been practiced  for  many  years
incidentally  when  iron was a  substantial  consitutent  of  raw
wastewater  and  intentionally when iron salts were ' added  as  a
                               1317

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coagulant  aid.   Aluminum or mixed iron-aluminum salt also  have
been used.   The addition of iron for co-precipitation to aid  in
toxic   metals   removal   is   considered   a  routine  part  of
state-of-the-art  lime  and settle technology  which  should   be
implemented  as  required  to  achieve  optimal  removal of toxic
metals.

Co-precipitation using large amounts of  ferrous  iron  salts  is
known  as ferrite co-precipitation because magnetic iron oxide or
ferrite is formed.  The addition of ferrous  salts  (sulfate)  is
followed   by   alkali  precipitation  and  air  oxidation.   The
resultant precipitate is easily removed by filtration and may  be
removed  magnetically.   Data  illustrating  the  performance  of
ferrite co-precipitation is shown in Table VII-7.

Advantages and Limitations.  Chemical precipitation has proved to
be an effective  technique  for  removing  many  pollutants  from
industrial  wastewater.  It operates at ambient conditions and is
well  suited  to  automatic  control.   The   use   of   chemical
precipitation may be limited because of interference by chelating
agents,  because  of  possible  chemical  interference with mixed
wastewaters  and  treatment  chemicals,   or   because   of   the
potentially  hazardous  situation  involved  with the storage and
handling   of  those  chemicals.    Nonferrous   metals   forming
wastewaters  do   not   normally  contain   chelating  agents  or
complex pollutant matrix formations which would interfere with or
limit  the  use  of chemical  precipitation.    Lime  is  usually
added  as  a slurry when used in  hydroxide  precipitation.   The
slurry  must   be   kept  well mixed  and  the   addition   lines
periodically checked to prevent blocking of the lines,  which may
result  from  a buildup of  solids.  Also,   lime   precipitation
usually    makes    recovery    of    the  precipitated    metals
difficult,   because   of  the  heterogeneous nature of most lime
sludges.

The major advantage of the sulfide precipitation process is  that
the extremely low solubility of most metal sulfides promotes very
high metal removal efficiencies; the sulfide process also has the
ability  to  remove chromates and dichromates without preliminary
reduction of the chromium to its trivalent state.   In  addition,
sulfide  can  precipitate  metals  complexed with most complexing
agents.  The process demands care, however, in maintaining the pH
of the solution at approximately 10 in order to restrict the gen-
eration  of  toxic  hydrogen  sulfide  gas.   For  this   reason,
ventilation  of the treatment tanks may be a necessary precaution
in most installations.  The use of insoluble sulfides reduces the
problem  of  hydrogen  sulfide  evolution.   As  with   hydroxide
precipitation,  excess  sulfide  ion must be present to drive the
precipitation reaction to  completion.   Since  the  sulfide  ion
itself is toxic, sulfide addition must be carefully controlled to
maximize  heavy  metals  precipitation  with  a minimum of excess
sulfide to avoid the necessity of post treatment.  At  very  high
excess  sulfide  levels  and  high  pH,  soluble  mercury-sulfide
compounds may also be formed.  Where excess sulfide  is  present,
aeration  of  the  effluent  stream can aid in oxidizing residual


                               1318

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sulfide to the less harmful sodium sulfate (Na2SC>4).  "re
cost  of   sulfide  precipitants  is  high   in   C'.\ _.a:.'jLt.on
hydroxide precipitants,  and disposal of metallic sulfide sludges
may  pose problems.     An   essential   element   in   effective'
sulfide  precipitation  is the removal  of  precipitated   solids
from   the  wastewater  and  proper disposal  in'  an  appropriate
site.   Sulfide  precipitation will also generate a higher volume
of   sludge   than  hydroxide    precipitation,    resulting   in
higher  disposal  and dewatering costs.   This is especially true
when  ferrous  sulfide is used as the precipitant.

Sulfide  precipitation may be used as a polishing treatment after
hydroxide    precipitation-sedimentation.      This     treatment
configuration  may  provide the better treatment effectiveness of
sulfide precipitation while minimizing the variability caused  by
changes   in  raw  waste  and  reducing  the  amount  of  sulfide
precipitant   required.    Sulfide   is  also  effective   as   a
pretreatment technology before lime and settle to remove specific
pollutants such as chromium.
                            Reliability:
Alkaline
chemical
Operational    Factors.
precipitation  is highly reliable, although proper monitoring and
control are  required.   Sulfide  precipitation  systems  provide
similar reliability.

Maintainability:   The  major  maintenance needs involve periodic
upkeep of  monitoring  equipment,  automatic  feeding  equipment,
mixing  equipment,  and  other  hardware.  Removal of accumulated
sludge is necessary for  efficient  operation  of  precipitation-
sedimentation systems.

Solid Waste Aspects:  Solids which precipitate out are removed in
a  subsequent  treatment  step.  Ultimately, these solids require
proper disposal.

Demonstration Status.  Chemical precipitation of metal hydroxides
HT a classic waste treatment technology used by  most  industrial
waste treatment systems.   Chemical precipitation of some metals,
in  particular  lead and antimony,  in the carbonate   form   has
been  found  to  be  feasible and is commercially used to  permit
metals   recovery  and  water  reuse.  Full   scale    commercial
sulfide   precipitation   units   are  in operation  at  numerous
installations.   As    noted  earlier,  sedimentation  to  remove
precipitates is discussed separately.

Use  in Nonferrous Metals Forming Plants.   Forty-six  nonferrous
metals  forming  plants currently operate chemical  precipitation
(lime or caustic systems).  The  quality  of treatment  provided,
however,  is variable.  A review of  collected data  and  on-site
observations  reveals  that control of system parameters is often
poor.    Where   precipitates   are  removed   by  clarification,
retention   times   are  likely  to  be  short  and cleaning  and
maintenance questionable.   Similarly,  pH control  is frequently
inadequate.   As  a result of these factors, effluent performance
                               1319

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 at   nonferrous metals  forming  plants   nominally   practicing    the
 same wastewater  treatment  is observed  to  vary  widely.

 3.   Cyanide Precipitation

 Cyanide  precipitation, although a method for  treating  cyanide  in
 wastewaters, does not  destroy  cyanide.  The  cyanide  is  retained
 in   the  sludge  that  is   formed.   Reports indicate that during
 exposure to sunlight,  the  cyanide complexes  can   break  down  and
 form  free  cyanide.   For this  reason,  the sludge  from  this
 treatment method must  be disposed of carefully.

 Cyanide may be precipitated and settled out  of wastewaters by the
 addition of zinc sulfate or ferrous sulfate.   In  the presence  of
 iron,  cyanide will form extremely stable  cyanide complexes.  The
 addition  of  zinc  sulfate or  ferrous   sulfate   forms    zinc
 ferrocyanide or  ferro  and  ferricyanide complexes.

 Adequate removal of the precipitated cyanide requires that the  pH
 must   be  kept   at  9.0  and   an  appropriate  retention  time  be
 maintained.  A study has shown that the formation of the  complex
 is very dependent on pH.   At a pH of either  8  or 10, the  residual
 cyanide concentration  measured is twice that of the same  reaction
 carried  out  at  a  pH  of  9.  Removal efficiencies also depend
 heavily on the retention time  allowed.   The  formation  of  the
 complexes  takes  place rather slowly.  Depending upon  the excess
 amount of zinc sulfate or  ferrous sulfate added, at  least  a   30
 minute  retention time should  be allowed for the formation of the
 cyanide  complex before continuing on to the clarification stage.

 One experiment with  an  initial  concentration  of  10  mg/1   of
 cyanide  showed  that 98 percent of the cyanide was complexed  ten
 minutes  after   the  addition  of  ferrous  sulfate  at twice the
 theoretical amount  necessary.    Interference  from  other  metal
 ions,  such  as  cadmium,   might  result  in   the need for longer
 retention times.

 Table  VII-8   presents cyanide precipitation  data   from  three
 coil   coating   plants.    A   fourth plant was  visited  for  the
 purpose of observing plant testing of the  cyanide  precipitation
 system.   Specific  data  from  this  facility  are  not included
 because:  (1) the pH was usually well below the .optimum  level  of
 9.0;   (2)   the  historical treatment data were hot obtained using
 the standard cyanide analysis procedure;  and (3)   matched  input-
 output  data  were not made available by the plant.   Scanning the
available data indicates that the raw waste CN level was  in  the
 range  of  25.0;  the pH 7.5; and treated CN level  was from 0.1 to
 0.2.

The  concentrations shown  on Table VII-8 are those of the  stream
entering    and   leaving  the   treatment   system.    Plant  1057
allowed  a  27-minute  retention time for the  formation  of  the
complex.    The   retention   time   for the other  plants  is  not
known.    The  data suggest that over a wide range    of     cyanide
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concentration    in    the  raw   waste,   the  concentration
cyanide can be reduced in the effluent stream to ur    .-u..l'j r.
                                                          of
Application and Performance.  Cyanide precipitation can  be  used
when  cyanide destruction is not feasible because of the presence
of cyanide complexes which are difficult,  to  destroy.   Effluent
concentrations of cyanide well below 0.15 mg/1 are possible.

Advantages   and   Limitations.     Cyanide  precipitation  is  an
inexpensive method of treating cyanide.  Problems may occur  when
metal ions interfere with the formation of the complexes.
4.
Granular Bed Filtration
Filtration   occurs   in   nature  as  the  surface  and   ground
waters are cleansed by sand.   Silica sand,  anthracite coal, and
garnet   are  common   filter ,  media  used  in  water' treatment
plants.  These are usually supported by gravel.  The media may be
used singly or  in combination.    The -multimedia filters may  be
arranged  to  maintain  relatively distinct layers by,  virtue  of
balancing  the  forces  of gravity,  flow,  and buoyancy  on  the
individual   particles.    This  is  accomplished   by  selecting
appropriate filter flow rates (gpm/sq-ft),  media grain size, and
density.

Granular bed filters may be classified  in  terms  of  filtration
rate,  filter  media,  flow pattern, or method of pressurization.
Traditional rate classifications are slow sand, rapid  sand,  and
high  rate  mixed  media.   In  the  slow  sand  filter,  flux or
hydraulic loading is relatively low, . and  removal  of  collected
solids  to  clean  the filter is therefore relatively infrequent-.
The filter is often cleaned by scraping off the inlet face  (top)
of  the  sand  bed.   In  the  higher  rate  filters, cleaning is
frequent and is accomplished by a periodic backwash, opposite  to
the direction of normal flow.

A  filter  may  use  a single medium.such as sand or diatomaceous
earth, but dual and mixed (multiple) media filters  allow  higher
flow rates and efficiencies.   Figure VII-32 shows five different
filter configurations.   The  dual  media filter usually consists
of  a fine bed of sand under a coarser bed of   anthracite  coal.
The  coarse coal removes most of the influent solids,  while  the
fine   sand  performs a polishing function.   At the end  of  the
backwash, the fine sand settles  to  the  bottom  because  it  is
denser  than  the  coal,  and  the  filter  is  ready  for normal
operation.   The  mixed  media  filter  operates  on   the   same
principle,  with  the  finer,  denser media at the bottom and the
coarser, less dense media at the top.  The usual  arrangement  is
garnet at the bottom (outlet end) of the bed, sand in the middle,
and  anthracite  coal  at  the  top.  Some mixing of these layers
occurs and is, in fact, desirable.

The flow pattern is usually top-to-bottom, but,other patterns are
sometimes used.  Upflow filters are  sometimes  used,  and  in  a
horizontal  filter  the  flow is horizontal.  In a biflow filter,
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the influent enters  both  the  top  and  the  bottom  and  exits
laterally.   The  advantage  of  an upflow filter is that with an
upflow backwash, the particles of  a  single  filter  medium  are
distributed and maintained in the desired coarse-to-fine (bottom-
to-top)  arrangement.   The disadvantage is that the bed tends to
become fluidized/ which ruins filtration efficiency.  The  biflow
design is an attempt to overcome this problem.

The  classic  granular  bed  filter  operates  by  gravity  flow;
however, pressure filters are fairly widely  used.   They  permit
higher  solids loadings before cleaning and are advantageous when
the filter effluent must be pressurized  for  further  downstream
treatment.   In  addition, pressure filter systems are often less
costly for low to moderate flow rates.

Figure VII-14 depicts a high rate,  dual media,  gravity downflow
granular bed filter, with  self-stored  backwash.   Both filtrate
and  backwash  are  piped around the bed in an  arrangement  that
permits  gravity  upflow of  the  backwash,   with   the   stored
filtrate   serving   as  backwash.   Addition  of  the  indicated
coagulant and polyelectrolyte usually results  in  a  substantial
improvement in filter performance.

Auxilliary filter cleaning is sometimes employed in the upper few
inches  of  filter  beds.   This is conventionally referred to as
surface wash and is accomplished by water  jets  just  below  the
surface  of  the  expanded  bed during the backwash cycle.  These
jets enhance the scouring action in the  bed  by  increasing  the
agitation.

An important feature for successful filtration and backwashing is
the  underdrain.  This is the support structure for the bed.  The
underdrain provides an area for collection of the filtered  water
without  clogging  from  either  the filtered solids or the media
grains.  In addition, the underdrain prevents loss of  the  media
with  the  water,  and during the backwash cycle it provides even
flow  distribution  over  the  bed.   Failure  to  dissipate  the
velocity  head during the filter or backwash cycle will result in
bed upset and the need for major repairs.

Several standard approaches are employed for filter  underdrains.
The  simplest  one  consists  of  a parallel porous pipe imbedded
under a layer of coarse gravel and attached via a  manifold to  a
header   pipe  for  effluent removal.   Other approaches  to  the
underdrain  system  are known as the Leopold and Wheeler   filter
bottoms.    Both   of these  incorporate  false concrete  bottoms
with  specific  porosity configurations to" provide  drainage  and
velocity head dissipation.

Filter system operation may be manual or automatic.   The  filter
backwash  cycle  may  be  on a timed basis, a pressure drop basis
with a terminal value which triggers backwash, or a solids carry-
over basis from turbidity monitoring of the outlet  stream.   All
of these schemes have been used successfully.
                               1322

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 Application  and
 use granular
                  Performance.
_   Wastewater treatment plants often
for  polishing  after  clarification,
 similar  operations.   Granular  bed
      application   to   nearly   all
              bed  filters
sedimentation,   or   other
filtration  thus  has  potential
industrial plants.  Chemical additives which enhance t*h«Tupstream
treatment  equipment may or may not be compatible with or enhance
the filtration process.  Normal operating flow rates for  various
types of filters are:
  Slow Sand
  Rapid Sand
                         2.04 - 5.30 1/sq m-hr

                        40.74 - 51.48 1/sq m-hr
  High Rate Mixed Media  81.48 - 122.22 1/sq m-hr

 Suspended  solids are commonly removed from wastewater streams bv
 filtering through a deep 0.3-0.9 m  (1-3   feet)   granular  filter
 bed.   The porous bed formed  by the granular media can be designed
 to  remove  practically  all suspended particles.   Even colloidal
 suspensions (roughly 1  to   100  microns)   are   adsorbed  on  the
 surface   of  the  media grains as they pass in close  proximity in
 the  narrow bed  passages.

 Properly  operated filters following  some pretreatment  to  reduce
 suspended  solids  below 200  mg/1 should  produce  water with less
 than  10 mg/1  TSS.   For example,  multimedia filters produced  the
 effluent  qualities  shown in  Table VII-9.

 Advantages  and  Limitations.  The principal advantages of  granular
 bed   filtration  are   its  comparatively   (to  other  filters)  low
 initial and operating  costs, reduced land  requirements  over  other
 methods   to  achieve   the  same   level  of  solids  removal,   and
 elimination  of  chemical  additions   to   the  discharge   stream
 However,  the  filter may  require  pretreatment if  the solids   level
 is  high   (over   100   mg/1).   Operator training must be  somewhat
 extensive due to  the controls and  periodic backwashing  involved,
 and   backwash  must   be  stored   and  dewatered   for   economical
 disposal.

 Operational Factors.   Reliability:  The  recent  improvements  in
 filter   technology    have   significantly   improved   filtration
 reliability.    Control  systems,   improved  designs,    and   good
 operating  procedures  have  made  filtration  a  highly  reliable
 method of water treatment.

 Maintainability:  Deep bed filters may be  operated  with  either
 manual  or  automatic  backwash.   in  either  case, they must be
 periodically inspected for media attrition, partial plugging, and
 leakage.   Where backwashing is not used, collected solids must be
 removed by shoveling, and filter media must be at least partiallv
 replaced.                                                        *

 Solid Waste  Aspects:   Filter • backwash  is  generally  recycled
within  the  wastewater  treatment  system,  so  that   the solids
                               1323

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 ultimately appear in the clarifier sludge stream  for  subsequent
 dewatering.   Alternatively, the backwash stream may be dewatered
 directly or, if there is no backwash, the collected solids may be
 disposed  of  in  a  suitable  landfill.   in  either  of   these
 situations  there is a solids disposal problem similar to that of
 clarifiers.

 Demonstration Status.  Deep bed filters  are  in  common  use  in
 municipal  treatment  plants.   Their use in polishing industrial
 clarifier effluent is increasing, and the  technology  is  proven
 and   conventional.     As  noted   previously,   however,  little
 data  is  available  characterizing  the effectiveness of filters
 presently  in  use within the industry.    One  nonferrous  metals
 forming plant has granular media filtration in place.

 5.   Pressure Filtration
 Pressure
 material
 pressure
 provides
 force.
 pressure
filtration works by pumping the liquid through a  filter
 which is impenetrable to the solid phase.  The positive
exerted by the feed  pumps  or  other  mechanical  means
the pressure differential which is the principal driving
 Figure VII-15 ) represents the operation of one type of
filter.
 A typical  pressure  filtration unit  consists  of  a  number  of  plates
 or trays which  are  held rigidly in  a  frame   to  ensure   alignment
 and  which  are  pressed  together  between   a  fixed  end   and  a
 traveling  end.  On  the  surface of each  plate, a  filter   made  of
 cloth or   synthetic  fiber  is mounted.   The  feed  stream  is  pumped
 into  the unit and passes through holes  in  the  trays  along  the
 length  of  the  press  until  the cavities or  chambers between  the
 trays are  completely  filled.   The solids are  then entrapped,   and
 a cake begins to  form on the  surface  of  the  filter material.   The
 water passes through  the fibers, and  the solids are  retained.

 At the  bottom of  the  trays  are drainage ports.  The filtrate is
 collected  and discharged to a  common  drain.  As the  filter medium
 becomes coated  with sludge, the  flow of  filtrate  through   the
 filter  drops sharply,  indicating that the capacity  of the filter
 has been exhausted.   The unit  must  then be cleaned of the sludge.
 After the  cleaning or replacement of  the filter media,  the  unit
 is again ready  for operation.

 Application  and  Performance.   Pressure  filtration  is used in
 nonferrous  metals forming plants for sludge dewatering and  also
 for_  direct removal   of   precipitated   and  other   suspended
 solids  from wastewater.   Because dewatering is such  a   common
 operation   in  treatment   systems,   pressure filtration  is  a
 technique  which can be  found  in many industries  concerned  with
 removing  solids  from their waste stream.

 In  a  typical  pressure filter, chemically preconditioned sludge
detained in the unit for  one  to  three  hours   under  pressures
varying  from  5 to 13 atmospheres exhibited final solids content
between 25  and 50  percent.
                               1324

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 Advantages  and  Limitations.   The pressures which may  be  applied
 to  a  sludge   for   removal   of   water  by filter presses that are
 currently available  range  from 5 to 13  atmospheres.   As a result,
 pressure  filtration  may    reduce   the    amount   of   chemical
 pretreatment  required for sludge dewatering.   Sludge retained in
 the form  of the filter cake  has  a  higher  percentage  of  solids
 than  that  from centrifuge  or  vacuum  filter.   Thus, it can be
 easily accommodated  by materials handling systems.

 As  a  primary   solids  removal   technique,  pressure  filtration
 requires  _less   space   than   clarification  and is well suited to
 streams with high solids loadings.   The sludge   produced  may  be
 disposed  without further  dewatering, but the amount of sludge is
 increased  by   the   use of   filter  precoat  materials  (usually
 diatomaceous  earth).   Also,  cloth pressure filters often do not
 achieve as  high a degree of  effluent  clarification as  clarifiers
 or granular media filters.

 Two disadvantages associated with pressure filtration in the  past
 have  been  the short  life  of  the  filter   cloths and lack of
 automation.  New synthetic fibers have largely  offset  the first
 of  these problems.    Also,   units  with  automatic  feeding and
 pressing  cycles are  now available.

 For  larger operations,  the relatively high space  requirements,  as
 compared  to those of a  centrifuge,  could  be prohibitive  in   some
 situations.

 Operational  Factors.   Reliability:   With  proper  pretreatment,
 design, and control, pressure  filtration  is a   highly  dependable
 system.

 Maintainability:   Maintenance   consists   of periodic cleaning  or
 replacement of  the filter  media,  drainage  grids,  drainage  piping,
 filter  pans, and other parts of  the system.  If   the   removal   of
 the  sludge cake is not automated, additional time is  required  for
 this operation.

 Solid   Waste  Aspects:   Because  it is generally  drier  than other
 types_of  sludges, the filter sludge  cake  can  be   handled  with
 relative  ease.   The accumulated  sludge may be disposed  by any  of
 the  accepted procedures depending on  its  chemical   composition.
 The  levels  of  toxic  metals  present   in  sludge  from treating
 nonferrous metals forming wastewater necessitate proper  disposal.

 Demonstration  Status.  Pressure filtration  is  a  commonly  used
 technology  in  a  great  many commercial applications.

 6.   Settling

 Settling is  a  process which removes solid particles from a liquid
matrix by gravitational force.  This  is  done  by  reducing  the
velocity  of  the feed stream in a large volume tank  or  lagoon so
                               1325

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 that gravitational settling can occur.   Figure VII-16  shows two
 typical settling devices.

 Settling  is  often  preceded  by  chemical  precipitation  which
 converts dissolved pollutants to solid form  and  by  coagulation
 which  enhances  settling  by  coagulating suspended precipitates
 into larger, faster settling particles.

 If no chemical pretreatment is used, the wastewater is fed into a
 tank or lagoon where it loses velocity and the  suspended  solids
 are  allowed  to  settle out.  Long retention times are generally
 required.     Accumulated   sludge   can   be   collected   either
 periodically or continuously and either manually or mechanically
 Simple   settling,    however,   may   require  excessively  large
 catchments,  and long  retention  times  (days  as  compared  with
 hours)   to  achieve  high removal efficiencies.   Because of this
 addition of  settling aids such as alum or  polymeric  flocculants
 is often economically attractive.

 In  practice, chemical precipitation often precedes settling,  and
 inorganic  coagulants or polyelectrolytic flocculants are  usually
 added  as  well.   Common coagulants include sodium sulfate, sodium
 aluminate,   ferrous  or  ferric  sulfate,   and  ferric  chloride
 Organic polyelectrolytes vary in structure,  but all usually form
 larger  floe  particles than coagulants used alone.

 Following  this  pretreatment,  the  wastewater can   be  fed  into  a
 holding tank or  lagoon for settling,  but  is more often piped into
 a   clarifier  for   the  same   purpose.  A  clarifier reduces space
 requirements,  reduces  retention   time,   and increases   solids
 removal efficiency.   Conventional  clarifiers  generally consist of
 a    circular  or   rectangular  tank   with   a mechanical   sludge
 collecting device or  with a sloping  funnel-shaped  bottom designed
 for  sludge collection.   In advanced   settling devices,  inclined
 plates,  slanted  tubes,   or   a  lamellar network  may  be included
 within  the clarifier  tank  in  order   to  increase   the   effective
 settling  area,  increasing  capacity.   A  fraction  of  the sludqe
 stream  is often recirculated to the inlet,  promoting formation of
 a  denser sludge.

 Settling is  based on  the ability of  gravity   (Newton's  Law)  to
 cause small  particles  to  fall or settle (Stokes1 Law) through  the
 fluid   they are  suspended  in.   Presuming  that  the   factors
 affecting chemical precipitation  are  controlled  to  achieve  a
 readily settleable precipitate, the principal factors controlling
 settling  are the particle characteristics and the upflow  rate of
 the suspending fluid.  When the effective settling area  is  great
 enough  to allow settling, any increase in the effective settling
 area will produce no increase in solids removal.

 Therefore,  if a plant has installed equipment that  provides  the
appropriate   overflow  rate,   the  precipitated  metals  in  the
effluent can be effectively  removed.   The  number  of  settling
devices  operated  in  series or in parallel by a facility is not
important  with regard to suspended  solids  removal;   rather it
                               1326

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is  important  that   the  settling  devices  provide  sufficient
effective settling area.

Another  important  facet  of ' sedimentation   theory   is   that
diminishing  removal  of 'suspended solids is achieved for a unit
increase in the -effective settling area.  Generally, it has•  been
found  that  suspended solids removal performance varies with the
effective up-flow rate.  Qualitatively the performance  increases
asymptotically  to a maximum level beyond which a decrease in up-
flow  rate  provides  incrementally  insignificant  increases  in
removal.   This  maximum  level  is  dictated  by  particle  size
distribution, density characteristic of  the  particles  and  the
water   matrix,   chemicals   used for precipitation  and  pH  at
which precipitation occurs.

Application and Performance.  Settling or clarification-  is  used
in    the    nonferrous  metals  forming  category    to   remove
precipitated  metals.   Settling  can  be  used  to  remove  most
suspended  solids  in a  particular  waste  stream;  thus  it  is
used  extensively  by many different industrial  waste  treatment
facilities.    Because  most metal  ion  pollutants  are  readily
converted   to  solid  metal hydroxide precipitates,  settling is
of particular  use  in  those industries  associated  with  metal
production,   metal  finishing,  metal  working,  and  any  other
industry  with  high  concentrations  of  metal  ions  in   their
wastewaters.     In   addition    to   toxic   metals,   suitably
precipitated   materials effectively removed by settling  include
aluminum,   iron,   manganese,   cobalt,   molybdenum,  fluoride,
phosphate, and many others.

A  properly  operating  settling  system  can  efficiently remove
suspended  solids,  precipitated  metal  hydroxides,  and   other
impurities  from  wastewater.   The  performance  of  the process
depends on a  variety  of  factors,  including  the  density  and
particle  size  of  the  solids,  the  effective  charge  on  the
suspended  particles,  and  the  types  of  chemicals   used   in
pretreatment.   The site of flocculant or coagulant addition also
may significantly influence the effectiveness  of  clarification.
If the flocculant is subjected to too much mixing before entering
the  clarifier,  the  complexes  may  be sheared and the settling
effectiveness diminished.  At the same time, the flocculant  must
have  sufficient  mixing and reaction time in order for effective
set-up and settling to occur.  Plant personnel have observed that
the line or trough leading into the clarifier is often  the  most
efficient  site  for  flocculant  addition.   The  performance of
simple settling is a function of  the  retention  time,  particle
size and density, and the surface area of the basin.

The   data displayed in Table VII-10  indicate  suspended  solids
removal    efficiencies   in   settling   systems.     The   mean
effluent  TSS concentration obtained by the plants shown in Table
VII-10 is 10.1 mg/1.  Influent concentrations averaged 838 .mg/1.
The maximum effluent TSS value reported is 23 mg/1.  These plants
all  use  alkaline pH adjustment to precipitate metal hydroxides,
and most add a coagulant or flocculant prior to settling.
                               1327

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Advantages  and  Limitations.   The  major  advantage  of  simple
settling  is  its simplicity as demonstrated by the gravitational
settling of solid particulate waste in a holding tank or  lagoon.
The major problem with simple settling is the long retention time
necessary   to  achieve  complete  settling,  especially  if  the
specific gravity of the suspended matter  is  close  to  that  of
water.   Some  materials  cannot be practically removed by simple
settling alone.

Settling performed in a clarifier is effective in removing  slow-
settling  suspended  matter  in  a shorter time and in less space
than a simple settling system.  Also, effluent quality  is  often
better  from a clarifier.  The cost of installing and maintaining
a clarifier, however, is substantially  greater  than  the  costs
associated with simple settling.

Inclined plate, slant tube, and lamella settlers have even higher
removal  efficiencies  than  conventional clarifiers,- and greater
capacities per unit area are possible.  Installed costs for these
advanced clarification systems are claimed to  be  one  half  the
cost of conventional systems of similar capacity.

Operational  Factors.   Reliability:   Settling  can  be a highly
reliable technology for removing  suspended  solids.   Sufficient
retention  time  and regular sludge removal are important factors
affecting  the  reliability  of  all  settling  systems.   Proper
control  of  pH adjustment, chemical precipitation, and coagulant
or flocculant addition are additional factors affecting  settling
efficiencies  in  systems  (frequently  clarifiers)  where  these
methods are used.

Those advanced settlers using slanted tubes, inclined plates,  or
a  lamellar  network  may  require  pre-screening of the waste in
order to eliminate any fibrous materials which could  potentially
clog the system.  Some installations are especially vulnerable to
shock  loadings,  as  from  storm water runoff, but proper system
design will prevent this.

Maintainability:  When  clarifiers  or  other  advanced  settling
devices  are  used,  the  associated system utilized for chemical
pretreatment and sludge dragout must be maintained on  a  regular
basis.    Routine   maintenance   of  mechanical  parts  is  also
necessary.   Lagoons  require  little,  maintenance   other   than
periodic sludge removal.

Demonstration  Status.  Settling represents the typical method of
solids removal and is employed extensively  in  industrial  waste
treatment.   The advanced clarifiers are just beginning to appear
in significant numbers in commercial applications.    Seventy-five
nonferrous metals forming plants currently operate  sedimentation
or clarification systems.           .
                               1328

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7.   Skimming                       .''",'..-      .

Pollutants with a specific gravity less  than  water  will  often
float  unassisted  to  the  Surface •: of- the wastewater .  Skimming
removes these floating wastes.  Skimming normally takes place  in
a  tank  designed to allow the floating debris to rise and remain
on the surface, while the liquid flows to an outlet located below
the floating layer.  Skimming devices are therefore suited to the
removal of non-emulsified oils from raw  waste  streams.   Common
skimming  mechanisms  include the rotating drum type, which picks
up oil from the surface of the water as  it  rotates;."   A  doctor
blade • scrapes  oil from the drum and collects it in a trough for
disposal or reuse.  The water portion is allowed  to  flow  under
the   rotating'  drum.   Occasionally,  an  underflow • baffle  is
installed after the drum; this has the advantage of retaining any
floating oil which escapes  the  drum  skimmer.   The  belt  type
skimmer  is  pulled  vertically through, the water, collecting oil
which is scraped off from the surface and collected  in  a  drum.
Gravity  separators (see Figure VII-33),   such  as 'the API type,
utilize  overflow  and underflow baffles to skim a  floating  oil"
layer  from   the   surface of  the   wastewater,.   An  overflow-
underflow  baffle  allows a small amount of wastewater  (the  oil
portion)  to flow over into a trough for disposal or reuse  while
the majority of  the  water, flows underneath  the  baffle.  This
is  followed  by an overflow baffle,  which is set  at  a  height
relative  to the first baffle  such  that only  the  oil  bearing
portion   will  flow over the first'baffle  during  normal  plant
operation.   A  diffusion   device,   such  as  a  vertical  slot
baffle, aids in creating a uniform flow through the system and in
increasing oil removal efficiency.

Application   and   Performance.     Oil   skimming  is  used  in
nonferrous  metals  forming plants to remove free oil used  as   a
forming  lubricant.   Another  source of oil is   lubricants  for
drive  mechanisms and other machinery contacted by process water.
Skimming  is  applicable    to   any   waste   stream  "containing
pollutants  which float to  the surface.   'It is commonly used  to
remove  free oil,  grease,  and soaps.  Skimming is often used in
conjunction  with  air flotation or clarification  in   order  to
increase its effectiveness.

The   removal  efficiency of a skimmer is partly a 'function of the
retention time of the water in the tank.   Larger,  more  buoyant
particles   require  less  retention, time than smaller particles.
Thus, the efficiency also depends on the composition of the waste
stream-.  The retention time required to  allow  phase  separation
and  subsequent skimming varies from 1 to 15 minutes, depending on
the  wastewater characteristics.

API  or other gravity-type separators tend to be-more suitable for
use  where the  amount of surface oil flowing through the system is
consistently   significant.  -Drum  and• belt  type  skimmers  are
applicable  to  waste streams which  evidence  smaller   amounts•• • of
 floating  oil  and where surges of floating oil are not a problem.
 Using an API separator system in conjunction  with  a  drum   type


                               1329

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 skimmer   is  a   very  effective  method  of  removing  floating
 contaminants from nonemulsified  oily  waste  streams.    Sampling
 data  shown in Table VII-11  illustrate the capabilities of   the
 technology  with  both  extremely  high and moderate oil influent
 levels.

 These data are intended to be illustrative of the very  high level
 of oil and grease removals attainable in a  simple  two-step  oil
 removal  system.    Based on the performance of installations in a
 variety of manufacturing plants and permit requirements that  are
 consistently  achieved,   it has been determined that effluent oil
 levels  may  be reliably reduced below  10  mg/1  with    moderate
 influent concentrations.     Very  high concentrations of oil such
 as the 22 percent shown above may require two-step  treatment  to
 achieve this level.

 Skimming which removes oil may also be used to remove base  levels
 of   organics.    Plant  sampling  data  show  that  many organic
 compounds tend to be removed  in  standard  wastewater   treatment
 equipment.   Oil separation not only removes oil  but  also organics
 that  are  more  soluble   in  oil  than  in water.   Clarification
 removes organic solids directly and  probably   removes   dissolved
 organics by adsorption on  inorganic solids.

 The   source  of these  organic pollutants  is not  always  known with
 certainty,  although  in metal  forming  operations  they   seem  to
 derive   mainly   from  various  process  lubricants.   They are also
 sometimes present  in the plant  water   supply,   as   additives   to
 proprietary  formulations   of  cleaners,   or   as   the   result   of
 leaching from plastic  lines  and other materials.

 High molecular  weight organics   in  particular   are, much  more
 soluble  in  organic  solvents than  in water.  Thus  they are much
 more concentrated  in the oil  phase  that is  skimmed   than in  the
 wastewater.   The  ratio of  solubilities of a  compound in oil and
 water phases  is called the partition  coefficient.  The   logarithm
 of   the partition coefficients  for selected polynuclear aromatic
 hydrocarbon  (PAH) and  other  toxic organic   compounds  in  octanol
 and  water are shown  in Table  VII-12.

 A  review  of  priority organic compounds commonly found in metal
 forming  operation waste streams  indicated that incidental removal
 of these compounds often occurs as a result  of  oil  removal  or
 clarification processes.  When all organics analyses from visited
 plants   are  considered,  removal  of  organic compounds by other
 waste treatment technologies   appears  to  be  marginal   in  many
 cases.   However, when only raw waste concentrations of  0.05 mg/1
 or   greater  are  considered,  incidental organics removal becomes
much more apparent.  Lower values, those  less  than  0.05  mg/1,
 are  much  more  subject  to  analytical  variation,  while higher
 values  indicate a significant presence of a given compound.   When
 these factors are taken into account, analysis data indicate that
most_clarification  and  oil   removal  treatment  systems  remove
 significant amounts of the toxic organic compounds present in the
                               1330

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 raw  waste.   The  API  oil-water  separation  system performed  no  anly
 in this  regard,  as shown  in Table VII-13.

 Data_  from  five  plant days demonstrate  removal of organics by  the
 combined oil skimming and settling operations performed  on  coil
 coating   wastewaters„   Days   were  .chosen where treatment system
 influent and effluent analyses provided paired  data  points   for
 oil  and grease and the  organics present.  All organics found at
 quantifiable levels  on  those days were  included.   Further,  only
 those  days   were  chosen where  oil  and  grease raw wastewater
 concentrations exceeded 10 mg/1 and where there was reduction  in
 oil  and grease going  through the treatment system.  All plant
 sampling days which  met the above criteria  are  included  below.
 The  conclusion  is that when oil and grease are removed, organics
 also are removed.

                           Percent Removal
Plant-Day
Oil & Grease
Organics
 1054-3
13029-2
13029-3
38053-1
38053-2
Mean
   95.9
   98.3
   95.1
   96.8
   98.5
   96.9
  98.2
  78.0
  77.0
  81.3
  86.3
  84.2
The unit operation most applicable to removal of  trace  priority
organics   is  adsorption,  and  chemical  oxidation  is  another
possibility.  Biological degradation is not generally  applicable
because  the organics are not present in sufficient concentration
to sustain a  biomass  and  because  most  of  the
resistant to biodegradation.
                                   organics  are
Advantages  and  Limitations.   Skimming  as  a  pretreatment  is
effective in removing naturally floating waste material.  It also
improves the performance  of  subsequent  downstream  treatments.
Many  pollutants,  particularly dispersed or emulsified oil, will
not float "naturally" but require additional treatments.   There-
fore, skimming alone may not remove all the pollutants capable of
being  removed  by  air  flotation  or  other  more sophisticated
technologies.
Operational Factors.  Reliability:  Because
skimming is a very reliable technique.
                            of  its  simplicity,
Maintainability:    The   skimming  mechanism  requires
lubrication, adjustment, and replacement of worn parts.
                                        periodic
Solid Waste Aspects:  The  collected  layer  of  debris  must  be
disposed  of  by  contractor  removal, landfill, or incineration.
Because relatively large quantities of water are present  in  the
                               1331

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            vast.es,   incineration   is  not  always a  viable disposal
method.

Demonstration  Status.   Skimming is a   common  operation  utilized
extensively  by  industrial waste  treatment  systems.  Oil skimming
is used  in 30  nonferrous metals forming plants.

8.  Chemical Emulsion Breaking

Chemical treatment  is often used  to break stable oil-in-water  (O-.
W)  emulsions.   An O-W emulsion consists  of  oil  dispersed   in
water, stabilized by electrical charges and emulsifying agent.  A
stable emulsion  will not separate or  break  down without some form
of treatment.

Once an  emulsion is broken,  the  difference in specific gravities
allows   the  oil to float to the  surface of the  water.   Solids
usually  form a layer between the  oil  and water, since some oil  is
retained in the  solids.   The longer  the retention time, the more
complete and distinct the separation  between the oil, solids, and
water  will  be.    Often  other methods of  gravity  differential
separation, such as air flotation or  rotational separation (e.g.,
centrifugation),  are  used to enhance and  speed  separation.   A
schematic  flow  diagram of one type  of application is  shown   in
Figure VII-31.

The  major  equipment  required for   chemical  emulsion  breaking
includes:   reaction  chambers with agitators,  chemical  storage
tanks, chemical feed systems, pumps,  and piping.

Emulsifiers  may  be used in the  plant to aid in  stabilizing   or
forming  emulsions.   Emulsifiers  are  surface-active agents  which
alter the characteristics of the  oil  and water interface.   These
surfactants  have   rather long polar  molecules.   One end of  the
molecule  is  particularly  soluble   in  water  (e.g.,  carboxyl,
sulfate,  hydroxyl,  or  sulfonate groups)  and the other  end   is
readily  soluble  in oils (an organic group which varies  greatly
with  the  different  surfactant  type).    Thus,  the  surfactant
emulsifies  or  suspends  the organic material  (oil)  in  water.
Emulsifiers also lower the surface tension of the O-W emulsion as
a result of solvation and ionic complexing.   These emulsions must
be destabilized in  the treatment  system.

Application and Performance.    Emulsion breaking is applicable to
waste  streams containing emulsified  oils or lubricants  such  as
rolling   and  drawing  emulsions.    Typical  chemical  emulsion
breaking efficiencies are given in Table VII-30.

Treatment of spent O-W emulsions  involves the use of chemicals to
break  the emulsion followed by gravity differential  separation.
Factors  to  be  considered for breaking emulsions  are  type  of
chemicals,   dosage and sequence of addition, pH, mechanical shear
and agitation,  heat, and retention time.
                               1332

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•  .'. •*!(:.. s,  alum,  ferric chloride,  and organic emulsion breakers
r,- eav.    emulsions  by  neutralizing  repulsive  charges   between
partjcles,  precipitating or salting out emulsifying  agents,  or
altering  the interfacial film between the oil and water so it is
readily  broken.   Reactive cations (e.g.,  H(+l), Al(+3), Fe(+3),
and  cationic  polymers) are particularly effective  in  breaking
dilute O-W emulsions.   Once the charges have been neutralized or
the interfacial film broken, the small oil droplets and suspended
solids   will -be  adsorbed on the surface of  the  floe  that  is
formed,  or  break  out and float to the top.   Various types  of
emulsion-breaking  chemicals  are used for the various  types  of
oils.

If more  than one chemical is required,  the sequence of  addition
can  make  quite  a difference in both  breaking  efficiency  and
chemical dosages.

Wastewater  pH  plays  an important role  in  emulsion  breaking,
especially  if cationic inorganic chemicals,  such as  alum,  are
used as  coagulants.   A depressed pH in the range of 2 to 4 keeps
the aluminum ion in its most positive state where it can function
most  effectively for charge neutralization.   After some of  the
oil   is broken free and skimmed,  raising the pH into the 6 to 8
range  with lime or caustic will cause the aluminum to  hydrolyze
and  precipitate  as alumium hydroxide.   This  floe  entraps  or
adsorbs  destabilized  oil droplets which can then  be  separated
from the water phase.  Cationic polymers can break emulsions over
a wider pH range and thus avoid acid corrosion and the additional
sludge  generated  from  neutralization;  however,  an  inorganic
flocculant is usually required to supplement the polymer emulsion
breaker's adsorptive properties.

Mixing   is important in breaking O-W emulsions.   Proper chemical
feed  and dispersion is required for effective  results.   Mixing
also  causes  collisions  which  help  break  the  emulsion,  and
subsequently helps to agglomerate droplets.

In  all  emulsions,  the  mix of two  immiscible  liquids  has  a
specific gravity very close to that of water.  Heating lowers the
viscosity   and   increases   the   apparent   specific   gravity
differential  between oil and water.    Heating also increases the
frequency  of  droplet collisions,  which helps  to  rupture  the
interfacial film.

Chemical  emulsion  breaking  can be used with  oil  skimming  to
achieve  the  treatment  effectiveness  concentrations  that  oil
skimming  alone  will achieve for non-emulsified  streams.   This
type  of  treatment is proven to be reliable  and  is  considered
state-of-the-art  for  nonferrous metals forming emulsified  oily
wastewaters.

Advantages  and Limitations.   Advantages gained from the use  of
chemicals  for  breaking  O-W  emulsions  are  the  high  removal
efficiency  potential and the possibility of reclaiming the  oily
waste.   Disadvantages  are  corrosion problems  associated  with


                               1333

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 acid-aJam  systems-    skilled  operator  requirements  foi   oa .'-n
 Treatment, and chemical sludges produced.

 Operational Factors.   Reliability:   Chemical emulsion breaking is
 a  very reliable process.    The main control parameters,   pH  and
 temperature, are fairly easy to control.

 Maintainability:   Maintenance is required on pumps,   motors,  and
 valves,  as  well as  periodic cleaning of  'the treatment  tank   to
 remove  any accumulated solids.   Energy use is limited to mixers
 and pumps.

 Solid  Waste Aspects:    The surface oil and oily sludge  produced
 are  usually  hauled   away by  a  licensed  contractor.   if  the
 recovered oil has a sufficiently low percentage of water,  it  may
 be burned for its fuel value or processed  and reused.

 Demonstration  Status.   Twelve  plants in the nonferrous  metals
 forming category currently break emulsions with chemicals.

 MAJOR TECHNOLOGY EFFECTIVENESS

 The  performance  of   individual   treatment   technologies   was
 presented  above.   Performance of  operating systems  is discussed
 here.   Two  different   systems  are  considered:   L&S   (hydroxide
 precipitation  and sedimentation  or  lime  and settle)  and LS&F
 (hydroxide precipitation,  sedimentation, and filtration or   lime,
 settle,   and filter).   Subsequently,  an analysis of effectiveness
 of such systems is made to develop  one-day maximum,  and  ten-day
 and  thirty-day  average  concentration levels   to  be  used   in
 regulating pollutants.   Evaluation  of the  L&S and  the LS&F
 systems   is' carried out on the assumption  that chemical reduction
 of chromium,  cyanide precipitation,  and oil removal are installed
 and operating properly  where  appropriate.

 L&S Performance — Combined Metals  Data Base       ,

 A  data base  known  as the "combined  metals  data base"   (CMDB)  was
 used  to   determine  treatment   effectiveness  of  lime  and  settle
 treatment  for  certain pollutants.   The  CMDB was   developed  over
 several  years   and  has   been   used  in a  number  of regulations.
 During the development  of   coil   coating   and  other  categorical
 effluent   limitations   and  standards, chemical analysis data were
 collected  of  raw  wastewater   (treatment   influent)  and  treated
 wastewater   (treatment  effluent)   from 55  plants  (126  data days)
 sampled by  EPA  (or  its   contractor)  using  EPA  sampling  and
 chemical  analysis  protocols.    These  data are  the initial data
 base for determining  the   effectiveness  of   L&S  technology  in
 treating nine pollutants.   Each of  the  plants  in  the initial data
 base   belongs   to  at  least  one  of  the   following   industry
 categories: aluminum forming, battery manufacturing, coil coating
 (including  canmaking),  copper   forming,    electroplating   and
porcelain  enameling.   All  of the plants employ pH adjustment and
hydroxide  precipitation  using   lime   or   caustic,  followed  by
 Stokes'  law  settling   (tank,  lagoon  or   clarifier) for solids


                               1334

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removal.    An  analysis  of  this  data  was  presented  in   the
development  documents  for  the  proposed  regulations  for coil
coating  and  porcelain  enameling  (January  1981).   Prior   to
analyzing  the data, some values were deleted from the data base.
These deletions  were  made  to  ensure  that  the  data  reflect
properly  operated treatment systems.  The following criteria were
used in making these deletions:

-  Plants  where malfunctioning processes or treatment systems at
   the time of sampling were identified.

   Data days  where pH was less than 7.0 for extended periods
   of time or TSS was greater than 50 mg/1 (these are prima
   facie  indications of poor operation).

In  response  to  the  coil  coating  and  . porcelain   enameling
proposals,  some  commenters claimed that it was inappropriate to
use data  from some categories for regulation of other categories.
In response to these comments, the Agency  reanalyzed  the  .data.
An  analysis of variance was applied to the data for the.126 days
of sampling to test the hypothesis of homogeneous plant mean  raw
and treated effluent levels across categories by pollutant.  This
analysis   is  described  in the report "A Statistical Analysis of
the Combined Metals Industries Effluent Data"  which  is  in  the
administrative record supporting this rulemaking.  Homogeneity is
the  absence  of  statistically discernable differences among the
categories,  while  heterogeneity  is  the  opposite,  i.e.,  the
presence   of  statistically  discernable  differences.   The main
conclusion drawn from the analysis of variance is that, with  the
exception  of electroplating, the categories included in the data
base are  generally homogeneous  with  regard  to  mean  pollutant
concentrations  in  both raw and treated effluent.  That is/ when
data from electroplating facilities are included in the analysis,
the hypothesis of . homogeneity  across  categories  is  rejected.
When  the  electroplating  data are removed from the analysis the
conclusion  changes   substantially   and   the   hypothesis   of
homogeneity  across  categories is not rejected.  On the basis of
this analysis, the electroplating data were removed from the data
base  used  to determine limitations for the  coil  coating,  and
porcelain  enameling,   copper   forming,    aluminum    forming,
battery    manufacturing,    nonferrous   metals   manufacturing,
canmaking, and nonferrous metals forming regulations.

The statistical  analysis  provides  support  for  the  technical
engineering   judgment   that   electroplating   wastewaters  are
sufficiently different from the wastewaters of  other  industrial
categories  in the,data base to warrant removal of electroplating
data  from  the   data   base   used   to   determine   treatment
effectiveness.

For   the   purpose   of   determining  treatment  effectiveness,
additional data were deleted from the data base.  These deletions
were made, almost  exclusively,  in  cases  where" effluent  data
points were  associated with low influent values.  This was done
in two steps.  First, effluent values measured on the same day as
                               1335

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influent values chat were less than or equal  to  0.1  mg/1  were
deleted.   Second,  the remaining data were screened for cases in
which all influent values at a plant were low  although  slightly
above  the  0.1  mg/1  value.   These  data  were  deleted not as
individual data points but as plant clusters of  data  that  were
consistently low and thus not relevent to assessing treatment.  A
few   data  points  were  also  deleted  where  malfunctions  not
previously identified were recognized.  The  data  basic  to  the
CMDB  are displayed graphically in Figures VII-4 to 12.

After all deletions, 148 data points  from  19  plants  remained.
These  data  were  used  to  determine the concentration basis of
limitations derived from the CMDB used for this regulation.

The  CMDB  was reviewed following its use in a number of proposed
regulations.   Comments   pointed out  a few errors in the  data,
and  the Agency's review identified a few  transcription   errors
and   some  data  points  that  were appropriate  for   inclusion
in   the   data that had not been used  previously   because   of
errors   in  data  record  identification numbers.   Documents in
the  record  of this rulemaking identify  all  the  changes,  the
reasons for the changes, and the effect of these changes  on  the
data  base.   Other  comments on the CMDB asserted that the  data
base  was  too small and that the statistical methods  used  were
overly complex.   Responses  to  specific  comments regarding the
application of the CMDB to the nonferrous metals forming category
are  included  in  the record of  this  rulemaking.   The '  Agency
believes  that  the data base is adequate to  determine  effluent
concentrations    achievable     with     lime     and     settle
treatment.   The statistical methods employed in the analysis are
well known and appropriate statistical references are provided in
the documents in the record that describe the analysis.

The revised  data  base  was  reexamined  for  homogeneity.   The
earlier  conclusions  were  unchanged.   The categories show good
overall homogeneity with respect to concentrations  of  the  nine
pollutants in both raw and treated wastewaters with the exception.
of electroplating.

Certain   effluent  data  associated  with  low  influent  values
were  deleted,  and  then  the  remaining  data  were fit   to  a
lognormal  distribution  to  determine  treatment   effectiveness
values.  The deletion of data was done  in  two  steps.    First,
effluent  values measured on the same day as influent values that
were less than  or  equal  to 0.1 mg/1 were deleted.   Second, the
remaining  data  were screened for cases in  which  all  influent
values  at  a plant were low although slightly above the 0.1 mg/1
value.   These  data   were   deleted  not  as   individual  data
points  but as plant clusters of data that were consistently  low
and  thus  not  relevant to  assessing  treatment.    The  revised
combined   metals   data   base   used   for   this     regulation
consists of 162 data points from 18 plants.
                               1336

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     One-day Effluent Values

The  concentrations  determined from the CMDB used  to  establish
limitations and standards at proposal were also used to establish
final limitations and standards.  The basic assumption underlying
the   determination   of  treatment effectiveness  is  that   the
data  for a particular pollutant are lognormally  distributed  by
plant.  The lognormal has  been  found to  provide a satisfactory
fit  to  plant effluent data in a number of  effluent  guidelines
categories  and there was no evidence  that the lognormal was not
suitable in the case of the CMDB.  Thus, we assumed  measurements
of  each pollutant from a particular plant,  denoted by  X,^ were
assumed to follow a lognormal distribution with log mean "y"  and
log  variancea2.   The  mean,  variance  and  99th percentile
of X are then:
mean of X = E(X) = exp (y + a /2)

variance of X = V(X) = exp  (2y + a2) [exp(a2) - 1]

99th percentile = X.99 = exp  (y + 2.33a)

where  exp  is  e,  the  base of the natural logarithm.  The term
lognormal is used  because   the  logarithm  of  X has  a   normal
distribution    with   mean   y  and  variance  ,cr^.   Using  .the
                     of   lognormality   the   actual   treatment
                    determined using a   lognormal   distribution
                     approximates   the  distribution of an  average
of   the  plants  in the  data  base,  i.e.,  an   "average   plant"
distribution.   The notion   of an   "average  plant"  distribution
is    not    a   strict  statistical concept but  is used  here   to
determine   limits  that would represent  the performance capability
of  an average  of   the  plants   in   the  data  base.

This  "average plant" distribution  for  a particular pollutant  was
developed as  follows: the  log mean  was  determined by   taking   the
average  of all the observations for  the pollutant across  plants.
The log  variance   was  determined   by   the   pooled   within-plant
variance.   This   is  the weighted average of  the  plant variances.
Thus, the  log  mean represents  the average of  all  the data  for  the
pollutant  and the log variance  . represents   the   average
plant   log  variances   or   average  plant   variability
pollutant.

 The one  day effluent  values were determined  as  follows:
basic   assumption
effectiveness  was
that,  in  a  sense,
                                                          of
                                                         for
                                                              the
                                                              the
Let Xij = the jth observation on a particular pollutant at
i where

   1 = 1,  . . . ,  I

   j = 1,  . . . ,  Ji

   I = total number of plants
                                                            plant
                                1337

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    Ji = number of observations at plant i

  Then  yij = In Xij

  where In means the natural logarithm.

  Then  y = log mean over all plants

                    I      Ji

                    2       E    yij/n,
  where  n = total number  of observations

                    I

                    2  Ji

                    i=l

  and  V(y)  = pooled log  variance

                    I
                    2   (Ji  -  1)  Si2
                    i = 1
where Si2 =
                   S   (Ji - 1)
                   i = 1

             log variance at plant i

                   Jj   •
                   Jj = 1
                             Yi)/(Ji - 1)
                yi = log mean at plant i.

Thus, y and V(y) are the log mean and log variance, respectively,
of  the  lognormal  distribution  used to determine the treatment
effectiveness.  The estimated mean and 99th  percentile • of  this
distribution  form  the basis for the long term average and daily
maximum effluent limitations, respectively.  The estimates are
mean = E\X) = exp(y)
                          (0.5V(y))
 99th percentile = X\99 = exp [y + 2.33 /vTy)  ]

where li'  ( . ) is a Bessel function and exp is e,  the base  of  the
natural  logarithms  (See  Aitchison,  J.  and  J.A.C. Brown, The
Lognormal Distribution, Cambridge University  Press,  r963).  ~Tn
cases where zeros were present in the data, a generalized form of
                               1338

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 the  lognormal,   known  as  the  delta distribution was used (See
 Aitchison and Brown,  op.  cit.,  Chapter 9).

 For certain pollutants,  this approach was  modified  slightly  to
 ensure   that  well-operated  lime  and settle plants in all CMDB
 categories  would  achieve  the  pollutant   concentration  values
 calculated  from  the  CMDB.   For  instance,  after excluding the
 electroplating data and  other data that did not reflect pollutant
 removal or proper treatment, the effluent copper  data  from  the
 copper  forming   plants   were statistically significantly greater
 than the copper  data  from the other plants.   This  indicated  that
 copper forming plants might  have difficulty achieving an effluent
 concentration value   calculated  from  copper data from all CMDB
 categories.    Thus,  copper effluent values  shown in Table  VII-14
 (page   )   are  based only on the copper effluent  data  from  the
 copper forming plants.  That is,  the log mean  for  copper  is  the
 mean  of  the logs   of all  copper values from the copper forming
 plants  only and the  log  variance is the pooled log  variance  of
 the copper forming  plant  data only.   A similar situation occurred
 in  the case  of lead.   That is,  after excluding the electroplating
 data,   the  effluent   lead  data   from battery manufacturing were
 significantly greater than the  other categories.   This  indicated
 that battery manufacturing plants might have difficulty achieving
 a   lead  concentration  calculated  from all the CMDB categories.
 The lead values  proposed  were  therefore based on  the  battery
 manufacturing lead   data only.   Comments on the proposed battery
 manufacturing regulation  objected to this procedure and  asserted
 that  the  lead,  concentration  values   were  too  low.   Following
 proposal,  the Agency  obtained additional lead  effluent data   from
 a   battery  manufacturing facility   with well-operated lime and
 settle  treatment.  These  data were  combined  with  the  proposal
 lead   data    and  analyzed   to   determine   the final  treatment
 effectiveness concentrations.  The  mean lead  concentration  is
 unchanged  at 0.12 mg/1 but  the final one-day  maximum and monthly
 10-day   average  maximum increased to 0.42  and  0.20    mg/1,
 respectively.   A  complete   discussion   of  the   lead  data and
 analysis   is   contained   in   a  memorandum   in the  record of this
 rulemaking.

 In  the  case  of cadmium, after excluding  the  electroplating   data
 and  data  that did not reflect removal or proper treatment,  there
 were insufficient data to  estimate the  log variance  for   cadmium.
 The   variance used to determine  the values  shown  in  Table VII-14
 for  cadmium was estimated  by  pooling the  within-plant    variances
 for  all   the other metals.   Thus, the cadmium variability is the
 average of the plant variability   averaged   over  all   the   other
metals.   The log mean for cadmium is the mean  of the  logs of the
 cadmium observations only.  A complete discussion of  the data and
 calculations  for  all    the   metals    is   contained    in   the
 administrative record for  this rulemaking.

     Average Effluent Values

Average_ effluent  values  that  form  the  basis for the monthly-
 limitations were developed in a manner consistent with the method


                               1339

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used to develop  one-day   treatment   effectiveness   in   that   the
lognormal   distribution used  for  the one-day  effluent values  was
also used as the basis  for   the  average  values.    That  is,  we
assume  a  number  of consecutive  measurements are drawn from  the
distribution  of  daily measurements.   .The   average    of    ten
measurements  taken  during  a  month was used as  the  basis for  the
monthly average  limitations.   The   approach  used   for  the  10
measurements  values  was  employed previously in regulations  for
other  categories  and  was proposed for  the   nonferrous metals
forming category.  That is,  the distribution of  the  average of 10
samples  from    a   lognormal  was   approximated   by    another
lognormal distribution.   Although the  approximation    is    not
precise  theoretically,  there is empirical   evidence   based  on
effluent  data from  a  number of categories that  the  lognormal
is  an  adequate approximation for the  distribution  of  small
samples.   In  the course  of  previous  work  the   approximation
was  verified  in a computer simulation study  (see   "Development
Document  for Existing  Sources Pretreatment   Standards   for   the
Electroplating  Point Source   Category",    EPA    440/1-79/003,
U.S.    Environmental Protection Agency, Washington,  D.C., August
1979).   We  also  note that   the  average values were   developed
assuming   independence   of   the  observations    although    no
particular  sampling  scheme   was  assumed.

     Ten-Sample Average

The   formulas  for the 10-sample  limitations  were derived on  the
basis of simple relationships  between, the mean  and   variance  of
the  distributions  of  the  daily pollutant measurements and  the
average of 10 measurements.  We assume  the  daily   concentration
measurements  for  a particular pollutant, denoted by X,  follow a
lognormal distribution  with  log mean  and log variance denoted  by
U  and a ,   respect ivey.   Let  X^Q  denote   the mean of
10  consecutive measurements.   The following  relationships  then
hold assuming the daily measurements  are independent:

 mean of X10 = E(X1()) = E(X)                          !

 variance of X10 = V(X10) = V(X) 10.

Where E(X) and V(X) are the mean and  variance  of X,  respectively,
defined   above.    We   then   assume  that   XIQ  follows  a
lognormal distribution with log mean  VIQ  and   log   standard
deviations2:^. The niean and variance of XIQ are then
E(X10) = exp
                    0.5a21Q)
V(X10) = exp  (2y10 + a2 0  [exp  (a2-,0) - 1]
Now, y1Q and cr210 can be derived in terms of p and a2! as

y!0 = y + ff2/2 - 0.5 In [1 + exp (a2 - 1)/N]
                              1340

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     = In
           I.
                      ... 2
Therefore,  !-io  and  " 10 can be estimated using the
above  relationships  and the estimates of u and a2  obtained
for   the underlying  lognormal  distribution.    The   10-sample
limitation  value  was  determined  by  the   estimate   of   the
approximate  99th percentile of the distribution of the 10-sample
average given by
X1Q (-99) = exp (:,,

Where (IJ_Q and a

respectively.
                  10 + 2.33.; 1Q).
                  are the estimates of IJ-,Q and
     Thirty-Sample Average

Monthly   average  values  based  on  the  average  of  30  daily
measurements were also calculated.  These  are  included  because
monthly  limitations  based  on  30 samples have been used in the
past and for comparison with the 10-sample values.   The  average
values  based on 30 measurements are determined on the basis of a
statistical result known as  the  Central  Limit  Theorem.   This
Theorem   states   that,   under   general ,  and   nonrestrictive
assumptions, the distribution of a sum  of  a  number  of  random
variables,  say  n,  is  approximated by the normal distribution.
The  approximation  improves  as  the  number  of  variables,  n,
increases.  -The  Theorem  is quite general in that no particular
distributional form  is  assumed  for  the  distribution  of  the
individual  variables.  In most applications (as in approximating
the distribution of 30-day averages)  the  Theorem  is  used   to
approximate  the distribution of the average of n observations of
a random variable.  The  result  makes  it  possible  to  compute
approximate  probability  statements  about the average in a wide
range of cases.  For instance, it is possible to compute a  value
below  which  a  specified  percentage  (e.g., 99 percent) of the
averages of n observations are likely to  fall.   Most  textbooks
state   that  25  or  30  observations  are  sufficient  for  the
approximation to be  valid.   In  applying  the  Theorem  to  the
distribution   of   the   30-day - average  effluent  values,   we
approximate the distribution of the average  of  30  observations
drawn  from  the  distribution  of daily measurements and use the
estimated 99th percentile of this distribution.

     Thirty-Sample Average Calculation

The   formulas  for  the  30-sample  average  were  based  on  an
application  of  the  Central  Limit  Theorem.   According to the
Theorem,  the  average  of  30  observations '" drawn   from   the
distribution   of   daily  measurements,   denoted  by   XSQ,
is approximately normally distributed.   The  mean  and  variance
of X3Q are:
                               1341

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  mean of X3g = E(X3o) = E(X)

  variance of X30 = V(X30) = V(X)/30.

 The   30-sample  average  value was determined by the estimate of
 the approximate  99th  percentile  of  the  distribution  of  the
 30-sample average given by
 Xso(.99) = E(X)  = 2.33 /T(X) -: 30

 where
       = exp(y) fn  (0.5V9y)~)

and V(X) = exp(2y)  [yn(2V(y)) - n  (n-2/n-])


 The   formulas   for   E(X)  and V(X)  are estimates of E(X)  and V(X),
 respectively,  given  in  Aitchison,   J.   and  J.A.C.   Brown,  The
 Lognormal  Distribution,   Cambridge   University Press,  1963, page
 45.                                                  ;

      Application

 In response  to the  proposed coil coating  and porcelain   enameling
 regulations,   the   Agency  received   comments  pointing   out that
permits usually required  less than 30 samples to be taken  during
a  month  while the monthly average  used  as  the basis  for permits
and pretreatment requirements usually is  based on the average  of
30 samples.

In  applying the treatment  effectiveness  values to regulations  we
have  considered the comments,  examined   the  sampling   frequency
required  by   many  permits  and considered the change in  values  of
averages depending  on the number of  consecutive sampling days  in
the   averages.  The most  common frequency of sampling required  in
permits is about ten samples  per month or slightly greater   than
twice weekly.   The 99th  percentiles   of   the  distribution  of
averages of ten consecutive sampling  days are  not substantially
different  from the 99th percentile  of the  distribution's  30-day
average.   (Compared to the one-day maximum,   the  ten-day average
is about 80 percent  of the difference  between   one-  and  30-day
values).   Hence  the ten-day average provides  a reasonable  basis
for a monthly  average limitation and  is typical  of the   sampling
frequency required  by existing permits.

The   monthly   average limitation is to be achieved in all permits
and pretreatment standards regardless of  the  number  of  samples
required  to   be  analyzed  and  averaged  by   the  permit or the
pretreatment authority.

Additional Pollutants

Twenty-three  additional pollutant parameters were evaluated   to
determine  the  performance of lime and settle treatment  systems
                                1342

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multiplying
appropriate
the  ratio
variability
in removing them from industrial  wastewater.   Performance  data
for   these parameters  is  not a part of the CMDB so other  data
available to the Agency from categories not included in the  CMDB
has  been used to  determine  the long-term  average  performance
of  lime and settle technology for each pollutant.   These   data
indicate   that   the  concentrations shown   in   Table   VII-15
are   reliably   attainable  with  hydroxide  precipitation   and
settling.    Treatment  effectiveness values  were  calculated by
             the  mean  performance from  Table  VII-15   by  the
              variability  factor.  (The  variability  factor  is
            of  the value of concern to the  mean).   The  pooled
vat-Lc^a.-^,  factors are:   one-day  maximum  -  4.100;   ten-day
average - 1.821; and 30-day average - 1.618 these one-, ten-, and
thirty-day values are tabulated   in  Table VII-21.

In establishing which data were suitable for use in Table  VII-14
two   factors  were  heavily  weighed:   (1)  the  nature  of  the
wastewater; and (2) the range of  pollutants or  pollutant  matrix
in  the  r-aw  wastewater.   These data  have  been selected from
processes that generate dissolved metals in  the  wastewater  arid
which  are  generally free from complexing agents.  The pollutant
matrix  was  evaluated  by  comparing    the   concentrations   of
pollutants  found  in  the  raw   wastewaters- with  the   range of •
pollutants in the raw wastewaters of  the  combined  metals  data
set     These   data are  displayed in Tables VII-16   and VII-17
and'  indicate  that  there   is   sufficient similarity    in  the
raw  wastes  to logically assume  transferability of  the   treated
pollutant  concentrations to   the  combined  metals data  base.
Nonferrous  metals forming wastewaters also  were compared to  the
wastewaters  from  plants in   categories  from  which  treatment
effectiveness values were calculated.   The  available   data  on
these  added  pollutants  do not allow homogeneity analysis as was
performed  on the combined metals  data base.  The data  source  for
each added pollutant  is  discussed separately.

Antimony   (Sb)   - The  treatment effectiveness  concentration   for
antimony   Isbased   on   data   from   a   battery   and   secondary
 lead  plant.    Both   EPA sampling data and  recent  permit_  data
 (1978-1982)    confirm   the   achievability  of  0.7  mg/1   in   the
 battery  manufacturing  wastewater  matrix  included  in the   combined
 data  set.    The untreated wastewater  matrix  shown  in  Table VII-17
 is  comparable   with  the untreated wastewater  from   the   combined
 metals  data  set.

 Arsenic    (AsJ_  -   The   treatment effectiveness  concentration   of
 0~5—mg/1  ~foF  arsenic   is  based  on  permit    data    from    two
 nonferrous    metals   manufacturing    plants.      The   untreated
 wastewater  matrix shown in Table VII-17  is comparable  with  the
 combined data set  matrix.

 Beryllium  (Be) -  The treatment effectiveness  of    beryllium   is
 transferredFrom  the nonferrous metals manufacturing  industry.
 The  0.3  mg/1 performance is achieved at a beryllium plant   with
 the   comparable untreated wastewater matrix shown in Table   VII-
 17.
                                1343

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Mercury    (Hg)   - The   0.06   mg/1   treatment    effectiveness
concentration  of  mercury is based on data  from   four  battery
plants.   The  untreated  wastewater matrix at these  plants  was
considered in the combined metals data set.
Selenium
                   - The   0.30   mg/1
	   _:	                  -„, _   treatment
concentration  of  selenium is  based on   recent
effectiveness
permit   data
from   one  of  the  nonferrous  metals manufacturing plants also
used   for  arsenic   performance.    The  untreated   wastewater
matrix  for  this  plant is shown in Table VII-17,

Silver  (Ag)  - The treatment effectiveness concentration of  0.1
mg/1 for silver  is  based  on  an estimate  from  the  inorganic
chemicals industry.  Additional data supporting a treatability as
stringent   or  more stringent  than  0.1 mg/1 is also
                                                         available
                                                     The untreated
                                                        summarized
from seven nonferrous metals manufacturing plants.
wastewater  matrix for these plants is comparable and
in Table VII-17.

Thallium
 	   (Tl)   -  The    0.50    mg/1     treatment    effectiveness
 concentration   for   thallium  is transferred   from  the  inorganic
 chemicals   industry.   Although  no  untreated  wastewater  data   are
 available   to   verify  comparability with   the  combined  metals
 data   set   plants,   no   other  sources  of  data   for    thallium
 treatability could  be identified.

 Aluminum   (Al)   - The    2.24  mg/1    treatment    effectiveness
 concentration   of aluminum is  based on  the  mean  performance  of
 three  aluminum  forming plants  and one coil  coating plant.   These
 plants are  from categories included in the  combined metals  data
 set,   assuring  untreated   wastewater matrix  comparability.

 Barium  (Ba)  - The treatment  effectiveness  concentration   for
 barium  (0.42  mg/1) is based  on data from  one nonferrous  metals
 forming  plant.   The untreated  wastewater  matrix  shown  in  Table
 VII-17 is comparable with  the  combined metals  data  base.

 Boron  (B)  - The treatment  effectiveness concentration  of  0.36
 mg/1   for boron is  based on  data from a  nonferrous  metals  plant.
 The  untreated  wastewater   matrix  shown   in  Table  VII-17   is
 comparable with the combined metals data base.

 Cesium  (Cs)  - The  treatment   effectiveness  concentration   for
 cesium  (0.124 mg/1) is based  on the performance  achievable   for
 sodium  using  ion  exchange  technology.     This  transfer   of
performance  is technically  justiciable because of  the similarity
of the chemical and physical behavior of these monovalent atoms.

Cobalt    (Co)    -  The    0.05   mg/1   treatment   effectiveness
concentration  is based on nearly complete  removal of cobalt at a
porcelain  enameling  plant with  a  mean   untreated  wastewater
cobalt^concentration of 4.31 mg/1.   in this case, the analytical
detection  using  aspiration   techniques for  this  pollutant  is
used  as the basis of the treatability.   Porcelain enameling  was
                              1344

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considered   in  the   combined   metals   data  base,
untreated wastewater matrix comparability.
assuring
Columbium (Cb) - Data collected at two refractory metals  forming
plants  indicate that lime and settle reduces columbium to  below
the  level  of  detection (using  x-ray  fluorescence  analytical
methods)  when an operating pH of eight is  maintained.   Another
sampled  lime and settle treatment system is operated at a higher
pH, from 10.5 to 11.5,  effluent concentrations of columbium from
this  system  are  significantly  higher.   Therefore,  the  data
indicate that if the treatment system is operated at a pH near 8,
columbium should be removed to below the level of detection.  The
level  of  detection (0.12 mg/1) is used as the  one-day  maximum
concentration  for lime and settle treatment  effectiveness.   No
long-term,  10-day,  and  30-day average treatment  effectiveness
values  are  established  since it  is  impossible  to  determine
precisely  what  concentrations are  achievable.   The  untreated
wastewater  matrix show in Table VII-17  is comparable  with  the
combined metals data base.

Fluoride    (F)    - The   14.5  mg/1   treatment   effectiveness
concentration  of  fluoride is based on  the   mean   performance
(216  samples)  of   an   electronics manufacturing  plant.   The
untreated wastewater matrix for this plant shown in Table  VII-17
is  comparable  to the combined metals data  set.   The  fluoride
level   in   the   electronics   wastewater •   (760   mg/1)    is
significantly  greater  than the fluoride level in raw nonferrous
metals  forming  wastewater leading to the  conclusion  that  the
nonferrous metals forming wastewater should be no more  difficult
to treat for fluoride removal than  the  electronics  wastewater.
The  fluoride level in the CMDB - electroplating data ranges from
1.29   to   70.0  mg/1.   Fluoride concentrations in  some  waste
streams,  such a hydrofluoric acid surface treatment  baths,  the
combined  raw waste concentrations that mix concentrated fluoride
wastewaters  with dilute wastewaters range from 5.3 to 117  mg/1.
leading to the  conclusion  that  the  nonferrous metals  forming
wastewater   should   be   no   more  difficult   to   treat   to
remove  fluoride  than electronics wastewater.

Gallium  (Ga)  - The  treatment  effectiveness  concentration  of
gallium  is  assumed  to be the same as the  level  for  chromium
(0.084  mg/1) for the reasons discussed below  for  indium.   The
Agency   requested  data  on  the  treatability  of  gallium  and
solicited   comment  on  the  assumption  that   the   achievable
performance for gallium should be similar received disputing this
claim.

Germanium  (Ge)  - The treatment effectiveness  concentration  of
germanium  is  assumed to be the same as the level  for  chromium
(0.084  mg/1)  for the reasons discussed for indium (see  below).
The  Agency requested data on the treatability of  germanium  and
solicited   comment   on  the  assumption  that  the   achievable
performance for germanium should be similar to that of  chromium.
No comments were received disputing this claim.
                               1345

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Gold (Au) - The treatment effectiveness concentration for gold is
based   on  the  performance  achieved  for  paladium  using  ion
exchange.    This   transfer   of  performance   is   technically
justifiable  because  of  the  similarity  of.  the  physical  and
chemical behavior of these precious metals.

Hafnium  (Hf)  - The treatment  effectiveness  concentration  for
hafnium  7.28  mg/1 is based on the transfer of performance  data
for  zirconium.    The  Agency  believes  that  since  the  water
chemistry for zirconium and hafnium is similiar,  hafnium can  be
removed to the same levels as zirconium.
Indium
- The  treatment  effectiveness  concentration  for
indium is assumed to be the same as the level for chromium (0.084
mg/1).    Lacking  any  treated  effluent  data  for  indium,   a
comparison  was  made  between the  theoretical  solubilities  of
indium and the metals in the combined Metals Data Base:  cadmium,
chromium,   copper,  lead,  nickel  and  zinc.   The  theoretical
solubility  of  indium  (2.5 x 10"') is more similar  to  the
theoretical solubility of chromium  (1.64 x 10 ° mg/1) than it
is  to the theoretical solubilities  of  cadmium,  copper,  lead,
nickel  or  zinc.  -The theoretical solubilities of these  metals
range from 20 x 10 3 to 2.2 x 10 5 mg/1.  This comparison
is  further supported by the fact that indium and  chromium  both
form hydroxides in the trivalent state.   Cadmium/  copper, lead,
nickel and zinc all form divalent hydroxides.

Magnesium  (Mg)  - Data  collected at a magnesium  forming  plant
indicate  that  lime and settle reduces magnesium  to  below  the
level of detection.  The level of detection (0.1 mg/1) is used as
the  one-day maximum concentration for lime and settle  treatment
effectiveness.    No  long-term,   10-day,   and  30-day  average
treatment  effectiveness  values  are  established  since  it  is
impossible   to  determine  precisely  what  concentrations   are
achievable.

Molybdenum   (Mo)   - The  1.83  mg/1   treatment   effectiveness
concentration   is  based  on  data  from  a  nonferrous   metals
manufacturing  and  forming,  plant which uses coprecipitation of
molybdenum with iron.   The treatment effectiveness concentration
of 1.83 mg/1 is achievable with iron coprecipitation and lime and
settle treatment.   The untreated wastewater matrix show in Table
VII-17  is comparable with the combined metals data base.
Phosphorus   (P)   - The  4.08  mg/1    treatment   effectiveness
concentration  of   phosphorus  is based  on  the   mean   of  44
samples  including 19 samples from the Combined Metals Data  Base
and  25 samples from the  electroplating data  base.    Inclusion
of  electroplating  data  with the  combined  metals   data   was
considered   appropriate,   since   the   removal  mechanism  for
phosphorus  is a precipitation reaction with calcium rather  than
hydroxide.
Platinum
  - The treatment effectiveness  concentration,  for
platinum is based on the performance achieved for pathadium using
                               1346

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ion  exchange.   This  transfer  of  performance  is  technically
justifiable  because  of  the  similarity  of  the  physical  and
chemical behavior of the these precious metals.

Radium  226 (Ra 226) - The treatment effectiveness  concentration
of 6.17 picocuries per liter for radium 226 is based on d^ata from
one  facility  in the uranium subcategory of the Ore  Mining  and
Dressing category which practices barium chloride coprecipitation
in  conjunction  with lime and settle treatment.   The  untreated
wastewater  matrix  shown in Table VII-17 is comparable with  the
combined metals data base.
Rhenium  (Re)  - The  treatment effectiveness  concentration  for
rhenium  (1.83  mg/1)  is based on the  performance, achieved  for
molybdenum  at  a  nonferrous metals  manufacturing  and  forming
plant.   This  transfer of performance is technically justifiable
because  of the similarity of the physical and chemical  behavior
of these compounds.

Rubidium  (Rb
	   Rb)  - The treatment effectiveness  concentration  for
rubidium (0.124 mg/1) is based on the performance achievable  for
sodium   using  ion  exchange  technology.    This  transfer   of
performance  is technically justifiable because of the similarity
of the chemical and physical behavior of these monvalent atoms.

Tantalum  (Ta)  - As  with  columbium,   data  collected  at  two
refractory  metals forming plants indicate that lime  and  settle
reduces  tantalum  to below the level of detection  (using  x-ray
fluorescence,analytical methods) when an operating pH of eight is
maintained.    Another sampled lime and settle treatment system is
operated   at,  a  higher  pH,   from  10.5  to  11.5.    Effluent
concentrations  of  tantalum from this system  are  significantly
higher.   Therefore,  the  data  indicate that if  the  treatment
system is operated at a pH near 8,  tantalum should be removed to
below the level of detection.  .The level.,.pf detection (0.45 mg/1)
is used as the one-day maximum concentration for lime and  settle
treatment  effectiveness.    No  long-term,  10-day,  and  30-day
average  treatment effectiveness values are established since  it
is  impossible  to  determine precisely what  concentrations  are
achievable.    The untreated wastewater matrix shown in Table VII-
17  is comparable with the combined metals data base.

Tin (Sn) - The treatment effectiveness concentration of 1.07 mg/1
for tin is based on data from one metal finishing tin plant.  The
untreated wastewater matrix shown in Table VII-17  is  comparable
with the combined metals data base.

Titanium   (Ti)   - The   0.19   mg/1   treatment   effectiveness
concentration is based on the mean performance of four nonferrous
metals forming plants.  A total of 9 samples were included in the
calculation  of the mean performance.   The untreated  wastewater
matrix  shown  in Table VII-17  is comparable with  the  combined
metals data base.
                               1347

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 Tungsten   £Wj_   - The   1.29   mg/.   treatment    effectiveness
 concentration  (using  x-ray fluorescene analytical  methods)  is
 based  on data collected from the refractory metals forming plant
 where  an  operation  pH of 10.5 to  11.5  was  used.   The  data
 indicate  that  maintaining  the pH within  this  range  achieves
 significantly  better  removal  of  tungsten than a  pH  near  8.
 Therefore,   refractory   metals   forming  plants   that   treat
 wastewaters containing both columbium,  tantalum and tungsten  or
 other  metals  that precipitate at a higher pH may need to use  a
 two-stage  lime and settle to remove all of  these  metals.   The
 untreated  wastewater matrix shown in Table VII-17  is comparable
 with the combined metals data base.

 Uranium (U) - The 4.00 mg/1 treatment effectiveness concentration
 (using   fluorometry   analytical  methods)  is  based   on   the
 performance  of  one  uranium  forming  plant.     The   untreated
 wastewater  matrix shown in Table VII-17  is comparable with  the
 combined metals data base.

 Vanadium  (V)  - Data collected at two nonferrous  metals  forming
 plants  indicate  that lime and settle reduces  vanadium to  below
 the detection limit.    The  level of  detection (0.10 mg/1)  is used
 as   the  one-day  maximum'  concentration  for  lime  and   settle
 treatment effectiveness.  No long-term,  10-day,  or 30-day  average
 treatment  effectiveness  values  are  established  since   it  is
 impossible   to  determine   precisely  what  concentrations   are
 achievable.    The untreated wastewater matrix shown in Table VII-
 17   is comparable with the  combined  metals  data  base.

 Zirconium  (Zr)   - The zirconium treatment  effectiveness of  7.28
 mg/1^  is  based on the  mean  performance of  two nonferrous   metals
     ^
 forming  plants with lime and  settle  treatment.   One plant  forms
 zirconium  and  the other plant   forms   refractory  metals.   The
 untreated wastewater matrix shown in  Table VII-17  is  comparable
 with the combined metals data  base.

 LS&F Performance

 Tables   VII-18  and VII-19  show long term data from two  plants
 which  have  well   operated   precipitation-settling   treatment
 followed   by   filtration.    The  wastewaters from both  plants
 contain  pollutants  from  metals   processing   and    finishing
 operations   (multi-category).    Both  plants  reduce  hexavalent
 chromium before neutralizing and  precipitating metals with   lime.
 A  clarifier  is  used  to  remove  much of the solids load  and a
 filter is used to  "polish"  or   complete  removal  of  suspended
 solids.   Plant  A  uses  a pressure filter, while Plant B uses a
 rapid sand filter.

Raw wastewater data  was  collected  only  occasionally  at  each
 facility   and  the  raw . wastewater  data  is  presented  as  an
 indication of the nature of the wastewater  treated.    Data  from
plant A was received as a statistical summary and is presented as
 received.    Raw  laboratory  data  was  collected  at Plant B and
reviewed for spurious points and discrepancies.   The  method  of


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treating the data base is discussed below under lime, settle, and
filter treatment effectiveness.

Table  VII-20  shows long-term data for zinc and cadmium  removal
at Plant C, a primary zinc smelter, which operates a LS&F system.
This   data   represents  about  4 months (103 data  days)  taken
immediately  before  the  smelter was  closed.    It   has   been
arranged  similarily  to  the  data from   Plants  A  and  B  for
comparison and use.

These  data  are  presented  to  demonstrate-  the  performance of
precipitation-settling-filtration (LS&F) technology under  actual
operating conditions and over a long period of time.

It should be noted that the iron content of the raw wastewater of
Plants  A  and  B  is  high  while that for Plant C is low.  This
results, for Plants A and B, in co-precipitation of toxic  metals
with  iron.  Precipitation using high-calcium lime for pH control
yields  the  results  shown  above.   Plant  operating  personnel
indicate that this chemical treatment combination (sometimes with
polymer  assisted coagulation) generally produces better and more
consistent metals removal than other combinations of  sacrificial
metal ions and alkalis.

The  LS&F  performance  data  presented here are based on systems
that provide polishing filtration after effective L&S  treatment.
We have previously shown that L&S treatment is equally applicable
to   wastewaters   from   the  five CMDB  categories  because  of
the  homogeneity  of  its  raw  and  treated   wastewaters,   and
other  factors.     Because  of the similarity of the  wastewaters
after  L&S treatment,  the Agency  believes   these   wastewaters
are   equally  amenable  to  treatment  using  polishing  filters
added  to  the L&S treatment system.   The Agency concludes  that
LS&F data  based  on porcelain  enameling  and  nonferrous metals
manufacturing is directly applicable to  the  aluminum   forming,
copper    forming,   battery   manufacturing,     coil    coating,
nonferrous  metals  forming   and  metal   molding   and  casting
categories,  and  the canmaking subcategory as well  as  it is to
porcelain enameling and nonferrous metals manufacturing  smelting
and refining.

Analysis of Treatment System Effectiveness

Data  are  presented  in Table VII-14 showing the mean,  one-day,
10-day and 30-day values for nine pollutants examined in the  L&S
combined metals  data base.  The  pooled  variability  factor  for
seven  metal  pollutants  (excluding cadmium because of the small
number of data points)  was determined and  is  used  to  estimate
one-day,  10-day  and  30-day values.   (The variability factor is
the ratio of the  value  of  concern  to  the  mean:  the  pooled
variability  factors  are:   one-day  maximum  -  4.100;  ten-day
average  - 1.821;  and 30-day average - 1.618.)  For  values  not
calculated  from the CMDB as previously discussed, the mean value
for pollutants shown in Table  VII-15  were  multiplied  by   the-
                               1349

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variability  factors to derive the value to obtain the one-,
and 30-day values.  These are tabulated in Table VII-21.
ten-
The  treatment  effectiveness  for  sulfide   precipitation   and
filtration  has  been  calculated  similarly.   Long term average
values  shown  in  Table  VII-6  have been   multiplied   by  the
appropriate variability factor to estimate one-day  maximum,  and
ten-day  and  30-day   average   values.  '  Variability   factors
developed  in the combined metals data base were used because the
raw wastewaters are  identical  and  the  treatment  methods  are
similar  as both use chemical precipitation and solids removal to
control metals.

LS&P technology data are presented in Tables VII-18  and  VII-19.
These  data represent two operating plants (A and B) in which the
technology has been installed and operated for some years.  Plant
A data was received as a statistical  summary  and  is  presented
without  change.   Plant  B  data  was received as raw laboratory
analysis data.  Discussions with plant personnel  indicated  that
operating  experiments  and changes in materials and ,reagents and
occasional  operating  errors  had  occurred  during   the   data
collection  period.   No  specific  information  was available on
those variables.  To sort out  high  values  probably  caused  by
methodological  factors  from  random statistical variability, or
data noise, the Plant B data were analyzed.   For  each  of  four
pollutants  (chromium,  nickel,  zinc,  and  iron),  the mean and
standard deviation (sigma) were calculated for  the  entire  data
set.   A data day was removed from the complete data set when any
individual pollutant concentration for that day exceeded the  sum
of  the mean plus three sigma for that pollutant.  Fifty-one data
days (from a total of about 1300) were eliminated by this method.

Another approach was also used as a check on the above method  of
eliminating  certain  high  values.   The  minimum  values of raw
wastewater  concentrations  from  Plant  B  for  the  same   four
pollutants  were  compared  to  the  total  set of values for the
corresponding  pollutants.   Any  day  on   which   the   treated
wastewater  pollutant  concentration  exceeded  the minimum value
selected from raw wastewater concentrations  for  that  pollutant
was  discarded.   Forty-five days of data were eliminated by that
procedure.  Forty-three days of data in common were eliminated by
either procedure.   Since common engineering practice (mean  plus
3  sigma)  and logic (treated wastewater concentrations should be
less than raw wastewater concentrations) seem  to  coincide,  the
data  base with the 51 spurious data days eliminated is the basis
for all further analysis.  Range, mean  plus  standard  deviation
and  mean plus two standard deviations are shown in Tables VII-18
and VII-19 for Cr, Cu, Ni, Zn and Fe.

The  Plant B data were separated into  1979,   1978,   and   total
data base  (six  years)  segments.  With the statistical analysis
from Plant A for 1978 and 1979, this in effect created five  data
sets  in   which   there is some overlap between  the  individual
years and total data sets from Plant B.   By comparing these five
parts,  it is apparent that they are quite similar and all appear
                               1350

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to  be  from the  same  family  of  numbers.    The  largest  mean
found among the five data sets for each pollutant was selected as
the   long-term  mean  for  LS&F  technology and is used -as  the
LS&F mean in Table VII-21.

Plant C data was used as a basis for cadmium removal  performance
and  as  a  check on the zinc values derived from Plants A and B.
The   cadmium  data  is  displayed  in  Table  VII-20    and   is
incorporated  into  Table  VII-21  for  LS&F.   The zinc data was
analyzed for compliance with the 1-day and 30-day values in Table
VII-21; no zinc value of the 103 data points exceeded  the  1-day
zinc value of 1.02 mg/1.  The 103 data points were separated into
blocks  of  30  points  and  averaged.  Each of the 3 full 30-day
averages was less than the  Table  VII-21  value  of  -.0.31  mg/1.
Additionally  the Plant C raw wastewater pollutant concentrations
(Table VII-20) are  well  within  the  range  of  raw  wastewater
concentrations  of  the combined metals data base (Table VII-16),
further supporting the conclusion that Plant C wastewater data is
comparable to similar data from Plants A and B.

Concentration values for regulatory use are  displayed  in  Table
VII-21.    Mean  one-day,  ten-day  and 30-day values for L&S for
nine pollutants were taken from Table VII-14; the remaining  L&S
values   were developed using the mean values in Table VII-15 and
the mean variability factors discussed above.

LS&F mean values for Cd,  Cr,  Ni,   Zn,   and  Fe  are   derived
from  Plants A,' B,  and C as discussed  above.   One-,  ten- and
thirty-day  values   are   derived by  applying  the  variability
factor  developed  from  the pooled data base  for  the  specific
pollutant  to the  mean for  that  pollutant.   Other LS&F, values
are calculated using the long  term  average  or  mean  and   the
appropriate  variability factors.

Mean  values  for LS&F for pollutants not already  discussed  are
derived  by  reducing the L&S mean by one-third.   The  one-third
reduction  was established after examining the percent  reduction
in concentrations going from L&S to LS&F data for Cd, Cr, Ni, Zn,
and   Fe.    The  average  reduction  is  0.3338  or   one-third.
Variability factors for these additional pollutants are identical
to  the  variabilities  established for L&S  treatment  of   these
pollutants  (using the variance from  the pooled metals data  base
or the mean of other pollutant variances if  a  pollutant-specific
variance   is  not  available).    Since  filtration  is  a  non-
preferential  technology  with  regard  to   metals  treated,  and
furthermore,  is being used  to polish relatively clean wastewater
(wastewater after lime and settle treatment),  EPA believes  it is
reasonable  to  assume that  these additional pollutants  will  be
removed at the same average  rate.

Copper  levels  achieved  at  Plants  A  and B may be lower than
generally achievable because of the high  iron   content  and low
copper  content  of  the  raw  v.-astewaters.   Therefore, the mean
concentration value from  Plants A and B achieved  is hot used; the
LS&F mean for copper is derived from  the L&S technology.
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  Uranium  levels   achieved by L&S treatment  showed  substantially
  ihp5  ,JaSSabJllty thai\ the nine  Parameters included in the  CUDE.
  The   standard  approach  to  the  derivation  of  LS&F  treatment
  effectiveness  concentrations results  in one-day,  10-day and  30-
  day   values   for LS&F  treatment that  are  greater  than  the
  corresponding  values  for L&S treatment.    Therefore,  the   LS&F
  «niUrfL f°irn Sranium_ar?Aderived by reducing the L&S  long  term,
  one-day,  10-day   and   30-day values  by one-third to  derive  the
  corresponding  LS&F values.                             ueiAve  tne

  L&S cyanide mean  levels shown in Table  VII-8 are ratioed to   one-
  ???'  ten~day  and 30-day  values  using mean variability factors.
  SS  JSS11 r SSnide 1Si calc^ated by   applying  the   ratios  of
  L&S  and  LS&F  removals  as  discussed previously for LS&F  metals
  limitations.  The  cyanide performance was  arrived  at by  usinq  the
  average metal variability factors.   The   treatment  method  used
          Sanihe P^^P^tion   Because cyanide precipitation is
          by  the   same   physical   processes   as    the   metal
           iSn'  P    1Su exPected   that   the  variabilities will be
           Therefore'  the average of the metal variability factors
   n     ,«5eJhaB4-a 53S1S -f°r  calculating  the  cyanide  one-day,
 ten-day and thirty-day average treatment effectiveness values.

 The  filter  performance for removing TSS as shown in Table VII-9
 yields a mean effluent concentration of 2.61 mg/1  and calculates
 to  a  10-day average of 4.33, 30-day average of 3.36 mg/1 and  a
 one-day  maximum of 8.88.    These  calculated  values  more  than
 amply   support the classic thirty-day and one-day values  of  10
 mg/1 and 15  mg/1,  respectively, which  are used for LS&Fo

 Although    iron    concentrations    were   reduced   with   the
 application   of  a filter  to the  lime   and  settle  system,  somJ
 facilities  using  that  treatment  introduce iron compounds to   aid
 settling.    Therefore,   the one-day,   ten-day  and 30-day  values
 for  iron  at LS&F  were  held at the L&S level  so as to not
penalize    the
objectionable
metals.
            -- -  	 ——— —. —.»•_-i. L^\^ u*^> t-\_/ iiw L.  unduly
operations  which   use   the   relatively   less
iron   compounds  to enhance  removals  of  toxic
The removal of additional fluoride  by  adding  polishing  filtration

fLSiSr ^eCa?Se ^mS  a?d  Settle   treatment   removes   calcium
fluoride  to a level near its solubility.  The one available  data
™£t appears to question the ability  of filters  to achieve   high
removals   of   additional   fluoride.    The   fluoride   levels
demonstrated for L&S are used as the treatment effectiveness  for
LS&F.

MINOR TECHNOLOGIES

Several other_treatment technologies were considered ;for possible
application  in  this category.   These technologies are presented
                         • •-
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9.   Carbon Adsorption

The use of activated carbon to  remove  dissolved  organics  from
water  and  wastewater  is a long demonstrated technology.  It is
one of the most efficient organic  removal  processes  available.
This sorption process is reversible, allowing activated carbon to
be  regenerated for reuse by the application of heat and steam or
solvent.  Activated carbon has also proved  to  be  an  effective
adsorbent for many toxic metals, including mercury.  Regeneration
of   carbon  which  has adsorbed significant amounts  of  metals,
however, may be difficult.

The term activated carbon applies to any amorphous form of carbon
that  has  been  specially  treated  to  give   high   -adsorption
capacities.   Typical  raw  materials include coal, wood, coconut
shells, petroleum base residues,  and  char  from  sewage  sludge
pyrolysis.    A  carefully  controlled  process  of  dehydration,
carbonization, and oxidation yields a  product  which  is  called
activated   carbon.   This  material  has  a  high  capacity  for
adsorption due primarily to the large surface area available  for
adsorption, 500 to 1500 m2/sq m resulting from a large number
of internal  pores.    Pore  sizes  generally  range  from  10 to
100 angstroms in radius.

Activated carbon removes contaminants from water by  the  process
of   adsorption,  or  the  attraction  and "accumulation  of  one
substance  on  the  surface   of   another.    Activated   carbon
preferentially  adsorbs  organic  compounds  and, because of this
selectivity,  is  particularly  effective  in  removing   organic
compounds' from aqueous solution.

Carbon   adsorption   requires   pretreatment  to  remove  excess
suspended solids,  oils, and greases.   Suspended  solids  in  the
influent  should  be  less  than  50  mg/1  to  minimize backwash
requirements; a downflow carbon bed can handle much higher levels
(up to 2000 mg/1)  but requires frequent backwashing.  Backwashing
more than two or three times a day is not desirable; at  50  mg/1
suspended  solids,  one  backwash  will  suffice.  Oil and grease
should be less than about 10 mg/1.   A  high  level  of  dissolved
inorganic  material  in  the  influent  may  cause  problems with
thermal carbon reactivation (i.e.,  scaling and loss of  activity)
unless  appropriate preventive steps are taken.  Such steps might
include pH control, softening, or the use of an acid wash on  the
carbon prior to reactivation.

Activated carbon is available in both powdered and granular form.
An  adsorption  column  packed with granular activated carbon  is
shown  in Figure VII-17.   A flow diagram of an activated  carbon
adsorption system,  with regeneration,  is  shown  in Figure VII-
35.    Powdered   carbon  is  less  expensive per unit weight  and
may  have  slightly higher adsorption capacity,  but it  is  more
difficult to handle and to regenerate.

Application and Performance.  Carbon adsorption is used to remove.
mercury  from wastewaters. " The removal rate is influenced by the
                               1353

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mercury level in the influent to the adsorption unit.   In  Table
VII-25 removal levels found at three manufacturing facilities are
listed.

In the aggregate these  data  indicate  that  very  low  effluent
levels  could  be  attained from any raw waste by use of multiple
adsorption  stages.   This  is   characteristic   of >  adsorption
processes.

Isotherm  tests  have  indicated  that  activated  carbon is very
effective  in  adsorbing  65  percent  of  the  organic  priority
pollutants  and  is  reasonably effective for another 22 percent.
Specifically, for the organics of particular interest,  activated
carbon   was   very  effective  in  removing  2,4-dimethylphenol,
fluoranthene,  isophorone,  naphthalene,  all   phthalates,   and
phenanthrene.     It   was   reasonably   effective   on   1,1,1-
trichloroethane, 1,1-dichloroethane, phenol, and toluene.   Table
VII-23   summarizes the treatment effectiveness for most of   the
organic  priority  pollutants  by  activated  carbon  as compiled
by EPA.  Table VTI-24  summarizes  classes  of organic  compounds
together  with  examples of organics that are readily adsorbed on
carbon.

Advantages  and  Limitations.   The  major  benefits  of   carbon
treatment include applicability to a wide variety of organics and
high  removal  efficiency.  Inorganics such as cyanide, chromium,
and  mercury  are  also  removed  effectively.    Variations   in
concentration  and  flow  rate are well tolerated.  The system is
compact,  and  recovery  of  adsorbed  materials   is   sometimes
practical.   However,  destruction  of  adsorbed  compounds often
occurs  during  thermal  regeneration.   If  carbon   cannot   be
thermally  desorbed,  it  must  be  disposed  of  along  with any
adsorbed pollutants.  The capital and operating costs of  thermal
regeneration are relatively high.  Cost surveys show that thermal
regeneration  is  generally  economical  when  carbon use exceeds
about 1,000 Ib/day.  Carbon cannot remove low molecular weight or
highly soluble  organics.   It  also  has  a  low  tolerance  for
suspended  solids,  which  must be removed to at least 50 mg/1 in
the influent water.

Operational Factors.  Reliability:  This system  should  be  very
reliable  with  upstream  protection  and  proper  operation  and
maintenance procedures.

Maintainability:  This system requires periodic  regeneration  or
replacement  of spent carbon and is dependent upon raw waste load
and process efficiency.

Solid  Waste  Aspects:   Solid  waste  from   this   process   is
contaminated  activated  carbon  that  requires disposal.  Carbon
which   undergoes   regeneration   reduces   the   solid    waste
problem  by reducing the frequency of carbon replacement.

Demonstration   Status.   Carbon  adsorption  systems  have  been
demonstrated to be practical and economical in reducing COD, BOD,
                               1354

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 and related parameters  in  secondary  municipal  and  industrial
 wastewaters;  in  removing  toxic  or  refractory  organics  from
 isolated  industrial  wastewaters;  in  removing  and  recovering
 certain organics from wastewaters; and in removing and some times
 recovering  selected  inorganic  chemicals  from  aqueous wastes.
 Carbon adsorption is a viable and economic  process  for  organic
 waste  streams  containing  up to 1 to 5 percent of refractory or
 toxic organics.   Its applicability for removal of inorganics such
 as metals has also been demonstrated.

 10.    Centrifugation

 Centrifugation  is  the  application  of  centrifugal  force   to
 separate  solids  and  liquids  in  a   liquid-solid mixture or to
 effect  concentration  of  the  solids.     The   application   of
 centrifugal   force   is   effective   because   of  the  density
 differential normally found between the  insoluble solids and  the
 liquid  in  which  they  are  contained.    As   a  waste treatment
 procedure, Centrifugation is applied to   dewatering  of  sludges
 One  type of centrifuge is shown in Figure VII-18.

 There   are  three common types of centrifuges;   disc,  basket,  and
 conveyor.    All   three  operate  by removing   solids   under  the
 influence  of centrifugal force.   The fundamental difference among
 the   three  types  is the method by which solids are collected in
 and  discharged from the bowl.

 In the disc centrifuge,  the sludge feed   is  distributed  between
 narrow  channels   that  are  present  as   spaces  between  stacked
 conical discs.   Suspended particles are collected  and   discharged
 continuously  through  small  orifices  in  the   bowl   wall   The
 clarified  effluent  is discharged through  an  overflow weir.

 A  second type  of  centrifuge which is useful  in dewatering  sludges
 is the_basket  centrifuge.   In  this   type   of  centrifuge,   sludge
 feed   is   introduced   at   the   bottom  of  the basket,  and  solids
 collect at  the bowl wall  while  clarified  effluent   overflows   the
 lip  _nng   at  the top.   Since  the basket  centrifuge  does not have
 provision  for  continuous  discharge  of collected  cake,   operation
 requires interruption of  the feed for cake discharge for a  minute
 or two  in a  10- to  30-minute overall cycle.

 The  third   type of centrifuge commonly used in  sludge  dewaterinq
 is the  conveyor type.  Sludge is  fed through  a  stationary  feed
 pipe   into   a  rotating  bowl in  which the solids are settled out
 against the  bowl wall  by centrifugal force.  From the bowl  wall,
 the  solids  are  moved  by a screw to the end of the machine, at
 which  point  they  are  discharged.   The  liquid  effluent   is
 discharged   through  ports  after  passing the length of the bowl
 under centrifugal force.

Application and  Performance.   Virtually  all   industrial  waste
 treatment  systems  producing  sludge  can  use Centrifugation to
dewater it.  Centrifugation is currently being  used  by  a  wide •
 range of industrial concerns.
                               1355

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The performance of sludge dewatering by centrifugation depends on
the  feed  rate,  the   rotational  velocity  of  the drum, and the
sludge composition and  concentration.  Assuming  proper design and
operation, the solids content of the sludge can  be  increased  to
20 to 35 percent.

Advantages  and  Limitations.  Sludge dewatering centrifuges have
minimal space requirements and show a  high  degree  of  effluent
clarification.   The  operation  is simple, clean, and relatively
inexpensive.   The  area  required  for   a   centrifuge   system
installation  is  less  than that required for a filter system or
sludge drying bed of equal capacity,  and  the   initial  cost  is
lower.                                              ;

Centrifuges have a high power cost that partially offsets the low
initial  cost.   Special  consideration  must  also  be  given to
providing sturdy foundations and  soundproofing  because  of  the
vibration  and  noise   that  result  from  centrifuge  operation.
Adequate electrical power  must  also  be  provided  since  large
motors  are  required.   The  major difficulty encountered in the
operation of centrifuges has been the disposal of the concentrate
which is relatively high in suspended, nonsettling solids.

Operational  Factors.   Reliability:   Centrifugation  is  highly
reliable  with  proper  control  of  factors such as sludge feed,
consistency, and temperature.  Pretreatment such as grit  removal
and  coagulant  addition  may  be  necessary,  depending  on  the
composition of the sludge and on the type of centrifuge employed.

Maintainability:  Maintenance consists of  periodic  lubrication,
cleaning, and inspection.  The frequency and degree of inspection
required  varies  depending  on  the  type of sludge solids being
dewatered and the maintenance service conditions.  If the  sludge
is  abrasive,  it is recommended that the first  inspection of the
rotating assembly be made  after  approximately  1,000  hours  of
operation.   If the sludge is not abrasive or corrosive,  then the
initial inspection might be delayed.   Centrifuges  not  equipped
with  a  continuous  sludge  discharge  system   require  periodic
shutdowns for manual sludge cake removal.

Solid Waste Aspects:    Sludge  dewatered  in  the  centrifugation
process  may  be disposed of by landfill.   The clarified effluent
(centrate), if high in dissolved or suspended solids,  may require
further treatment prior to discharge.

Demonstration Status.  Centrifugation  is   currently  used  in  a
great  many  commercial  applications to dewater sludge.   Work is
underway to improve the efficiency,  increase  the  capacity,   and
lower the costs associated with centrifugation.

11.  Coalescing

The  basic  principle  of  coalescence  involves the preferential
wetting of a coalescing medium by oil  droplets  which   accumulate


                               1356

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on  the  medium  and  then rise to the surface of the solution as
they combine  to  form  larger  particles.   The  most  important
requirements  for  coalescing  media  are wettability for oil and
large surface area.  Monofilament line is  sometimes  used  as  a
coalescing medium.

Coalescing  stages  may  be  integrated  with  a  wide variety of
gravity oil separation devices, and some systems may  incorporate
several   coalescing  stages.   In  general,  a  preliminary  oil
skimming step is desirable to avoid overloading the coalescer.

One  commercially  marketed  system  for  oily  waste   treatment
combines   coalescing   with   inclined   plate   separation  and
filtration.  In  this  system,  the  oily  wastes  flow  into  an
inclined  plate  settler.   This  unit  consists  of  a  stack of
inclined baffle plates in a cylindrical  container  with  an  oil
collection chamber at the top.  The oil droplets rise and impinge
upon the undersides of the plates.  They then migrate upward to a
guide  rib  which  directs the oil to the oil collection chamber,
from which oil is discharged for reuse or disposal.

The oily water continues on through another  cylinder  containing
replaceable  filter  cartridges, which remove suspended particles
from the  waste.   From  there  the  wastewater  enters  a  final'
cylinder in which the coalescing material,is housed.  As the oily
water  passes  through  the  many  small,  irregular,  continuous
passages in the coalescing material, the  oil  droplets  coalesce
and rise to an oil collection chamber.

Application  and  Performance.   Coalescing is used to 'treat oily
wastes which do not separate readily in simple  gravity  systems.
The  three-stage  system  described  above  has achieved effluent
concentrations of 10 to 15 mg/1 oil and grease  from  raw   waste
concentrations of 1000 mg/1 or more.

Advantages  and  Limitations.   Coalescing  allows removal of oil
droplets  too   finely   dispersed   for   conventional   gravity
separation-skimming technology.  It also can significantly reduce
the residence times (and therefore separator volumes) required to
achieve  separation  of  oil  from  some  wastes.  Because of its
simplicity, coalescing provides generally  high  reliability  and
low  capital  and  operating  costs.  Coalescing is not generally
effective in removing soluble or chemically stabilized emulsified
oils.   To  avoid  plugging,  coalescers  must  be  protected  by
pretreatment from very high concentrations of free oil and grease
and  suspended solids.  Frequent replacement of prefilters may be
necessary when raw waste oil concentrations are high.

Operational  Factors.   Reliability:  Coalescing  is   inherently
highly  reliable  since  there  are  no  moving  parts,  and  the
coalescing  substrate  (monofilament,  etc.)   is  inert  in  the
process  and  therefore  not  subject to frequent regeneration or
replacement   requirements.    Large    loads    or.    inadequate
pretreatment,  however,  may  result  in  plugging  or  bypass of
coalescing stages.


                               1357

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 Maintainability:  Maintenance requirements are  generally  limited
 to replacement of the coalescing medium on an infrequent basis.

 Solid  Waste  Aspects:  No appreciable solid waste is generated by
 this  process.

 Demonstration  Status.  Coalescing has been'fully demonstrated in
 industries      generating    oily    wastewater,    although  no
 nonferrous  metals forming plants specifically reported their use.

 12. Cyanide Oxidation by Chlorine

 Cyanide oxidation using chlorine is   widely  used  in  industrial
 waste  treatment  to  oxidize  cyanide.   Chlorine can  be utilized in
 either   the elemental   or  hypochlorite  forms.   This   classic
 procedure   can be illustrated  by the following two step chemical
 reaction:

 1.  Cl2  + NaCN  + 2NaOH 	>  NaCNO +  2NaCl + H2O

 2.  3C12 + 6NaOH +  2NaCNO	> 2NaHCC-3 + N32 + 6NaCl  +
    2H20

 The reaction presented  as Equation 2  for the oxidation of cyanate
 is  the  final step in the oxidation of cyanide.   A complete system
 for the alkaline  chlorination of cyanide is shown in Figure   VII-
 19.

 The   alkaline   chlorination  process   oxidizes  cyanides  to carbon
 dioxide and  nitrogen.    The   equipment  often  consists of  an
 equalization  tank   followed  by two  reaction  tanks,  although  the
 reaction can be carried  out  in  a single  tank.   Each  tank   has  an
 electronic   recorder-controller   to   maintain  required  conditions
 with  respect to pH and oxidation reduction  potential   (ORP).   In
 the   first   reaction tank,  conditions   are  adjusted  to oxidize
 cyanides to  cyanates.    To  effect   the  reaction, :  chlorine  is
metered  to  the  reaction tank  as  required  to maintain  the ORP in
 the range of 350  to 400  millivolts,   and  50   percent   aqueous
 caustic  soda   is  added  to maintain  a pH range  of 9.5  to 10.  In
 the second  reaction  tank,  conditions  are  maintained   to   oxidize
 cyanate  to carbon dioxide  and nitrogen.   The desirable ORP and pH
 for  tthis  reaction   are  600 millivolts  and a pH of 8.0.   Each of
 the reaction tanks is equipped with a propeller  agitator  designed
 to provide approximately  one turnover per minute.   Treatment  by
 the  batch  process   is   accomplished by  using  two tanks, one for
collection of water  over  a specified  time period, and one  for the
treatment of an accumulated  batch.   If  dumps  of  concentrated
wastes are frequent,  another tank may be  required to equalize the
flow  to  the treatment tank.  When the holding  tank is full, the
liquid is transferred to  the reaction tank for  treatment.   After
treatment,   the  supernatant  is  discharged  and thfe sludges are
collected for removal and ultimate disposal.
                               1358

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Application and Performance.  The oxidation of cyanide  .waste  by
chlorine  is  a  classic  process and is found in most industrial
plants using cyanide.   This  process  is  capable  of  achieving
effluent   levels   that   are  nondetectable*   The  process  is
potentially  applicable  to nonferrous metals forming  facilities
where cyanide  is  a component in wastewater.

Advantages   and   Limitations.    Some  advantages  of  chlorine
oxidation for handling process effluents are operation at ambient
temperature, suitability for automatic  control,  and  low  cost.
Disadvantages  include  the need for careful pH control, possible
chemical interference in the treatment of mixed wastes,  and  the
potential hazard of storing and handling chlorine gas.

Operational  Factors.  Reliability:  Chlorine oxidation is highly
reliable  with  proper  monitoring   and   control   and   proper
pretreatment to control interfering substances.

Maintainability:   Maintenance  consists  of  periodic remoyal of
sludge and recalibration of instruments.

Solid Waste Aspects:  There is no solid waste problem  associated
with chlorine oxidation.                                 .

Demonstration .  Status.   The  oxidation  of  cyanide  wastes  by
chlorine is a widely used process  in  plants  using  cyanide  in
cleaning  and  metal  processing baths.  Alkaline chlorination is
also used for cyanide treatment in a number of inorganic chemical
facilities producing hydroganic acid and various metal  cyanides.
One  nonferrous  metals  forming plant is  currently  using  this
technology to treat process wastewaters.

13.  Cyanide Oxidation By^ Ozone

Ozone is a highly reactive oxidizing agent which is approximately
ten times more soluble than oxygen on a weight  basis  in  water.
Ozone  may  be  produced  by  several  methods,  but  the  silent
electrical discharge method is predominant  in  the  field.   The
silent  electrical  discharge  process  produces ozone by passing
oxygen or air  between  electrodes  separated  by  an  insulating
material.   A  .complete ozonation system is represented in Figure
VII-20.

Application  and  Performance.   Ozonation   has   been   applied
commercially to oxidize cyanides, phenolic chemicals, and organo-
metal  complexes.   Its applicability to photographic wastewaters
has been studied in the laboratory with good results.   Ozone  is
used  in  industrial waste treatment primarily to oxidize cyanide
to cyanate and to oxidize  phenols  and  dyes  to  a  variety  of
colorless nontoxic products.

Oxidation of cyanide to cyanate is illustrated below:

     CN~ + O3 	> CNO~ + 02
                               1359

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 Continued   exposure   to  ozone will  convert the cyanate  formed  to
 carbon  dioxide  and ammonia;  however,   this   is   not   economically
 practical.

 Ozone   oxidation  of  cyanide  to cyanate requires 1.8  to 2.0 pounds
 ozone per pound of CN-;  complete  oxidation  requires   4.6 to  5.0
 pounds  ozone per  pound  of CN-.  Zinc,  copper, and  nickel cyanides
 are  easily destroyed   to  a  nondetectable level, but cobalt and
 iron cyanides are more  resistant  to  ozone treatment.

 Advantages  and  Limitations.  Some advantages of ozone   oxidation
 for  handling   process  effluents  are its suitability  to  automatic
 control and  on-site   generation and the fact  that   reaction
 products are not  chlorinated organics  and no dissolved solids are
 added   in the treatment  step.   Ozone in the presence  of  activated
 carbon,  ultraviolet,   and  other promoters shows   promise    of
 reducing  reaction   time and improving ozone utilization, but the
 process at  present is limited  by  high  capital   expense,   possible
 chemical  interference   in  the treatment of mixed wastes, and  an
 energy  requirement of 25 kwh/kg of ozone generated.   Cyanide   is
 not economically  oxidized beyond  the cyanate form.

 Operational  Factors.    Reliability:   Ozone oxidation  is highly
 reliable  with  proper   monitoring  and   control,    and  proper
 pretreatment to -control  interfering substances.

 Maintainability-:   Maintenance  consists  of periodic removal  of
 sludge, and periodic renewal of filters arid  desiccators  ' required
 for  the  input   of  clean   dry air; filter  life is a function  of
 input concentrations of  detrimental constituents.

 Solid Waste Aspects:  Pretreatment to  eliminate substances  which
 will  interfere with the  process  may be necessary.  Dewatering  of
 sludge  generated  in the  ozone oxidation  process  or  in  an  "in
 line" process may be desirable prior to disposal.
14.  Cyanide Oxidation By_ Ozone With UV Radiation

One  of  the  modifications  of  the  ozonation
simultaneous application of ultraviolet light and
treatment  of  wastewater,  including  treatment
organics.  The  combined  action  of  these  two
reactions   by   photolysis,  photosensitization,
oxygenation,  and  oxidation.   The  process  is
several reactions and reaction species are active
process  is  the
 ozone  for  the
 of  halogenated,
 forms  produces
  hydroxylation,
 unique  because
 simultaneously.
Ozonation  is  facilitated by ultraviolet absorption because both
the ozone and the reactant  molecules  are  raised  to  a  higher
energy  state so that they react more rapidly.  In addition, free
radicals for use in the reaction are readily  hydrolyzed  by  the
water  present.  The energy and reaction intermediates created by
the introduction of both ultraviolet and ozone greatly reduce the
amount of ozone required  compared  with  a  system  using  ozone
alone.   Figure  VII-21   shows a three-stage UV-ozone system.  A-
system  to  treat  mixed cyanides   requires   pretreatment  that
                               1360

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involves  chemical  coagulation,   sedimentation,  clarification,
equalization, and pH adjustment.

Application  and Performance.  The ozone-UV radiation process .was
developed primarily for cyanide treatment in  the  electroplating
and  color  photo-processing  areas.   It  has  been successfully
applied to mixed cyanides and  organics  from  organic  chemicals
manufacturing  processes.  The process is particularly useful for
treatment of complexed  cyanides  such  as  ferricyanide,  copper
cyanide,  and nickel cyanide, which are resistant to ozone alone.
Ozone  combined with UV radiation is a relatively new technology.
Four units are currently in operation, and all four treat cyanide .
bearing waste.

Ozone-UV  treatment  could be used in  nonferrous metals  forming
plants to  destroy cyanide present in  some waste streams.

15.  Cyanide Oxidation By Hydrogen Peroxide

Hydrogen  peroxide  oxidation  removes both cyanide and metals in
cyanide containing wastewaters.  In this process, cyanide bearing
waters  are  heated to 49 to 54C (120 to 130F) and  the   pH   is
adjusted  to 10.5 to 11.8.  Formalin  (37 percent formaldehyde) is
added while the tank  is  vigorously  agitated.   After  2  to   5
minutes,  a  proprietary  peroxygen compound'(41 percent hydrogen
peroxide with a catalyst and additives) is added.  After an  hour
of mixing, the reaction is complete.  The cyanide is converted to
cyanate, and the metals are precipitated as oxides or hydroxides.
The  metals  are then removed from solution by either settling or
filtration.

The main equipment required for this process  is two holding tanks
equipped with heaters and air spargers  or  mechanical  stirrers.
These  tanks  may  be used in a batch or continuous fashion, with
one tank being used  for  treatment  while  the  other  is  being
filled.  A settling tank or a filter  is needed to concentrate the
precipitate.

Application  and  Performance.   The  hydrogen peroxide oxidation
process is applicable to cyanide-bearing wastewaters,  especially
those containing metal-cyanide  complexes.    In  terms  of  waste
reduction  performance,  this process can reduce total cyanide to
less than 0.1 mg/1 and the zinc or cadmium to less than 1.0 mg/1.

Advantages and Limitations.  Chemical costs are similar to  those
for alkaline chlorination using chlorine and  lower than those for
treatment  with  hypochlorite.   All  free  cyanide reacts and is
completely   oxidized  to  the   less   toxic  cyanate  state.    In
addition, the metals precipitate and  settle quickly, and they^may
be  recoverable  in many  instances.  However,  the process requires
energy  expenditures to heat  the wastewater prior to treatment.

Demonstration Status.  This  treatment process was  introduced  in
1971  and is  used  in several facilities.   No nonferrous  metals
forming plants use oxidation by hydrogen peroxide.


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  16.  Evaporation
 Evaporation  is a concentration process.  Water  is  evaporated  from
 a  solution,  increasing  the  concentration  of   solSte   in  the
 remaining solution,  if the resulting water  vapor   isP conSensel
    «3  i'-       '    e evaP°^ton-condesation proes is
called distillation.  Howe
     «3  i'-
 called distillation.  However, to  be  consistent  with  industrv
 terminology,  evaporation is used in this report to describe both
 processes.  Both atmospheric and vacuum evaporation^ arl  coLoSlv
 used  in  industry  today.   Specific  evaporation techni^Sre
 shown in Figure VII-22  and discussed below.       ^ecnniques are

 Atmospheric evaporation could be accomplished simply  by  boilinq
 the  liquid.   However,  to  aid  evaporation,  heated  liquid if
 sprayed on an evaporation surface, and  air  is  blown  ovlr  the
 surface  and  subsequently  released  to  the  atmosphere   Thus
 evaporation occurs by humidification of the air  strlam,   similar
 to  a  drying  process.   Equipment  for carrying out atmospheric
 evaporation is quite similar for most  applications    The  maior
 element  is generally a packed column with an accumulator bo t?o£
 Accumulated wastewater is pumped from the  base  of  the   column'
 through  a  heat  exchanger, and back into the top of the column'
 where it  is sprayed into the packing.    At  the  same  time   air
 drawn .upward  through  the   packing   by  a   fan  is  heat Pd^^
 2S2*S?S-  th* hot.li<3uid-   *he  liquid ypa?tifajy  valises  and
 humidifies the air  stream.   The fan  then blows the  hot, humid  air
 to  the  outside atmosphere.   A scrubber   is often unnecessarv
 because the  packed  column itself  acts  as  a scrubber?   unnecessary
        -     °f atmosPheric evaporator  also  works  on   the  air
 humidification  principle,  but the evaporated water is  recovered
 for  reuse by condensation.  These air  humidification  technioues
 operate  well  below  the  boiling point of wate? aSd can utiliw
 waste process heat to supply the energy required.         utilize

 In vacuum evaporation,' the evaporation  pressure  is  lowered  to
 cause  the  liquid  to  boil  at reduced temperature.  Jn"f the
 water vapor is condensed, and to maintain the  vacuum  condition
 2SSS °nd*nsible  ^ases (air in particular) are removed by a vacuum
 pump.  Vacuum evaporation may be either single or double  effect
 In  double  effect evaporation, two evaporators are used, Ind the
 S^^Va?°r fr°!? fc?e flrSt evaP°rator (Shich  may  be  hea?2d  by
 steam   is  used  to supply heat to the second evaporator   As it
 supplies  heat,  the  water  vapor  from  the 'firSt   evaporltor
 condenses.   Approximately  equal  quantities  of  wastlwater a?e

                                                   «
ss-


                               1362

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Another  means  of  increasing   energy   efficiency   is   .vapor
recompression  evaporation,  which enables heat to be transferred
from the condensing water vapor to  the  evaporating  wastewater.
Water  vapor generated from incoming wastewaters flows to a vapor
compressor.   The  compressed  steam  than  travels  through  the
wastewater  via an enclosed tube 'or coil in which it condenses as
heat is transferred to the surrounding solution.   In  this  way,
the   compressed   vapor  serves  as  a  heating  medium.   After
condensation, this distillate is drawn off  continuously  as  the
clean  water  stream.  The heat contained in the compressed vapor
is used to heat the  wastewater,  and  energy  costs  for  system
operation are reduced.

In  the most commonly used submerged tube evaporator, the heating
and condensing coil are contained in a single  vessel  to  reduce
capital  cost.   The  vacuum  in  the  vessel is maintained by an
eductor-type pump, which creates the required vacuum by the  flow
of  the  condenser  cooling  water through a venturi.  Wastewater
accumulates in the bottom of the vessel, and it is evaporated  by
means  of  submerged  'steam  coils.   The  resulting  water vapor
condenses as it contacts the condensing coils in the top  of  the
vessel.   The condensate then drips off the condensing coils into
a  collection  trough  that  carries  it  out  of   the   vessel.
Concentrate is removed from the bottom of the vessel.

The   major  elements  of  the climbing  film  evaporator are the
evaporator, separator, condenser, and vacuum pump.  Wastewater is
"drawn" into the system by the vacuum so that a  constant  liquid
level  is  maintained in the separator.  Liquid enters the steam-
jacketed evaporator tubes, and part of it evaporates  so  that  a
mixture  of vapor and liquid enters the separator.  The design of
the separator is such that the liquid is continuously  circulated
from  the  separator  to  the evaporator.  The vapor entering the
separator flows out through a mesh entrainment separator  to  the
condenser,  where  it  is  condensed as it flows down through the
condenser tubes.  The condensate, along with any  entrained  air,
is  pumped  out  of  the bottom of the condenser by a liquid ring
vacuum pump.  The liquid seal provided by  the  condensate  keeps
the vacuum in the system from being broken.

Application   and   Performance.   Both  atmospheric  and,  vacuum
evaporation are used in many industrial plants,  mainly  for  the
concentration  and  recovery of process solutions.  Many of these
evaporators also recover water for rinsing.  Evaporation has also
been applied to recovery of phosphate metal cleaning solutions.

In theory, evaporation should yield a concentrate and a deionized
condensate.  Actually,  carry-over  has  resulted  in  condensate
metal concentrations as high as 10 mg/1, although the usual level
is  less  than  3  mg/1,',  pure enough for most final rinses.  The
condensate may also contain organic brighteners  and  antifoaming
agents.   These  can  be removed with an activated carbon bed, if
necessary.  Samples from one plant showed 1,900 mg/1 zinc in  the
feed,  4,570  mg/1  in  the  concentrate,  and  0.4  mg/1  in the


                               1363

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 condensate.  Another plant had 416 mg/1 copper in  the  feed  and
 21,800 mg/1 in the concentrate.  Chromium analysis for that plant
 indicated  5,060  mg/1  in  the  feed  and  27,500  mg/1  in  the
 'concentrate.  Evaporators are available in a range of capacities,
 typically from 15  to  75  gph,  and  may  be  used  in  parallel
 arrangements for processing of higher flow rates.

 Advantages   and  Limitations.   Advantages  of  the  evaporation
 process are that it permits recovery of a wide variety of process
 chemicals, and it is often applicable to concentration or removal
 of compounds which cannot be accomplished  by  any  other  means.
 The  major  disadvantage is that the evaporation process consumes
 relatively large amounts.of energy for the evaporation of  water.
 However,   the  recovery  of  waste  heat  from  many  industrial
 processes (e.g., diesel  generators,  incinerators,  boilers  and
 furnaces)  should  be  considered  as a source of this heat for a
 totally integrated evaporation system.  Also, in some cases solar
 heating ^could  be  inexpensively  and  effectively  applied   to
 evaporation   units.    Capital   costs   for  vapor  compression
 evaporators are substantially higher  than  for  other  types  of
 evaporation equipment.   However, the energy costs associated with
 the operation of a vapor compression evaporator are significantly
 lower   than   costs   of   other  evaproator  types.   For  some
 applications, pretreatment may be required to  remove  solids  or
 bacteria  which  tend  to  cause  fouling  in  the  condenser  or
 evaporator.  The buildup of  scale  on  the  evaporator  surfaces
 reduces   the   heat   transfer  efficiency  and  may  present  a
 maintenance problem or  increase operating cost.  However,  it  has
 been  demonstrated that fouling of the heat transfer surfaces can
 be  avoided  or  minimized  for  certain  dissolved   solids   by
 maintaining  a  seed slurry which provides preferential sites for
 precipitate deposition.  In addition, low temperature differences
 in  the  evaporator  will   eliminate   nucleate   boiling   and
 supersaturation  effects.    Steam  distillable  impurities in the
'process stream are carried over with the product water  and  must
 be handled by pre- or post-treatment.

 Operational   Factors.    Reliability:   Proper  maintenance  will
 ensure a high degree of reliability for  the system.   Without such
 attention, rapid fouling or deterioration  of  vacuum < seals  may
 occur, especially when  corrosive liquids are handled.

 Maintainability:     Operating  parameters  can  be  automatically
 controlled.   Pretreatment  may be required,  as  well   as periodic
 cleaning of'the system.  Regular replacement of seals,  especially
 in a corrosive environment,  may be necessary.

 Solid  Waste  Aspects:    With  only a few exceptions,  the  process
 does not generate appreciable quantities of solid waste *
 Demonstration  Status.
Evaporation  is   a   fully   developed,
wastewater treatment system.   It is used
                 in  the  electroplating
 commercially  available
 extensively to recover plating  chemicals               	t	=
 industry,  and a pilot scale  unit  has  been  used  in connection with
 phosphating  of  aluminum.   Proven  performance  in silver recovery
                                1364

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indicates that evaporation could be a useful treatment  operation
for  the  photographic  industry, as well as for metal finishing.
Vapor compression evaporation has been  practically  demonstrated
in a number of industries, including chemical manufacturing, food
processing, pulp and paper, and metal working.

17.  Flotation

Flotation  is  the  process  of  causing  particles  such  as metal
hydroxides or oil to float to the surface of a  tank where  they
can  be  concentrated  and  removed.   This  is  accomplished   by
releasing gas  bubbles  which  attach  to  the  solid  particles,
increasing   their  buoyancy  and   causing  them   to float.    In
principle, this process is the opposite of sedimentation.  Figure
VII-23   shows one type of flotation system.

Flotation  is  used  primarily  in   the  treatment   of  wastewater
streams  that carry  heavy  loads of finely divided suspended solids
or   oil.   Solids having  a specific gravity only slightly greater
than 1.0,  which  would   require  abnormally   long  sedimentation
times,   may be  removed  in much less time by flotation.   Dissolved
air  flotation  is of greatest  interest  in removing  oil  from  water
and  is  less effective  in  removing heavier  precipitates.

This process   may  be  performed  in  several ways:   foam,  dispersed
air, dissolved air, gravity,  and vacuum flotation   are   the  most
 commonly  used  techniques.   Chemical  additives are often used to
 enhance the performance of  the  flotation process.

 The  principal  difference among  types of flotation  is  the  method
 of  generating  the   minute  gas  bubbles  (usually  air)  in  a
 suspension of  water and small particles.   Chemicals.may  be   used
 to  improve   the  efficiency  with any of  the basic methods.  The
 following paragraphs  describe the different  flotation  techniques
 and the method of  bubble generation for each process.

 Froth  Flotation - Froth flotation is based on differences in the
 physiochemical properties in various particles.  Wettability  and
 surface  properties  affect  the  particles'   ability  to  attach
 themselves to 'gas  bubbles  in  an  aqueous  medium.    In  froth
 flotation, air is blown through the solution containing flotation
 reagents.   The  particles with water repellant surfaces stick to
 air bubbles as they rise and  are  brought  to  the  surface.    A
 mineralized  froth  layer, with mineral particles attached to air
 bubbles, is  formed.   Particles  of  other  minerals  which  are
" readily wetted by water do not stick to air bubbles and remain in
 suspension.

 Dispersed Air Flotation - In dispersed air flotation, gas bubbles
 are generated  by  introducing  the  air  by means of mechanical
 agitation with impellers or by forcing air through  porous  media.
 Dispersed  air  flotation  is  used  mainly  in the metallurgical
 industry.
                                 1365

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 Dissolved Air Flotation - In dissolved air flotation, bubbles are
 produced by releasing air from a  supersaturated  solution  under
 relatively high pressure.  There are two types of contact between
 the  gas bubbles and particles.  The first type is predominant in
 the  flotation  of  flocculated  materials   and   involves   the
 entrapment  of rising gas bubbles in the flocculated particles as
 they increase in size.  The bond between the bubble and  particle
 is  one  of physical capture only.  The second type of contact is
 one  of  adhesion.   Adhesion  results  from  the  intermolecular
 attraction  exerted  at  the interface between the solid particle
 and gaseous bubble.

 Vacuum Flotation  -  This  process  consists  of  saturating  the
 wastewater  with  air  either directly in an aeration tank,  or by
 permitting air to enter on the suction of a wastewater  pump.    A
 partial vacuum is applied, which causes the dissolved air to come
 out  of  solution as minute bubbles.   The bubbles attach to  solid
 particles and rise to the surface to  form a scum  blanket,   which
 is  normally  removed  by  a  skimming mechanism.   Grit  and  other
 heavy solids that settle to the bottom are generally  raked   to  a
 central sludge pump for removal.   A typical vacuum flotation unit
 consists  of a covered cylindrical tank in which a partial vacuum
 is maintained.   The tank is equipped  with scum and sludge removal
 mechanisms.   The floating material is continuously swept  to  the
 tank  periphery,  automatically discharged into a scum trough,  and
 removed from the unit   by  a  pump also   under  partial vacuum.
 Auxiliary  equipment includes  an  aeration tank for saturating  the
 wastewater  with air, a tank  with a   short  retention  time  for
 removal of  large bubbles,  vacuum  pumps, and sludge pumps.

 Application  and Performance.   The primary variables for  flotation
 design   are  pressure,   feed  solids  concentration, and  retention
 period.   The suspended solids  in  the  effluent  decrease,   and  the
 concentration   of   solids   in  the float increases  with increasing
 retention period.   When  the  flotation process  is   used  primarily
 for  clarification,  a retention period of  20 to  30  minutes usually
 is adequate  for  separation and concentration.

 Advantages   and  Limitations.   Some  advantages of the  flotation
 process  are  the high levels of solids separation achieved in many
 applications, the relatively low  energy  requirements,  and  the
 adaptability  to  meet  the  treatment  requirements of different
 waste types.  Limitations of flotation are that it often requires
 addition of chemicals  to enhance process performance and that  it
 generates large quantities of solid waste.

Operational  Factors.   Reliability:   Flotation systems normally
are very reliable with proper maintenance of the sludge collector
mechanism and the motors and pumps used for aeration.

Maintainability:  Routine.maintenance  is required  on  the  pumps
and  _motors.   The  sludge  collector   mechanism  is  subject  to
possible  corrosion  or  breakage  and   may   require   periodic
replacement.
                               1366

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Solid  Waste  Aspects:   Chemicals  are  commonly used to aid the
flotation process by creating a surface or a structure  that  c^n
easily  adsorb  or entrap air bubbles.  Inorganic chemicals, such
as the aluminum and ferric salts, and activated silica* can  bind
the  particulate  matter together and create a structure that can
entrap air bubbles.  Various organic  chemicals  can  change  the
nature  of  either  the  air-liquid interface or the solid-liquid
interface, or both.   These  compounds  usually  collect  on  the
interface   to  bring  about  the  desired  changes.   The  added
chemicals plus the particles in solution combine to form a  large
volume  of  sludge  which  must  be  further  treated or properly
disposed.                                .

Demonstration Status.  Flotation is a fully developed process and
is readily available for the  treatment  of  a  wide  variety  of
industrial  waste streams.

18«  Gravity Sludge Thickening

In  the  gravity  thickening process, dilute sludge is fed from a
primary settling tank or clarifier to  a  thickening  tank  where.
rakes  stir  the  sludge gently to density it and to push it to a
central collection well.  The  supernatant  is  returned  to  the
primary settling tank.  The thickened sludge that collects on the
bottom  of  the  tank is pumped to dewatering equipment or hauled
away."  Figure  VII-24   shows  the  construction  of  a  gravity
thickener.

Application  ,and  Performance.   Thickeners are generally used in
facilities where the  sludge is  to  be  further  dewatered  by  a
compact  mechanical device such as a vacuum filter or centrifuge.
Doubling  the  solids  content  in  the  thickener  substantially
reduces  capital  and operating cost of the subsequent dewatering
device and  also  reduces  cost  for  hauling.   The  process  is
potentially applicable to almost any industrial plant.

Organic  sludges  from  sedimentation units of one to two percent
solids concentration  can usually be gravity thickened to  six  to
ten   percent;  chemical  sludges  can be thickened to four to six
percent.

Advantages and Limitations.  The principal advantage of a gravity
sludge thickening process is that it facilitates  further  sludge
dewatering.   Other   advantages  are high reliability and minimum
maintenance  requirements.

Limitations  of the  sludge thickening process are its - sensitivity
to  the   flow  rate   through the thickener and the sludge removal
rate.  These  rates   must  be  low  enough  not  to  disturb  the
thickened  sludge.

Operational  Factors.   Reliability:   Reliability  is  high with
proper design and  operation.   A  gravity thickener is designed  on
the   basis   of   square  feet  per  pound of solids per day,  in which
the  required surface  area  is related  to the solids  entering  and


                               1367

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 leaving the unit.  Thickener area requirements are also expressed
 in  terms  of  mass loading, grams of solids per square meter r>er
 day (Ibs/sq ft/day).

 Maintainability:   Twice a year,  a thickener must be shut down for
 lubrication of the drive mechanisms.   Occasionally, water must be
 pumped back through the system in order to clear sludge pipes.

 Solid Waste Aspects:   Thickened  sludge from a gravity  thickening
 process   will   usually  require  further  dewatering  prior  to
 disposal, incineration, or drying.   The  clear  effluent  may  be
 recirculated in part,  or it may  be subjected to further treatment
 prior to discharge.

 Demonstration  Status.    Gravity  sludge  thickeners  are   used
 throughout industry to reduce water content to a level where   the
 sludge may be efficiently handled.   Further dewatering is usually
 practiced  to  minimize  costs  of hauling the sludge to approved
 landfill areas.

 19.   Insoluble Starch  Xanthate                                '

 Insoluble  starch  xanthate is essentially an ion exchange medium
 used  to remove dissolved heavy metals from wastewater.   The water
 may then either be reused (recovery .application)   or  discharged
 (end-of-pipe  application).   In  a commercial electroplating oper-
 ation,  starch xanthate is coated on a filter medium.   Rinse water
 containing dragged out heavy metals .is   circulated  through   the
 filters  and  then reused  for   rinsing.   The starch-heavy metal
 complex is disposed of  and  replaced periodically.    Laboratory
 tests   indicate   that   recovery   of  metals  from  the  complex is
 feasible,  with regeneration  of   the   starch  xanthate.    Besides
 electroplating,   starch xanthate is potentially applicable to  any
 other  industrial  plants where dilute  metal  wastewater  streams  are
 generated.   Its present use  is   limited   to  one   electroplating
 plant.

 20.  Ion Exchange

 Ion  exchange  is  a process  in  which  ions,  held by electrostatic
 forces  to  charged functional  groups on the   surface   of   the   ion
 exchange  resin, are exchanged for ions of similar charge  from  the
 solution  in which the  resin  is immersed.  This  is classified as a
 sorption   process   because   the  exchange occurs on  the surface of
 the resin, and the  exchanging  ion must undergo  a  phase   transfer
 from  solution phase to  solid phase.  Thus,  ionic contaminants in
 a waste  stream can  be  exchanged  for  the  harmless  ions   of   the
 resin.

Although the precise technique may vary slightly according to the
application  involved, a generalized process description follows.
The wastewater stream being treated passes  through  a  filter  to
 remove  any  solids,  then flows through a  cation exchanger which
contains the ion  exchange resin.   Here, metallic impurities  such
as copper, iron, and trivalent chromium are  retained.  The stream


                               1368

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then passes through the anion exchanger and its associated resin.
Hexavalent  chromium, for example, is retained in this stage.  if
one pass does not reduce the contaminant levels sufficiently, the
stream may then enter another series  of  exchangers.   Many  ion
exchange   systems  are  equipped  with  more  than  one  set  of
exchangers  for  this reason.   A strongly basic  anion  exchange
resin may be used alone to remove precious metals,  such as gold,
palladium and platinum.

The other major portion of the ion exchange process concerns  the
regeneration  of  the  resin,  which  now  holds those impurities
retained from the waste stream.  An ion exchange  unit  with  in-
place  regeneration  is shown in Figure VII-25.   Metal ions such
as  nickel are  removed  by  an  acid,   cation  exchange  resin,
which    is  regenerated  with  hydrochloric  or  sulfuric  acid,
replacing the metal ion with one or more hydrogen  ions.   Anions
such  as dichromate are removed by a basic, anion exchange resin,
which is regenerated with sodi'um hydroxide, replacing  the  anion
with  one  or  more  hydroxyl  ions.  The three principal methods
employed by industry for regenerating the spent resin are:

     A)   Replacement   Service:       A   regeneration   service
          replaces   the spent  resin  with  regenerated   resin,
          and  regenerates the spent resin at its  own  facility.
         .The  service  then  has the  problem  of  treating  and
          disposing of the spent regenerant.

     B)   In-Place  Regenerations   Some establishments may  find
         . it  less expensive to do their own  regeneration.   The
          spent   resin  column is  shut  down  for  perhaps   an
          hour,   and   the   spent resin is  regenerated.   This
          results in one or  more  waste  streams  which must  be
          treated  in  an  appropriate  manner.   Regeneration is
          performed as the resins require it,  usually every  few
          months.

     C)   Cyclic Regeneration:  In this process, the regeneration
          of the spent"resins takes place within the ion exchange
          unit   itself   in  alternating  cycles  with  the  ion
          removal process.   A regeneration frequency of twice an
          hour  is  typical.    This   very   short   cycle  time
          permits  operation  with a very small quantity of resin
          and with fairly concentrated solutions,  resulting in a
          very   compact  system.   Again,  this  process  varies
          according  to application,  but the regeneration  cycle
          generally begins with caustic being pumped through  the
          anion  exchanger, carrying out hexavalent chromium, for
          example,  as sodium dichromate.   The sodium dichromate
         . stream  then   passes   through  a   cation  exchanger,
          converting  the  sodium  dichromate  to  chromic  acid.
          After concentration  by  evaporation or  other   means,
          the  chromic acid can be returned to the process  line.
          Meanwhile,   the   cation   exchanger  is   regenerated
          with sulfuric  acid,  resulting  in a.waste acid stream'
          containing  the metallic impurities  removed   earlier.
                               1369

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          Flushing   the   exchangers with  water  completes  the
          cycle.  Thus, the wastewater is purified and,  in  this
          example,   chromic   acid   is   recovered.    The  ion
          exchangers, with newly regenerated  resin,  then  enter
          the  ion removal cycle again.

Application  and  Performance.   'The list of pollutants for which
the ion exchange system has proved effective  includes  aluminum,
arsenic,  cadmium,  chromium  (hexavalent and trivalent), copper,
cyanide,  gold,  iron,  lead,  manganese,  nickel,  platinum  and
palladium,  selenium,   silver,  tin,  zinc,  and more.  Thus, it
can be applied to a wide variety of industrial concerns.  Because
of  the heavy  concentrations  of metals  in   their  wastewater,
the  metal  finishing industries utilize ion exchange in  several
ways.   As an end-of-pipe  treatment,  ion  exchange is certainly
feasible, but its greatest value is in recovery1applications.  It
is   commonly   used  as  an  integrated treatment   to   recover
rinse    water  and  process  chemicals.    Some   electroplating
facilities  use  ion   exchange   to   concentrate   and   purify
plating baths.  Also, many industrial concerns use  ion  exchange
to reduce salt concentrations in incoming water sources.

Ion  exchange  is  highly  efficient  at recovering metal bearing
solutions.  Recovery of chromium, nickel, phosphate solution, and
sulfuric  acid  from  anodizing  is  common.   . A; chromic   acid
recovery  efficiency  of  99.5  percent  has  been  demonstrated.
Typical data for purification of rinse water have  been  reported
and  are  displayed  in Table VII-26..   Sampling at a  nonferrous
metals  manufacturing  battery manufacturing plant  characterized
influent   and   effluent streams for an ion exchange unit  on  a
silver bearing waste.   This system  was in start-up at the  time
of  sampling,   however,  and  was  not  found  to  be  operating
effectively.
Advantages
technology
            and  Limitations.
 Ion  exchange
a  great  many
is   a   versatile
situations.   This
             applicable   to
flexibility, along with its compact nature and performance, makes
ion exchange a very effective  method  of  wastewater  treatment.
However,  the  resins in these systems can prove to be a limiting
factor.  The thermal limits of the anion resins, generally in the
vicinity  of 60C,  could prevent its use in  certain  situations.
Similarly,  nitric  acid, chromic acid, and hydrogen peroxide can
all damage the resins, as will iron, manganese, arid  copper  when
present  with  sufficient  concentrations  of  dissolved  oxygen.
Removal of a particular trace  contaminant  may  be  uneconomical
because  of  the  presence  of  other  ionic  species  that   are
preferentially' removed.  The regeneration of the resins presents
its  own problems.   The cost of the regenerative chemicals   can
be   high.  In  addition,  the waste streams originating from the
regeneration   process   are   extremely   high   in    pollutant
concentrations,   although  low   in  volume.    These  must   be
further  processed for proper disposal.          ;
                               1370

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 Operational  Factors.
 occasional  clogging
 — ~^,_..-. j.v^iiiij.  <-j.wyyo.ny  i_i j.  J-UUJ-J.Iig OT TZne TS
 proved to be a highly dependable technology
  Reliability:   With  the   exception   of
or  fouling of the resins, ion exchange ha?
    nrJAhl £* 1-ooHnr*\l r-\mr
 Maintainability:  Only the normal maintenance of  pumps,  valves
 piping  and  other  hardware  used in the regeneration process is
 required.

 Solid Waste Aspects:  Few, if any, solids accumulate  within  the
 ion  exchangers, and those which do appear are removed by the re-
 generation process.  Proper prior treatment and planning can eli-
 minate   solids  buildup  problems   altogether.     The    brine
 resulting  from   regeneration   of  the   ion   exchange   resin
 usually  must  be  treated to remove  metals  before  - discharge
 This  can  generate solid waste.

 Demonstration  Status.   All of the applications mentioned in this
 document are available  for commercial use, and  industry  sources
 estimate  the number of units currently in the field at well over
 120.  The research and  development in ion exchange is focusinq on
 improving the quality and efficiency of the resins,   rather  than
 new  applications.    Work  is  also  being  done  on a continuous
 regeneration process whereby the resins are contained on a fluid-
 transfusible belt.   The belt passes through  a  compartmentalized
 tank  with ion exchange,  washing,  and regeneration sections.  The
 resins are therefore continually used and fegenerated.    No  such
 system,  however,  has been reported beyond the pilot  stage.

 21.   Membrane Filtration

 Membrane   filtration    is   a   treatment  system  for   removing
 precipitated metals  from  a wastewater  stream.   It  must   therefore
 be   preceded  by   those   treatment  techniques  which  will  properly
 prepare  the  wastewater  for solids  removal.   Typically, a  membrane
 filtration unit  is preceded by pH  adjustment  or  sulfide   addition
 for  precipitation of the  metals.   These  steps  are  followed  by  the
 addition of   a  proprietary   chemical   reagent  which causes  the
 precipitate  to be nongelatinous,   easily  dewatered,  and  highly
 J™in;  •      ^suiting   mixture   of  pretreated  wastewater  and
 reagent  is continuously recirculated through a filter module  and
 back   into  a  recirculation   tank.   The  filter module  contains
 tubular  membranes.  While  the  reagent-metal hydroxide precipitatl
 mixture  flows  through the  inside of the  tubes, the watSr  and  any
 dissolved  salts  permeate  the membrane.  When the  recirculating
 slurry reaches a concentration of 10 to  15 percent solids, it  il
 pumped out of the system as sludge.                ^xxas, ic  is

 Application  and  Performance.  Membrane filtration appears  to be
 applicable to any wastewater or process  water  containing   meta!
 ions  which  can  be  precipitated  using  hydroxide,  sulfide or
 carbonate  precipitation.   It  could  function  as  the  primary
 trSSSS ,S??tem' bu^ ajs°.»i9ht find application as a pollshfng
 treatment (after precipitation and settling) to ensure  continued
 compliance  with metals  limitations.  Membrane fil^tion systemt
are  being  used  in  a   number   of   industrial   2pp?icltions?'
                               1371

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particularly   in   the  metal  finishing area.   They  have  also  been
used for toxic metals  removal in  the metal   fabrication   industry
and the paper  industry.

The  permeate  is claimed by one manufacturer  to  contain  less  than
the  effluent  concentrations  shown  in  Table VII-27  regardless
of   the   influent    concentrations.   These claims  have   been
largely  substantiated by the analysis of1   water   samples   at
various plants in  various industries.

In  the  performance   predictions  for this  technology,  pollutant
concentrations are reduced to the levels shown  in  Table  VII-27
unless lower levels are present in the influent  stream.

Advantages  and  Limitations.   A major advantage of the membrane
filtration system  is that  installations  can use  most of  the
conventional   end-of-pipe  systems  that may  already be  in place.
Removal efficiencies are  claimed  to  be  excellent,  even   with
sudden   variation  of   pollutant  input   rates;  however,  the
effectiveness  of the membrane filtration system  can be limited by
clogging of the filters.  Because pH changes  in  the waste  stream
greatly  intensify clogging  problems,  the  pH  must be  carefully
monitored  and controlled'.    Clogging can force  the shutdown   of
the system  and  may   interfere  with  production.   In  addition,
the  relatively  high  capital cost of this system may  limit  its
use.

Operational Factors.   Reliability:  Membrane  filtration  has   been
shown  to  be  a   very reliable  system, provided that  the pH is
strictly controlled.   Improper pH can result  in  the  clogging  of
the  membrane.  Also,  surges  in the flow rate  of the waste stream
must be controlled  in  order  to  prevent  solids  from passing
through the filter and into the effluent.

Maintainability:    The   membrane   filters  must  be   regularly
monitored, and cleaned or replaced as  necessary.   Depending  on
the  composition  of the waste stream and its  flow rate,  frequent
cleaning  of   the  filters  may  be  required.    Flushing   with
hydrochloric  acid  for  6  to 24 hours will usually suffice.   In
addition, the  routine maintenance of  pumps,  valves,   and  other
plumbing is required.

Solid  Waste Aspects:  When the recirculating  reagent-precipitate
slurry reaches 10 to 15 percent solids, it is pumped out   of  the
system.   It can then be disposed of directly or it can undergo a
dewatering process.  Because this sludge contains  toxic   metals,
it requires proper disposal.

Demonstration Status.  There are more than 25 membrane filtration
systems   presently   in  use  on  metal  finishing  and   similar
wastewaters.   Bench scale and pilot studies are being  run  in   an
attempt to expand the list of pollutants for which this system is
known  to be effective.
                               1372

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22.  Peat Adsorption

Peat moss is a complex natural organic material containing lignin
and   cellulose   as  major  constituents.   These  constituents,
particularly  lignin,  bear  polar  functional  groups,  such  as
alcohols,  aldehydes,  ketones,  acids,  phenolic hydroxides, and
ethers, that can be involved in chemical bonding.  Because of the
polar nature of the material, its adsorption of dissolved  solids
such  as  transition  metals and polar organic molecules is quite
high.  These properties have led to the use of peat as  an  agent
for the purification of industrial wastewater.

Peat  adsorption  is a "polishing" process which can achieve very
low effluent  concentrations  for  several  pollutants.   If  the
concentrations  of  pollutants  are  above  10  mg/1,  then  peat
adsorption  must  be  preceded  by  pH  adjustment   for   metals
precipitation and subsequent clarification.  Pretreatment is also
required  for  chromium  wastes  using ferric chloride and sodium
sulfide.  The wastewater  is  then  pumped  into  a  large  metal
chamber  called  a  kier  which  contains a layer of peat through
which the waste stream passes.  The water flows to a second  kier
for  further  adsorption.   The  wastewater  is  then  ready  for
discharge.  This system may be automated or manually operated.

Application and Performance.  Peat  adsorption  can  be  used  in
nonferrous  metals  forming for  removal  of  residual  dissolved
metals from  clarifier  effluent.   Peat  moss  may  be  used  to
treat  wastewaters   containing  heavy  metals  such as  mercury,
cadmium,  zinc, copper, iron,  nickel,  chromium,  and  lead,  as
well   as organic   matter   such   as   oil,   detergents,  'and
dyes.    Peat  adsorption  is  currently used commercially  at  a
textile  plant,   a newsprint facility,  and a metal  reclamation
operation.

Table   VII-28 contains performance figures obtained  from  pilot
plant studies.  Peat adsorption  was  preceded  by  pH adjustment
for precipitation and by clarification.

In  addition,  pilot plant studies have shown that chelated metal
wastes, as well as the chelating agents themselves,  are  removed
by contact with peat moss.

Advantages  and  Limitations.  The major advantages of the system
include its ability to yield low  pollutant  concentrations,  its
broad .scope  in  terms  of  the  pollutants  eliminated, and its
capacity to accept wide variations of waste water composition.

Limitations  include  the  cost  of  purchasing,   storing,   and
disposing of the peat moss; the necessity for regular replacement
of  the  peat  may  lead to high operation and maintenance costs.
Also,  the  pH  adjustment  must  be  altered  according  to  the
composition of the waste stream.

Operational  Factors.   Reliability:  The  question  of long term
reliability is not yet fully answered.  Although the manufacturer
                               1373

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 reports it to be a highly reliable system,
 is needed to verify the claim.
                    operating  experience
 Maintainability:   The  peat  moss  used  in  this  process  soon
 exhausts its capacity to adsorb pollutants.  At  that  time,   the
 kiers  must  be  opened,  the peat removed, and fresh peat placed
 inside.   Although  this  procedure   is   easily   and   quickly
 accomplished,  it  must  be  done  at  regular  intervals, or the
 system's efficiency drops drastically.

 Solid Waste Aspects:  After removal from the kier, the spent  peat
 must be eliminated.  If incineration is used, precautions  should
 be  taken  to insure that those pollutants removed:from the water
 are not released again in the combustion  process.   Presence  of
 sulfides in the spent peat, for example, will give rise to sulfur
 dioxide  in  the fumes from burning.   The presence of significant
 quantities  of  toxic  heavy  metals  in  battery   manufacturing
 wastewater  will in general preclude incineration of peat used in
 treating these wastes.
 Demonstration  Status.
 Only  three  facilities  currently   use
systems  in the United States - a textile
 commercial  adsorption   ^           		    _  	_,__
 manufacturer,  a  newsprint facility,  and  a  metal  reclamation  firm"
 No  data  have been reported showing  the use of  peat  adsorption  in
 nonferrous metals forming plants.

 23.  Reverse Osmosis

 The process of osmosis involves  the  passage of a liquid  through a
 semipermeable  membrane  from  a dilute  to   a  more concentrated
 solution.   Reverse osmosis  (RO)  is an operation  in  which pressure
 is applied to  the more concentrated  solution,  forcing   the  per-
 meate  to   diffuse through the  membrane and into the more dilute
 solution.   This  filtering action produces   a   concentrate  and  a
 permeate   on opposite  sides of the membrane.   The concentrate can
 then_be further  treated or  returned  to the  original operation for
•continued  use, while the  permeate water  can be recycled  for  use
 as   clean  water.     Figure VII-26   depicts a  reverse  osmosis
 system.

 As  illustrated   in  Figure VII-27,   there   are   three  basic
 configurations     used in   commercially available  RO  modules:
 tubular, spiral-wound,  and  hollow fiber.  All  of  these operate on
 the principle  described above, the major difference  being  their
 mechanical  and structural design characteristics.

 The  tubular  membrane  module uses a porous tube  with a cellulose
 acetate membrane  lining.  A common tubular module consists  of  a
 length  of   2.5   cm  (1 inch) diameter tube wound on a supporting
 spool and encased  in a  plastic shroud.   Feed water is driven into
 the tube under pressures varying from 40 to 55 atm  (600-800 psi).
 The permeate  passes   through  the  walls  of  the  tube  and  is
 collected   in  a manifold while the concentrate is drained off at
 the end of  the tube.  A less widely used tubular RO module uses a
                               1374

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straight tube contained in a housing, under
conditions.
the  same  operating
Spiral-wound  membranes  consist  of  a porous backing sandwiched
between two cellulose acetate membrane sheets  and  bonded  along
three  edges.  The fourth edge of the composite sheet is attached
to a large permeate collector tube.   A  spacer  screen  is  then
placed  on  top of the membrane sandwich, and the entire stack is
rolled around the centrally located tubular  permeate  collector.
The  rolled  up package is inserted into a pipe able to withstand
the high operating pressures employed in this process, up  to  55
atm  (800  psi) with the spiral-wound module.  When the system is
operating, the pressurized product water permeates  the  membrane
and  flows  through the backing material to the central collector
tube.  .The concentrate is drained off at the end of the container
pipe and can be reprocessed or sent to further treatment  facili-
ties.

The hollow fiber membrane configuration is made up of a bundle of
polyamide  fibers  of  approximately 0.0075 cm (0.003 in.) OD and
0.0043 cm (0.0017 in.) ID.  A commonly used hollow  fiber  module
contains  several hundred thousand of the fibers placed in a long
tube, wrapped around a flow screen, and  rolled  into  a  spiral.
The  fibers are bent in a U-shape and their ends are supported by
an epoxy bond.  The hollow fiber unit is operated  under  27  atm
(400  psi), the feed water being dispersed from the center of the
module through a porous distributor tube.  Permeate flows through
the membrane to  the  hollow  interiors  of  the  fibers  and  is
collected at-the ends of the fibers.

The  hollow fiber and spiral-wound modules have a distinct advan-
tage over the tubular system in that they are able to load a very
large membrane surface  area  into  a  relatively  small  volume.
However,  these  two  membrane types are much more susceptible to
fouling than the tubular system, which has a larger flow channel.

This characteristic also makes the tubular membrane  much  easfer
to  clean  and  regenerate than either the spiral-wound or hollow
fiber  modules.    One  manufacturer  claims  that  their  helical
tubular  module  can  be physically wiped clean by passing a soft
porous polyurethane plug under pressure through the module.

Application and Performance.   In a  number  of  metal  processing
plants,  the  overflow  from  the first rinse in a countercurrent
setup is  directed  to  a  reverse  osmosis  unit,  where  it  is
separated  into  two  streams.    The concentrated stream contains
dragged out chemicals and is  returned to the bath to replace  the
loss  of  solution caused by  evaporation and dragout.   The dilute
stream (the permeate)  is routed to the last rinse tank to provide
water for the  rinsing operation.  The rinse flows from  the   last
tank to the first tank,  and the cycle is complete.

The closed-loop system described above may be supplemented by the
addition  of  a  vacuum  evaporator after the RO unit in order to-
further reduce the volume of  reverse  osmosis  concentrate.    The
                               1375

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 evaporated  vapor can be condensed and  returned  to  the  last  rinse
 tank or sent on for further  treatment.

 The largest application has  been for the recovery of nickel  solu-
 tions.  It has been shown that RO can   generally  be  applied  to

             ™e£a]Vv,bathS uWith  a  high degree  of  Performance,
            that  the  membrane  unit  is  not   overtaxed.    The
 limitations  most  critical  here  are  the allowable pH ranqe and
 maximum operating pressure   for  each   particular  configuration.
 Adequate  prefiltration  is  also essential.  Only three membrane
 types are readily available  in commercial  RO  units/  and   their
 overwhelming  use has been for the recovery of various acid metal
 baths.  For the purpose of calculating performance predictions of
 this technology, a rejection ratio of 98 percent is  assumed  for
 dissolved salts, with 95 percent permeate recovery.
   i
 Advantages  and  Limitations.   The  major  advantage  of reverse
 osmosis  for  handling  process  effluents  is  its  ability   to
 concentrate  dilute solutions for recovery of salts and chemicals
 with lowmpower requirements.   No latent heat of  vaporization  or
 fusion  is  required  for  effecting separations; the main energy
 requirement is for a high pressure pump.  It requires  relatively
 little  floor   space  for  compact,   high  capacity units, and it
 exhibits good  recovery  and  rejection  rates  for   a  number  of
 typical  process  solutions.   A limitation of the reverse osmosis
 process  for  treatment   of  process   effluents  is  its  limited
 temperature range  for   satisfactory  operation.    For  cellulose
 acetate systems,  the preferred limits are 18 to 30C (65   to 85F) •
 higher   _  temperatures    will  increase   the  rate   of    membrane
 hydrolysis and reduce  system  life, while lower temperatures  will
 result   in  decreased  fluxes  with   no   damage  to the  membrane.
 Another limitation is  inability   to   handle  certain solutions.
 Strong   oxidizing   agents,  strongly   acidic  or  basic solutions,
 solvents,  and  other  organic compounds can  cause  dissolution of
 the  membrane.   Poor rejection of some  compounds such as  borates
 and  low molecular  weight organics  is  another problem.  Foulinq of
 membranes  by slightly soluble components in  solution  or  colloids
 has  caused failures, and fouling of membranes  by  feed waters  with
 V^h    levels  of  suspended  solids can  be a   problem.   A  final
 limitation is inability to treat or  achieve high   concentration
 with_ some solutions.   Some concentrated  solutions  may   have
 initial  osmotic   pressures  which are so high  that   they   either
 exceed   available  operating  pressures  or  are  uneconomical  to
 treat.

 Operational Factors.   Reliability:   Very  good  reliability  is
 achieved   so long as the proper precautions are taken to minimize
 the chances of fouling or  degrading  the  membrane.   Sufficient
 testing  of the waste stream prior to application of an RO system
 will provide  the  information  needed   to  insure  a  successful
 application.

Maintainability:   Membrane  life  is estimated to range from six
months to three years,  depending  on  the  use  of  the  system.
Downtime for flushing or  cleaning is on the order of two hours as
                               1376

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often  as  once  each  week; a substantial portion of maintenance
time must be spent on cleaning any prefilters installed ahead  of
the reverse osmosis unit.

Solid   Waste  Aspects:   In a closed loop system  utilizing  RO,
there  is  a  constant recycle of concentrate   and   a   minimal
amount  of solid  waste.    Prefiltration  eliminates many solids
before  they  reach the module and helps keep the  buildup  to  a
minimum.   These solids require proper disposal.

Demonstration  Status.   There are presently at least one hundred
reverse  osmosis  wastewater  applications  in   a   variety   of
industries.  In addition to these, there are 30 to 40 units being
used  to  provide  pure  process  water  for  several -industries.
Despite the many types and configurations of membranes, only  the
spiral-wound  cellulose  acetate membrane has had widespread suc-
cess in commercial applications.

24.  Sludge Bed Drying

As a waste treatment procedure, sludge bed drying is employed  to
reduce  the  water  content  of a variety of sludges to the point
where they are amenable to mechanical collection and  removal  to
landfill.   These  beds  usually  consist of 15 to 45 cm (6 to 18
in.) of sand over a 30 cm (12 in.) deep gravel drain system  made
up  of  3  to 6 mm (1/8 to 1/4 in.) graded gravel overlying drain
tiles.   Figure  VII-28   shows  the  construction  of  a  drying
bed.

Drying  ' beds   are   usually   divided   into   sectional  areas
approximately 7.5 meters (25 ft) wide x 30 to 60 meters  (100  to
200  ft) long.  The partitions may be earth embankments, but more
often are made of planks and supporting grooved posts..

To apply liquid sludge to the sand bed, a  closed  conduit  or  a
pressure pipeline with valved outlets at each sand bed section is
often  employed.  Another method of application is by means of an
open channel with appropriately placed side  openings  which  are
controlled  by slide gates.  With either type of delivery system,
a concrete splash slab should be provided to receive the  falling
sludge and prevent erosion of the sand surface.

Where  it  is necessary to dewater sludge continuously throughout
the year regardless of the weather, sludge beds  may  be  covered
with  a  fiberglass  reinforced  plastic  or other roof.  Covered
drying beds permit a greater volume of sludge drying per year  in
most  climates  because  of  the protection afforded from rain or
snow and  because  of  more  efficient  control  of  temperature.
Depending on the climate, a combination of open and enclosed beds
will  provide  maximum  utilization  of  the  sludge  bed  drying
facilities.

Application and Performance.  Sludge drying beds are. a  means  of
dewatering  sludge  from  clarifiers  and  thickeners.   They are
                               1377

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facilities'^
                           municiPal    and   industrial   treatment
 Dewatering  of   sludge   on   sand   beds   occurs  by two mechanism^-
 fiiS?"?" 0?.W^er  thr°Ugh  the bed  and  evaporation  of wa£er  Is  a
 result of radiation  and convection.    Filtration  is  generally
 complete   in    one   to two  days  and may   result  in   solids
 concentrations as  high  as  15   to  20  percent.    The rate of
 filtration depends on the drainability of the sludge.

 The  rate  of  air   drying   of  sludge is related  to temperature,
 relative humidity, and air velocity.  Evaporation  will proceed at
 a constant rate  to a critical moisture content, then at a falling
 rate to an equilibrium moisture content.  The average  evaporation
 rate for a sludge is about 75 percent of that from I  free  water
 Advantages  and Limitations.  The main advantage of sludge dryinq
 beds over other types of sludge dewatering is the relatively  low
 cost of construction, operation, and. maintenance.
 weathr
                   *    x, -    large area of land ^quired and long
                   depend, to  a  great  extent,  on  climate  and
 Operational  Factors.    Reliability:    Reliability  is  high with
 favorable climatic conditions,  proper bed.  design  and  clre  to
 a^d«--eXCe?S1Ve -°r  unec*ual  sludge  application.    if climatic
 conditions in a given  area are not favorable for adequate dryino
 a cover  may be necessary.                                  ux.yj.ug,

 Maintainability:    Maintenance  consists   basically   of  periodic
 re?£VaJ   °? Jthe  dried Slud9e.   Sand removed from the drying bed
 with  the sludge must be replaced and  the  sand layer  resurfaced.

 The resurfacing of sludge  beds  is the   major  expense  item  in
 sludge   bed  maintenance,   but  there are  other  areas which may
 require  attention.   Underdrains  occasionally become   clogged   and
 have  to  be  cleaned.  Valves or sludge gates  that control the  flow
 °Ja,;^dge, to   the  beds  must be  kept watertight.   Provision for
 drainage  of _ lines  in winter should be provided to  prevent  damage
 £u°?  Jrfezin?-    The   partitions  between beds should  be tight so
 that  sludge will not flow  from one compartment to  another.   The
 outer walls  or  banks around the  beds  should  also be  watertight.

 Solid  Waste  Aspects:  The full sludge drying bed must  either be
 abandoned or  the collected  solids  must be  removed  to a   landfill
 These  solids  contain  whatever   metals   or other materials were
«JvJi;  in  the clanfier.  Metals  will be  present as  hydroxides,
oxides,  sulfides,  or  other  salts.  They have the potential for
leaching and contaminating ground water, whatever the location of
the semidried solids.  Thus the abandoned bed or landfill  should
include provision for runoff control and leachate monitoring.
                               1378

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 Demonstration  Status.  "  Sludge  beds   have been in common use in
 both  municipal  and  industrial   facilities  for   many   yea;o.
 However,   protection  of   ground   water from contamination is not
 always adequate.

 25.   Ultrafiltration

 Ultrafiltration  (UF)   is  a   process   which  uses   semipermeable
 polymeric  membranes  to  separate emulsified  or colloidal  materials
 suspended  in  a  liquid phase by pressurizing the  liquid so that it
 permeates   the  membrane.   The membrane of  an ultrafliter forms a
 molecular  screen  which  retains molecular particles  based on their
 differences in  size, shape, and chemical structure.   The membrane
 permits passage of solvents and lower molecular  weight molecules.
 At present, an  ultrafilter  is  capable of removing materials  with
 molecular   weights in the range of  1,000 to 100,000  and  particles
 of comparable or  larger sizes.

 In an  Ultrafiltration  process,   the   feed  solution is  pumped
 through a  tubular  membrane  unit.  Water  and some  low  molecular
 weight materials  pass through   the  membrane  under   the  applied
 pressure of 2 to  8 atm  (10  to  100 psig).  Emulsified oil droplets
 and   suspended  particles are  retained,  concentrated,  and removed
 continuously.   In  contrast   to  ordinary   filtration,   retained
 materials  are  washed off the  membrane  filter rather than held by
 it.    Figure  VII-29  represents  the    ulfcrafiltration   process!
 Figure VI1-34  . shows  a  flow  diagram  for  a   batch  treatment
 Ultrafiltration system.

 Application   and  Performance.   Ultrafiltration  has  potential
 application   to   nonferrous  metals   forming   wastewater    for
 separation  of   oils  and  residual  solids   from  a  variety   of
 waste  streams.  In treating nonferrous metals forming  wastewater,
 its  greatest  applicability would be as a polishing treatment  to
 remove   residual   precipitated   metals      after      chemical
 precipitation   and   clarification. Successful  commercial  use,
 however,   has   been  primarily  for separation   of  emulsified
 oils from wastewater.  Over one hundred such units now operate  in
 the  United States,  treating  emulsified oils  from  a   variety
 of   industrial   processes.   Capacities of currently   operating
 units  range from a few hundred gallons a week to 50,000  gallons
 per  day.    Concentration of oily emulsions to 60 percent oil  or
more   is possible.   Oil concentrates of 40  percent or more  are
 generally  suitable for incineration,  and the permeate  can   be
 treated  further  and in some cases recycled back to the process.
 In  this way,   it is   possible  to  eliminate  contractor removal
 costs for  oil  from some oily waste streams.

The   test  data  in   Table  VII-29    indicate   Ultrafiltration
performance  (note  that  UF  is not intended to remove dissolved
solids). The removal  percentages  shown  are  typical,  but  they
can  be influenced by pH and other conditions.

The  permeate   or   effluent  from   the   Ultrafiltration  unit  is
normally  of  a   quality  that  can  be  reused   in   industrial


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 applications  or  discharged  directly.  The concentrate from the
 ultrafiltration unit can be disposed of  as  any  oily  or  solid
 waste.

 Advantages  and  Limitations.   Ultrafiltration  is  sometimes an
 attractive alternative to chemical  treatment  because  of  lower
 capital  equipment,  installation, and operating costs, very high
 oil  and  suspended   solids   removal,   and   little   required
 pretreatment.    It  places  a positive barrier between pollutants
 and effluent which reduces the possibility of extensive pollutant
 discharge due to operator error or upset in settling and skimming
 systems.  Alkaline values in alkaline cleaning solutions  can 'be
 recovered and reused in process.

 A   limitation   of  ultrafiltration  for  treatment  of  process
 effluents  is   its narrow temperature range  (18  to   30C)    for
 satisfactory  operation.    Membrane  life  decreases  with higher
 temperatures,   but  flux  increases  at  elevated   temperatures.
 Therefore,    surface   area   requirements   are  a  function of
 temperature and  become  a  trade-off  between   initial   costs
 and   replacement   costs  for  the   membrane.     In   addition,
 ultrafiltration  cannot  . handle   certain   solutions.    Strong
 oxidizing   agents,  solvents,  and  other organic compounds  can
 dissolve the  membrane.   Fouling is sometimes a  problem,  although
 the  high  velocity of  the wastewater   normally  creates enough
 turbulence  to  keep fouling at a minimum.    Large solids  particles
 can   sometimes  puncture  the membrane  and  therefore  must  be
 removed  by   gravity   settling  or   filtration  prior   to    the
 ultrafiltration unit.

 Operational , Factors.   Reliability:    The reliability    of  an
 ultrafiltration  system  is   dependent   on the proper  filtration,
 settling or other treatment  of incoming waste streams  to   prevent
 damage   to  the  membrane.   Careful  pilot studies  should be  done in
 each  instance  to determine necessary  pretreatment  steps   and  the
 exact membrane  type to  be  used.

 Maintainability:    A limited   amount   of   regular' maintenance is
 required for the pumping  system.    In addition,    membranes  must
 be  periodically changed.    Maintenance associated with  membrane
 plugging can be reduced by  selection of a membrane with  optimum
 physical   characteristics   and   sufficient  velocity   of   the
 waste   stream.     It    is  occasionally  necessary  to   pass   a
 detergent   solution through the system to remove  an   oil   and

 grease   film which  accumulates  on  the  membrane.   With proper
 maintenance, membrane life can be greater than twelve months.

 Solid  Waste  Aspects:   Ultrafiltration  is  used  primarily  to
 recover  solids  and liquids.  It therefore eliminates solid waste
problems when the solids  (e.g., paint solids)  can be recycled  to
 the  process.   Otherwise,   the  stream containing solids must be
 treated  by  end-of-pipe  equipment.   In   the   most   probable
applications   within   the  nonferrous metals forming  category,
                               1380

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the  ultrafilter would remove hydroxides or sulfides
which have recovery value.
                                      of
metals
Demonstration   Status.   The  ultrafiltration  process  is  well
developed and commercially available for treatment of  wastewater
or  recovery  of  certain  high molecular weight liquid and solid
contaminants.
use.
One  nonferrous metals forming plant reported its
26.  Vacuum Filtration

In wastewater  treatment  plants,  sludge  dewatering  by  vacuum
filtration  generally uses cylindrical drum filters.  These drums
have a filter medium which  may  be  cloth  made  of  natural  or
synthetic  fibers  or  a wire-mesh fabric.  The drum is suspended
above and dips into a vat of sludge.  As the drum rotates slowly,
part of its circumference is subject to an internal  vacuum  that
draws  sludge  to  the filter medium.  Water is drawn through the
porous filter cake to a discharge port, and the dewatered sludge,
loosened by compressed air, is  scraped  from  the  filter  mesh.
Because  the.dewatering of sludge on vacuum filters is relatively
expensive per kilogram of water removed,  the  liquid  sludge  is
frequently  thickened  prior  to  processing.  A vacuum filter is
shown in Figure VII-30.

Application and Performance.  Vacuum filters are frequently  used
both  in  municipal  treatment  plants  and  in a wide variety of
industries.  They are most commonly used  in  larger  facilities,
which  may  have  a  thickener  to  double  the solids.content of
clacifier. sludge before vacuum filtering.

The function of vacuum filtration is to reduce the water  content
of  sludge,  so  that  the  solids content increases from about  5
percent to about 30 percent.

Advantages and Limitations.  Although the initial cost  and  area
requirement of the vacuum filtration system are higher than those
of  a  centrifuge,  the  operating  cost is lower, and no special
provisions for sound and vibration protection need be made.   The
dewatered sludge from this process is in the form of a moist cake
and can be conveniently handled.

Operational  Factors.   Reliability:   Vacuum filter systems have
proven  reliable  at  many  industrial  and  municipal  treatment
facilities.  At present, the largest municipal installation is at
the   West  Southwest  wastewater  treatment  plant  of  Chicago,
Illinois,  where  96  large  filters  were  installed  in   1925,
functioned  approximately  25  years, and then were replaced with
.larger units.  Original vacuum filters at  Minneapolis-St,.  Paul,
Minnesota,  now  have  over  28  years of continuous service, and
Chicago has some units with similar or greater service life.

Maintainability:   Maintenance   consists  of  the   cleaning   or
replacement of the filter media, drainage grids, drainage piping,
filter  pans,  and other parts of the equipment.  Experience  in  a'
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 number  of  vacuum  filter  plants  indicates  that   maintenance
 consumes  approximately  5  to  15 percent of the total time.  If
 carbonate  buildup  or.  other  problems  are  unusually   severe,
 maintenance  time may be as high as 20 percent.  For this reason,
 it is desirable to maintain one or more spare units.

 If intermittent operation is used, the filter equipment should be
 drained and washed each time it is  taken  out  of  service.   An
 allowance for this wash time must be made dn filtering schedules.

 Solid  Waste Aspects:  Vacuum filters generate a solid cake which
 is usually trucked directly  to  landfill.   All  of  the  metals
 extracted  from  the  plant  wastewater  are  concentrated in the
 filter cake as hydroxides,  oxides, sulfides, or other salts.
 Demonstration Status.   Vacuum filtration has been widely used for
                    a fully proven,  conventional  technology  for
                                                     used  in   18
many years.  It is
sludge   dewatering.     Vacuum   filtration   is
nonferrous metals forming plants for sludge dewatering.
 27.   Permanganate Oxidation

 Permanganate oxidation is a chemical reaction by which wastewater
 pollutants can be oxidized.  When  the  reaction  is  carried  to
 completion,   the   byproducts   of   the   oxidation   are   not
 environmentally harmful.   A large number  of  pollutants  can  be
 practically   oxidized   by   permanganate,   including  cyanides,
 hydrogen sulfide, and phenol.   In addition,  the  chemical   oxygen
 demand ^  (COD)   and  many   odors in wastewaters and sludges can be
 significantly reduced by  permanganate oxidation  carried  to  its
 end   point.   Potassium permanganate can  be added to wastewater in
 either dry or  slurry form.   The oxidation occurs optimally in the
 8  to  9 pH range.   As an example  of  the  permanganate  oxidation
 process,   the   following  chemical equation shows the oxidation of
 phenol by potassium  permanganate:

 3  C6H5(OH).   +  28  KMn04  + 5H2 ---- > 18 CO2  +  28KOH  +  28
One of the byproducts of  this  oxidation  is  manganese  dioxide
(Mn02)f   which   occurs   as  a  relatively  stable  hydrous
colloid usually having a negative charge.   These properties,  in
addition to  its  large surface area, enable manganese dioxide to
act  as a sorbent for metal cation,  thus enhancing their removal
from  the wastewater.

Application  and  Performance.   Commercial  use  of permanganate
oxidation has been primarily for the control of phenol and  waste
odors.   Several municipal waste treatment facilities report that
initial hydrogen sulfide  concentrations  (causing  serious  odor
problems)  as high as 100 mg/1 have been reduced to zero  through
the  application  of  potassium  permanganate.   A   variety   of
industries  (including  metal finishers and agricultural chemical
manufacturers)   have  used  permanganate  oxidation  to   totally
                               1382

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destroy phenol in their wastewaters.

Advantages  and  Limitations.  Permanganate oxidation has several
advantages as a wastewater  treatment  technique.   Handling  and
storage  are  facilitated  by  its  non-toxic  and  non-corrosive
nature.  Performance has been proved in a number of municipal and
industrial applications.  The tendency of the  manganese  dioxide
by-product to act as a coagulant aid is a distinct advantage over
other types of.chemical treatment.

The  cost  of  permanganate  oxidation  treatment can be limiting
where very large  dosages  are  required  to  oxidize  wastewater
pollutants.   In  addition,  care  must  be  taken  in storage to
prevent exposure to intense  heat,  acids,  or  reducing  agents;
exposure  could  create  a  fire  hazard or cause explosions.  Of
greatest concern is the environmental hazard  which  the  use  of
manganese chemicals in treatment could cause.  Care must be taken
to remove the manganese from treated water before discharge.

Operational   Factors.    Reliability:  Maintenance'  consists  of
periodic  sludge  removal  and  cleaning  of  pump  feed   lines.
Frequency    of    maintenance   is   dependent   on   .wastewater
characteristics.

Solid Waste Aspects:  Sludge is generated by  the  process  where
the  manganese dioxide byproduct tends to act as a coagulant aid.
The sludge from  permanganate  oxidation  can  be  collected  and
handled  by  standard  sludge treatment and processing equipment.

Demonstration Status.  The oxidation of wastewater pollutants  by
potassium  permanganate  is a proven treatment process in several
types of industries.  It has been shown effective in  treating  .a
wide  variety  of  pollutants  in  both  municipal and industrial
wastes.   No  nonferrqus  metals forming plants are know  to  use
permanganate oxidation for wastewater treatment at this time.

28.  Ammonia Steam Stripping

Ammonia,  often used as a process reagent,  dissolves in water to
an  extent governed by the partial pressure of the gas in contact
with  the  liquid.    The  ammonia may  be  removed  from  process
wastewaters by stripping with air or steam.

Air  stripping takes place in a packed or lattice tower;  air  is
blown through the packed bed or lattice,   over which the ammonia-

laden stream flows.    Usually,   the wastewater is heated prior to
delivery to the  tower, and air  is used at ambient temperature.

The  term  "ammonia  steam stripping" refers to  the  process  of
desorbing  aqueous   ammonia  by  contacting  the  liquid  with  a
sufficient amount of ammonia-free steam.   The steam is introduced
countercurrent  to  the wastewater to maximize removal of ammonia.
The  operation  is   commonly carried out  in packed  bed  or  tray
columns,  and the pH is adjusted to 12 or more with lime.  Simple'
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tray designs  (such as dish and doughnut trays) are used in  steam
stripping because of the presence of appreciable suspended solids
and  the scaling produced by lime.   These allow easy cleaning of
the tower,  at the expense of somewhat lower steam water  contact
efficiency,  necessitating  the  use of more trays for  the  same
removal efficiency.

Application  and Performance.   The evaporation of water and  the
volatilization  of  ammonia  generally produces a  drop  in  both
temperature and pH, which ultimately limit the removal of ammonia
in  a  single air stripping tower.   However,  high removals  are
favored by:

1.    High pH values,  which shift the equilibrium from  ammonium
      toward free ammonia;

2.    High temperature, which decreases the solubility of ammonia
      in aqueous solutions; and

3.    Intimate and extended contact between the wastewater to * be
      stripped and the stripping gas.

Of  these factors,  pH and temperature are generally  more  cost-
effective to optimize than increasing contact time by an increase
in  contact tank volume or recirculation ratio.   The temperature
will,  to some extent,  be controlled by the climatic conditions;
the  pH  of  the wastewater can be  adjusted  to  assure  optimum
stripping.

Steam  stripping  offers  better ammonia removal (99  percent  or
better) than air stripping for high-ammonia wastewaters found  in
the  magnesium  forming,  titanium forming and  zirconium-hafnium
forming  subcategories of this category.   The performance of  an
ammonia  stripping column is influenced by a number of  important
variables  that are associated with the wastewater being  treated
and column design.  Brief discussions of these variables follow.

Wastewater pH:  Ammonia in water exists in two forms, NH3 and
NH4+,  the distribution of which is pH-dependent.   Since
only  the molecular form of ammonia  (NH3) can  be  stripped,
increasing  the fraction of NH3 by increasing the pH enhances
the rate of ammonia desorption.

Column  Temperature:   The  temperature of the  stripping  column
affects the equilibrium between gaseous and dissolved ammonia, as
well  as the equilibrium between the molecular and ionized  forms
of ammonia in water.   An increase in the temperature reduces the
ammonia solubility and increases the fraction of aqueous  ammonia
that  is  in  the molecular form,  both of which  have  favorable
effects on the desorption rate.

Steam rate:   The rate of ammonia transfer from the liquid to gas
phase   is  directly  proportional  to  the  degree  of   ammonia
undersaturation  in the desorbing gas.   Increasing the  rate  of
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steam  supply,  therefore,  increases undersaturation and ammonia
transfer.

Column  design:   A  properly designed stripper  column  achieves
uniform distribution of the feed liquid across the  cross-section
of  the column,  rapid renewal of the liquid-gas  interface,  and
extended liquid-gas contacting area and time.

Chemical  analysis  data were collected for raw waste  (treatment
influent)  and treated waste (treatment effluent) from one  plant
in the iron and steel category.  EPA collected six paired samples
over  a  two-month  period.   These data are the  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  steam  injected
countercurrently to the flow of the wastewater.,    A lime reactor
for pH adjustment separated the two stripping columns.

An  arithmetic  mean of the treatment effluent data  produced  an
ammonia long-term mean value of 32.2 mg/1.   The one-day maximum,
10-day,  and 30-day average concentrations attainable by  ammonia
steam  stripping were calculated using the long-term mean of  the
32.2  mg/1 and the variability factors developed for the combined
metals  data  base.    This produced  ammonia  concentrations  of
133.3,  58.6,  and 52.1 mg/1 ammonia for the one-day maximum, 10-
day and 30-day averages, respectively.

EPA  believes  the  performance  data from  the  iron 'and  steel
category provide a valid measure of this technology's performance
on nonferrous metals forming category wastewater.

The  Agency has verified the proposed steam stripping performance
values  using  steam  stripping data collected  at  a  zirconium-
hafnium  manufacturing plant,  a plant in the  nonferrous  metals
manufacturing  category  which has raw ammonia concentrations  as
high  as  any in the nonferrous metals  forming  category.   Data
collected  by  the  plant represent almost  two  years  of  daily
operations,  and  support  the long-term mean used  to  establish
treatment effectiveness.

Several  comments  were  received regarding  the  application  of
ammonia   steam   stripping  technology  to   nonferrous   metals
manufacturing  wastewaters.   These comments stated that  ammonia
steam  stripping performance data transferred from the  iron  and
steel  category  are  not appropriate for the  nonferrous  metals
manufacturing category.   Many of the commenters believe plugging
of  the  column due to precipitates will adversely  affect  their
ability  to achieve the promulgated steam  stripping  performance
values.   In developing compliance costs, the Agency designed the
steam  stripping  module to allow for a weekly acid  cleaning  to
reduce  plugging problems (see Section VIII,  p.   xxx).    Through
Section 308 information requests,  the Agency attempted to gather
data  at plants which stated they could not achieve the  proposed
limits.   However,  very  little data were submitted  to  support


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 their  claims  or document column  performance.   Therefore,  the
 Agency  has retained the proposed performance based on  the  data
 from the iron and steel category.

 Commenters  on  the limitations and standards for  the  secondary
 aluminum  subcategory  of  the  nonferrbus  metals  manufacturing
 category  contend that stripped ammonia will have to be  disposed
 of as corrosive hazardous waste.   The Agency does not agree with
 the  commenters  because  ammonia has an  Intrinsic  value.   The
 ammonia  can  either  be sold,  given  away,  or  reused  in  the
 manufacturing  process.  Steam stripping can recover  significant'
 quantities   of  reagent  ammonia  from  wastewaters   containing
 extremely  high initial ammonia concentrations,  which  partially
 offsets the capital and energy costs of the technology.

 Advantages  and  Limitations.    Strippers  are  widely  used  in
 industry  to  remove a variety of materials,  including  hydrogen
 sulfide  and volatile organics as well as ammonia,  from  aqueous
 streams.    The basic techniques have been applied both in-process
 and in wastewater treatment applications and are well understood
 The  use  of steam strippers with and without  pH  adjustment  is
 standard practice for the  removal of hydrogen sulfide and ammonia
 in   the  petroleum  refining  industry  and  has  been   studied
 extensively  in  this context.   Air stripping is used  to  treat
 municipal  and  industrial   wastewater and is  recognized  as  an
 effective  technique of broad applicability.   Both  air and steam
 stripping^  have  successfully treated  ammonia-laden  wastewater,
 both within the nonferrous  metals manufacturing  category and  for
 similar wastes in closely related industries.

 The major  drawback  of air stripping  is the low efficiency  in cold
 weather   and  the   possibility  of   freezing  within   the   tower
 Because   lime  may  cause scaling  problems and the  types  of   towers
 used in   air  stripping are not  easily cleaned,   caustic soda is
 generally   employed  to  raise  the  feed  pH.    Air stripping   simply
 transfers  the  ammonia from water  to air,   whereas  steam  stripping
 allows for  recovery  and,  if  so desired,   reuse of ammonia.   The
 two major limitations of steam strippers are the critical  column
 design required for  proper operation and the operational problems
 associated with fouling of the packing material.

 Operational Factors.  Reliability and Maintainability:  Strippers
 are  relatively easy to operate.   The most  complicated part  of a
 steam stripper is the boiler.   Periodic maintenance will prevent
 unexpected shutdowns of the boiler.

 Packing  fouling  interferes  with  the  intimate  contacting  of
 liquid-gas, thus decreasing the column efficiency, and eventually
 leads to flooding.  The stripper column is periodically taken out
 of  service  and cleaned with acid and water with  air  sparging
 Column cutoff is predicated on a maximum allowable pressure  drop
 across the packing of maximum "acceptable" ammonia content in the
 stripper bottoms.  Although packing fouling may not be completely
avoidable due to endothermic CaS04 precipitation,  column runs
could  be  prolonged by a preliminary treatment step designed  to
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remove suspended solids originally present in the feed and  those
precipitated after lime addition.

Demonstration  Status.    Steam  stripping  has proved  to  be  an
efficient,  reliable process for the removal of ammonia from many
types  of industries wastewaters that contain high concentrations
of ammonia.   Industries using ammonia steam stripping technology
include  the  fertilizer,  iron and  steel,  petroleum  refining,
organic   chemicals   manufacturing,    and   nonferrous   metals
manufacturing  industries.   One nonferrous metals forming  plant
reported using this technology.

             IN-PROCESS POLLUTION CONTROL TECHNIQUES

In general, the most  cost-effective • pollution  reduction  tech-
niques   available  to  any  industry  are  those  which  prevent
completely the entry of pollutants  into  process  wastewater  or
reduce  the volume of wastewater requiring treatment.  These "in-
process"  controls  can  increase  treatment   effectiveness   by
reducing     the    volume    of   wastewater    to    treatment,
resulting  in more concentrated waste streams from which they can
be more completely removed, or by  eliminating  pollutants  which
are   not   readily removed   or   which   interfere   with   the
treatment   of  other pollutants.   They also  frequently   yield
economic  benefits  in reduced water consumption, decreased waste
treatment costs and decreased consumption or recovery of  process
materials.

Techniques which may be applied to  reduce  pollutant  discharges
from    most  nonferrous  metals  forming  subcategories  include
wastewater  segregation,  water  recycle  and  reuse,  water  use
reduction,   process   modification,   and plant maintenance  and
good  housekeeping.  Effective   in-process   control   at   most
plants   will   entail  a combination   of   several  techniques.
Frequently,  the  practice of one in-process control technique is
required for  the  successful implementation  of   another.   For
example,  wastewater  segregation is frequently  a   prerequisite
for  the  extensive  practice  of wastewater recycle or reuse. ,

Wastewater Segregation

The  segregation  of  wastewater  streams is  a  key  element  in
implementing  pollution control in the nonferrous metals  forming
category.   Separation  of  noncontact    cooling    water   from
process   wastewater  prevents dilution of the process wastes and
maintains the character of the non-contact stream for  subsequent
reuse  or discharge.   Similarly,  the  segregation  of   process
wastewater     streams    differing  significantly    in    their
chemical   characteristics   can  reduce  treatment   costs   and
increase  effectiveness.

Mixing process wastewater with noncontact cooling water increases
the total volume of process  \vascewater.   This  has  an  adverse
effect  on  both  treatment  performance and cost.  The increased
volume of wastewater increases the  size  and  cost  of treatment


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 facilities.    Since  a given treatment technology has a  specific
 treatment  effectiveness and can only achieve  certain  discharge
 concentrations of pollutants,  the total mass of pollutants which
 is  discharged  increased  with  dilution.   Thus  a  plant  which
 segregates noncontact cooling water and  pther nonprocess  waters
 from   process   wastewater  will almost always achieve  a  lower
 mass   discharge  of  pollutants•  while   substantially  reducing
 treatment costs.

 Nonferrous  metals  forming  plants   commonly  produce  multiple
 process  and  nonprocess  wastewater   streams.    The  identified
 nonprocess  streams include wastewater streams that are  reusable
 after  minimal  treatment and other streams that are not  reusable.
 Reusable  waters are most often noncontact  cooling waters.    This
 water  is uncontaminated and can be recycled in a closed  indirect
 cooling configuration as well as use as makeup for process  water.
 Noncontact cooling water is commonly recycled for reuse.

 The  segregation of dilute process waste streams from those bear-
 ing  high pollutant loads may allow further  use of   the  dilute
 streams.   Sometimes  the lightly polluted  stream may be  recycled
 to  the  process  from  which  they  were  discharged,   such as
 annealing.   Other wastewater  streams  may  be   suitable for use
 in another process with only minimal treatment.

 Segregation    of wastewater streams may allow separate treatment
 of  the   wastewater   stream  which  often  costs  less.     For
 example,   wastewater  streams containing high levels  of suspended
 solids   may  be   treated  in    separate   inexpensive   settling
 systems   rather   than  a  more  expensive   lime   and    settle
 treatment system.    Often  the   clarified  wastewater  is  suitable
 for  further   process   use and both  pollutant   loads   and   the
 wastewater volume requiring further treatment  are  reduced.

 Segregation and  separate treatment  of  selected wastewater streams
 may  yield an additional economic benefit  to the  plant  by  allowing
 increased recovery of  process  materials.    The   solids  borne  by
 wastewater  from  a specific   process   operation   are  primarily
 composed  of   materials  used    in    that   operation.    Sludges
 resulting  from  separate   settling   of  these   streams  may  be
 reclaimed for  use  in the process with  little or  no  processing  or
 recovered for reprocessing.

 Wastewater  Recycle  and Reuse

 The  recycle   or   reuse  of  process  wastewater is  a  particularly
 effective  technique   for   the  re-duction  of  both   pollutant
 discharges and treatment  costs.  The term "recycle"  is  used  to
 designate the   return   of  process wastewater,   usually   after
 some    treatment,    to   the  process  or processes  from which  it
 originated, while  "reuse" refers  to  the use  of wastewater from
 one  process   in   another.   Both recycle and  reuse  of  process
 wastewater   are   presently   practiced   at   nonferrous  metals
 forming plants,    although  recycle  is more extensively used.  The
most frequently  recycled waste streams include wet air  pollution


           *                   1388

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control  wastewater discharges,"-   casting contact cooling  water,
annealing  and  heat treatment contact cooling water and  rolling
emulsions.  Numerous  other  process  wastewater   streams-   from
nonferrous  metals  forming  processes may also  be  recycled  or
reused.  Both  recycle and reuse are frequently possible  without
extensive  treatment   of  the   wastewater;  process  pollutants
present  in  the  waste  stream   are   often    tolerable    (or
occasionally    even  beneficial) for process  use.   Recycle  or
reuse  in  these instances yields   cost  savings   by   reducing
the  volume  of  wastewater requiring treatment.  Where treatment
is   required   for  recycle   or  reuse,    it   is   frequently
considerably  simpler  than the treatment  necessary  to  achieve
effluent   quality  suitable  for  release  to  the  environment.
Treatment  prior  to  recycle  or  reuse   observed   in  present
practice    is   generally  restricted  to  simple  settling   or
neutralization.  Since these treatment practices are less  costly
than   those  used  prior  to  discharge,  economic  as  well  as
environmental benefits are  usually  realized.   In  addition ' to
these   in-process  recycle  and  reuse  practices,  some  plants
return part or all of the treated  effluent  from  an end-of-pipe
treatment system for further process use.

Recycle can usually be implemented with minimal expense and comp-
lications because the required treatment is often minimal and the
water for recycle is immediately available.   As an example,  hot
rolling   contact  cooling  water  can  be * collected   in    the
immediate   area  of  the rolling mill cooled in a cooling tower,
and recycled for use in the rolling process.   A flow diagram for
recycling  direct  chill casting water with a  cooling  tower  is
shown in -Figure VII-36.

The rate of water used in wet air scrubbers is determined by  the
requirement  for adequate contact with the air being scrubbed and
not by the mass of  pollutants  to  be  removed.   As 'a  result,
wastewater  streams  from  once-through  scrubbers are character-
istically very dilute and high  in  volume.   These  streams  can
usually   be  recycled  extensively  without  treatment  with  no
deleterious effect on scrubber  performance.   Limited  treatment
such as neutralization where acid fumes are scrubbed can signifi-
cantly increase the practical recycle rate.

Water  used  in  washing  process  equipment and production floor
areas frequently serves primarily to remove solid  materials  and
is  often  treated  by  settling  and recycled.  This practice is
especially  prevalent in the precious metals subcategory but   is
observed  in   other   subcategories  as  well.   The  extent  of
recycle  of  these waste streams may be  very high,  and in  many
cases no wastewater is discharged from the recycle loop.

Water  used in surface treatment rinsing is also recirculated  in
some   cases.   This  practice  is  ultimately  limited  by   the
concentrations  of  materials  rinsed off   the  product  in  the
rinsewater.   Wastewater from contact cooling operations also may
contain  low concentrations of pollutants which do not  interfere.
with  the recycle of these streams.   In some cases,  recycle  of
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 contact   cooling  water  with  no   treatment   is   observed  while   in
 others,   provisions  for heat removal  in  cooling towers or   closed
 heat  exchangers is required.  Where contact cooling  water  becomes
 heavily    contaminated   with   acid,     neutralization   may    be
 required to minimize corrosion.

 Water   used  in  vacuum pump  seals  and steam  ejectors  commonly
 becomes   contaminated  with  process pollutants.    The  levels   of
 contaminants  in  these  waste streams  are sometimes  low   enough
 to allow  recycle   to   the   process  with  minimal treatment.   A
 high  degree of recycle  of wastewater  from contact  cooling  streams
 may require provisions  for neutralization or removal of  heat.

 The   extent  of   recycle possible  in most process  water  uses  is
 ultimately limited   by   increasing  concentrations  of   dissolved
 solids   in  the   water.  The  buildup  of  dissolved  salts  generally
 necessitates some small discharge or  "blowdown"  from the  process
 to treatment.    In   those   cases,  where the rate of addition  of
 dissolved salts is balanced  by  removal   of  dissolved  solids   in
 water entrained  in settled  solids,   complete   recycle  with  no
 discharge can be  achieved.   In  other  instances,  the  contaminants
 which build up in the recycle loop may be compatible with  another
 process   operation,   and ' the  "blowdown"   may  be  used in  another
 process.    An example  of this  is the reuse of  alkaline  cleaning
 rinsewater   as make-up  to an  acid fume wet  air  pollution  control
 recirculating system.    The  rinsewater provides alkaline  species
 to neutralize the acid  fumes.

 Water  Use   Reduction

 The   volume   of   wastewater discharge from  a  plant  or  specific
 process   operation   may   be   reduced   by   simply eliminating
 excess _  flow  and  unnecessary water use.    Often  this  may   be
 accomplished with   no  change in the  manufacturing   process   or
 equipment   and without any capital expenditure.    A  comparison  of
 the   volumes  of process  water  used  in  and   discharged   from
 equivalent    process  operations  at  different  plants   or    on
 different    days   at  the  same  plant    indicates  substantial
 opportunities   for water use reductions.   Additional reductions
 in   process  water  use  and  discharge  may  be  achieved     by
modifications to process techniques and equipment.

Many   production   units  in  nonferrous metals  forming  plants
were  observed to operate intermittently or  at   highly   variable
production   rates.    The practice of  shutting  off  process  water
 flow  during  periods  when the unit is not   operating   and   of
adjusting  flow   rates  during  periods  of  low production  can
prevent  much unnecessary water use.    Water may be   shut   off
and   controlled manually  or  through  automatically  controlled
valves.    Manual  adjustments have  been  found   to  be  somewhat
unreliable in practice;   production personnel often fail  to  turn
off manual valves  when production units are  shut down and tend to
increase  water  flow rates to maximum - levels   "to  insure  good
operation"  regardless  of  production activity. Automatic shut-
off  valves   may   be  used  to  turn   off    water    flows   when
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production  units  are  inactive.   Automatic  adjustment of flow
rates according to production levels requires more  sophisticated
control systems incorporating, production, rate . sensors .

Observations  and flow measurements at visited nonferrous  metals
forming  plants   indicate  that  automatic  flow   controls  are
rarely  employed.   Manual  control  of  process  water  use   is
generally observed in process rinse operations,  and little or no
adjustment  of  these  flows  to production level  is  practiced.
The  present situation is exemplified by a rinse operation at one
plant  where the  daily  average production normalized  discharge
flow  rate  was observed to vary from 287 to 1230 1/kkg  over   a
three-day  span.  Thus,   significant  reductions  in   pollutant
discharges  can be achieved by the application of flow control in
this   category  at essentially  no  cost.    (A  net savings may
be  realized  from  the  reduced  cost  of   water   and   sewage
charges.)    Additional  .flow reductions   may  be  achieved   by
the  implementation  of  more effective water use in some process
operations.

Rinsing is a common operation in nonferrous metals forming plants
and  a  major  source of wastewater  discharge  at  most  plants.
Efficient rinsing requires the removal of the  greatest  possible
mass   of  material   in   the  smallest   possible   volume   of
water.    It is achieved by ensuring that the  material   removed
is  distributed uniformly through the rinse water.

Rinsing  efficiency  is  also increased by the use of multi-stage
and  countercurrent  cascade rinses (see figures VII-37 and  VII-
38). Multi-stage rinses reduce the total rinse water requirements
by  allowing  the removal of much of the contaminant  in  a  more
concentrated rinse with only the  final stage  rinse  diluted  to
the   levels  required  for final product  cleanliness..    In   a
countercurrent   cascade   rinse,    dilute wastewater from  each
rinse  stage is reused in the preceding rinse stage  and  all  of
the  contaminants are discharged in a single concentrated   waste
stream.       The     technical    aspects     of   countercurrent
cascade  rinsing  are  detailed  later  in  this section.

Equipment  and  area cleanup practices observed   at   nonferrous
metals  forming  plants   vary   widely.     While   some   plants
employ  completely  dry cleanup  techniques,   many   others   use
water   with varying  degrees  of  efficiency.    The practice of
"hosing down" equipment and production areas  generally represents
a  very  in-efficient  use  of  water,   especially when hoses are
left   running   during  periods  when  they    are   not    used.
Alternative   techniques  which   use   water   more  efficiently
include  vacuum pick-up floor wash machines and bucket and sponge
or bucket and mop  techniques as observed at  some plants.

Additional   reduction   in  process  water and  wastewater  dis-
charge may be achieved by the substitution of dry  air  pollution
control  devices  such  as  baghouses for wet scrubbers where the
emissions requiring control are amenable to these techniques.
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 Countercurrent Cascade Rinsing and Multistage Rinsing

 Of the many schemes discussed above for reduction of water use in
 nonferrous   metals  forming  plant,    countercurrent    cascade
 rinsing    is  most   likely   to   result   in   the    greatest
 reduction  of  water consumption and use.

 Countercurrent cascade rinses are already employed in some plants
 in   the  nonferrous metals forming category.    in  most  cases,
 however,  these  techniques are not combined with effective  flow
 control,  and   the  wastewater  discharge   volumes   from   the
 countercurrent  cascade  rinses  are as large as or  larger  than
 corresponding single  stage rinse  flows  at other plants.

 Rinse water  requirements  and  the  benefits  of  countercurrent
 cascade  rinsing  may  be  influenced  by  the volume of drag-out
 solution carried into  each  rinse  stage  by  the  electrode  or
 material being rinsed,  by the number of rinse stages used, by the
 initial  concentrations  of  impurities being removed,  and by the
 final product  cleanliness  required.    The  influence   of  these
 factors  is expressed in the rinsing equation which may be stated
 simply as:                .                        .

                 Vr = Co (1/n)  x VD

                      Cf

 Vr   is the flow through each  rinse  stage.

 Co   is  the  concentration of  the  contaminant(s)  in   the   initial
      process, bath

 Cf   is the concentration of the contaminant(s)  in
      the final  rinse to  give acceptable product   cleanliness
 n
 VD
is the number of rinse stages employed,
and

is the flow of drag-out carried into each  rinse stage
For a multistage rinse, the total volume of rinse  wastewater   is
equal  to  n times Vr while for a countercurrent rinse, Vr is the
total volume of wastewater discharge.

For a multistage rinse,  the total volume of rinsewater is  equal
to  n times Vr while for a countercurrent rinse the total  volume
of water equals Vr.   As an example,  the flow reduction achieved
for pickling a nickel sheet can be estimated through the use of a
two-stage  countercurrent  cascade  rinse following  the  surface
treatment bath.   The mass of nickel in one square meter of sheet
that  is 6 mm (0.006 m) in thickness can be calculated using  the
density of nickel,  8.90 kkg/m-* (556 Ibs/cu ft), as follows;

= (0.006 m) x (8.90 kkg/m3) = 0.053 kkg/m2 of sheet.
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Using  the  mean surface treatment rinsewater discharge,  Vr  can
then be calculated as follows:

Vr ='(0.053 kkg  x 10,600  1  = 561.8 1/m2 of sheet
              m^         kkg

Drag-out  is solution which remains on the surface  of  materials
being  rinsed  when it is removed from process baths  or  rinses.
Without  specific plant data available to determine drag-out,  an
estimate  of rinsewater reduction to be achieved  with  two-stage
countercurrent rinsing can be made by assuming a thickness of any
process  solution  film as it is introduced into the rinse  tank.
If  the  film on a piece of nickel sheet is 0.015  mm   (0.6  mil)
thick,  (equivalent  to  the  film  on  a  well-drained  vertical
surface)  then the volume of process solution,  VD,  carried into
the rinse tank on two sides of a one square metter of sheet  will
be:

VD =  (0.015 mm) x ( 1 ra/mm)  x (1000 1/m3) x 2
                   1000

   = 0.030 1/m2 of sheet

 Let r   = Co, then r = 1/n - Vr.
          Cf~              VD

 For  single-stage  rinsing, n  =  1,  therefore,  r = Vr
                                                VD

 and  r  =  561.8   =  18,727

         0.030

 For  a 2-stage  countercurrent  cascade  rinse  to  obtain the  same r,
 that is  the  same  product  cleanliness,

     Vr = r  1/2' therefore Vr  = 18,727  1/2  =  136.8
     VD~                   VD

 But  VD  =  0.030  1/m2  of  sheet;   therefore,   for  2-stage
 countercurrent cascade' rinsing,  Vr is:

 Vr = 136.8 x 0.030 - 4.10 1/m2 of sheet

 In this theoretical calculation, a flow reduction of greater than
 99  percent  can  be  achieved.    The  actual  numbers  may  vary
 depending on efficiency of squeegees or air knives, and the rinse
 ratio desired.
                                1393

-------
Significant  flow  reductions  can be achieved by  the  addition  of
only  one  other   stage  in  the  rinsing  operation,  as  discussed
above.   The largest  reductions are made by adding the  first  few
stages.   Additional   rinsing stages cost additional money.   The
actual number of stages  added depends on site-specific  layout and
operating  conditions.   With  higher costs for  water   and  waste
treatment,  more stages  might be economical.  With very low water
costs, fewer stages would be  economical.  In considering retrofit
applications,  the space available for additional tanks is  also
important.   After considering all of these points,  the  Agency
believes that countercurrent  cascade rinsing is  an effective  and
economical  means  of  reducing  wastewater flow   and  consequently
pollutant discharge.

If  the  flow  from stage to  stage can be  effected  by gravity,
either-  by raising the latter rinse stage tanks  or by varying the
height of the overflow weirs,   countercurrent cascade rinsing  is
usually quite economical.   If,  on the other hand, pumps and level
controls must be used, then other methods, such  as spray rinsing,
may be more feasible.

Another factor is  the need  for  agitation, which  will reduce short
circuiting  of the flow. '   Large amounts of short circuiting  can
reduce  the  flow  reduction attained by adding more  stages.   In
cases  where  water is cascading in enormous  quantities  over  a
workpiece,  the high flow usually provides enough agitation.   As
more staging is applied  to  reduce the amount of  water,  the point
will  be  reached  where  the flow of the  water  itself  is  not
sufficient  to  provide  agitation.    This  necessitates  either
careful baffling of the  tanks or additional mechanical  agitation.

Countercurrent  cascade  rinsing has been widely used as  a  flow
reduction technique in the  metal finishing industry.   In aluminum
conversion  coating  lines.that are subject to the  coil  coating
limitations,  countercurrent  cascade rinsing is  currently used in
order  to  reduce  costs  of  wastewater  treatment  systems  (by
allowing  use  of  smaller  systems) for  direct  dischargers  and
additionally  to   reduce sewer  charges for  indirect  dischargers
since those costs  are based on  flow.

Countercurrent  cascade  rinsing  is currently  practiced  at  12
nonferrous metals  forming plants.

      Rinsing

Spray  rinsing is another method used to dilute the concentration
of  contaminants  adhering  to the surface of  a  workpiece.    The
basis of this approach is to spray water onto the surface of  the
workpiece as opposed to submerging it into a tank.  The amount of
water contacting the workpiece,  and therefore the amount of  water
discharged,   is  minimized  as  a  result.    The  water  use  and
discharge  rates can be further  reduced through recirculation  of
the rinse water.
                               1394

-------
 The  equipment  required  for  spray rinsing  includes  piping,   spray
 nozzles,   a   pump,   a  holding  tank and  a collection  basin.    The
 holding  tank  may  serve as  the  collection basin to  collect  the
 rinse  water  prior to   recirculation  as  a   method  of   space
 economization.    Spray  rinsing  is demonstrated in  plants in  the
 nonferrous metals forming category.

 Regeneration  of Chemical Baths

 Regeneration  of chemical baths is used  to  remove contaminants  and
 recover  and  reuse the  bath   chemicals,   thus minimizing  the
 chemical  requirements  of the bath while achieving zero  discharge.

 Chemical   bath   regeneration is  applicable to  recover .  and   reuse
 chemicals   associated  with  caustic   surface   treatment baths,
 sulfuric   acid   surface  treatment  baths,   chromic  acid  surface
 treatment  baths,  and  alkaline cleaning baths.

 Some  metal   salts  can be precipitated out  of chemical  baths   by
 applying   a   temperature change  or  shift to the  bath.   Once  the
 metal   salts  are   precipitated  out  of  solution,  the   chemical
 properties and  utility of  the bath  can then be  restored by adding
 fresh chemicals.    The addition  of  lime may aid  in  precipitating
 dissolved metals  by forming carbonates or  hydroxides.

 Ultrafiltration,  previously  discussed in 'this  section,  can   be
 used  to   remove  oils and particulates  from  alkaline   cleaning
 baths,  allowing the  recovery of  the water and alkali  values  to  be
 a   reused  in the make-up of fresh bath rather than treating and
 discharging them..

 Ultrafiltration membranes allow  only low molecular weight solutes
 and  water to pass  through and return to the  bath;   particulates
 and oils are held back in a concentrated phase.  The  concentrated
 material is then disposed of separately as  a solid waste.

 The  advantages  of bath regeneration are:    (1) it   reduces  the
 volume of discharge of the chemical bath water;   (2)  the  surface
 treatment operations are made more efficient because  the bath can
 be  kept  at a relatively constant strength;  (3) it  results   in
 reduced  maintenance labor associated with  the bath;  and (4)   it
 reduces  chemical  costs by recovering chemicals  and  increasing
 bath life.

 Chemical  bath  regeneration results in lower  maintenance   labor
 because  the bath life  is extended.   Regeneration also increases
 the process reliability in that it eliminates extended periods of
 downtime to dump the entire bath  solution.

 It may be necessary  to  allow baths normally operated at  elevated
 temperatures to  cool prior to regeneration.   As an example,   hot
 detergent   baths will  require   cooling   prior  to  introducing
material into the ultrafiltration membrane.
                               1395

-------
Regeneration of caustic,  detergent,  chromic acid,  and sulfuric
acid  baths  results in the  formation  of  precipitates.   These
precipitates  are collected,  dewatered,  if necessary,  and then
disposed  of  as solid wastes.   The  metal  sulfate  precipitate
resulting   from   sulfuric  acid  baths  .may   be   commercially
marketable.   The  solid  waste aspects of  wastewater  treatment
sludges  similar to regeneration sludges are discussed in  detail
in Section VIII.

There  are commercial processes available for regenerating  baths
which  are patented or claimed confidential.   In general,  these
regeneration  processes  are based on  the  fundamental  concepts
described above.

As discussed previously in this section,  ultrafiltration is well
developed   and  commercially  available  for  recovery  of  high
molecular  weight  liquids and solid contaminants.   EPA  is  not
aware  of any nonferrous metals forming plants that have  applied
ultrafiltration  for the purpose of regenerating bath  materials.
There  are two aluminum forming plants and one nonferrous  metals
forming  plant using ultrafiltration to recover  spent  lubricant
Since alkaline cleaning baths are used to remove these lubricants
from  the  metalsurface  prior  to  further  processing,   it  is
reasonable  to assume that ultrafiltration is equally  applicable
for separating these same lubricants from alkaline cleaning baths
used in nonferrous metals forming plants.

Regeneration  may  be applicable in specific applications in  the
nonferrous  metals forming category although at present  it  does
not appear to be applicable on a nationwide basis.

Contract Hauling

Contract  hauling refers to. the industry practice of  contracting
with  a  firm  to  collect  and  transport  wastes  for  off-site
disposal.   This  practice  is  particularly applicable  to  low-
volume, high concentration waste streams.  Examples of such waste
streams  in the nonferrous metals forming industry  are  pickling
baths, drawing lubricants, and cold rolling lubricants.

The  dcp data identified several waste solvent haulers,  most  of
whom  haul  solvent  in  addition to their  primary  business  of
hauling  waste  oils.    The value of waste solvents seems  to  be
sufficient  to  make  waste solvent hauling  a  viable  business.
Telephone  interviews conducted during the development  of  metal
finishing regulations indicate that the number of solvent haulers
is  increasing  and  that  their  operations  are  becoming  more
sophisticated  because  of the increased value of waste  solvent.
In addition, a number of chemical suppliers include waste hauling
costs  in their new solvent price.    Some of the  larger  solvent
refiners  make  credit  arrangements with  their  clientele;   for
example,  it was reported that one supplier returns 50 gallons of
refined solvent for every 100 gallons hauled.
                               1396

-------
Lubricating Oil and Deoiling Solvent Recovery

The  recycle  of  lubricating oils is a common  practice  in  the
industry.   The  degree of recycle is dependent upon any  in-line
treatment  (e.g.,  filtration  to  remove metal fines  and  other
contaminants),  and  the useful life of the specific oil  in  its
application.   Usually, this involves continuous recirculation of
the  oil,  with losses in the recycle loop from evaporation,  oil
carried off by the metal product, g and minor losses from  in-line
treatment.   Some plants periodically replace the entire batch of
oil once its required properties are depleted.  In other cases, a
continuous  bleed or blowdown stream of oil is withdrawn from the
recycle loop to maintain a constant level of oil quality.   Fresh
make-up  oil  is added to compensate for the blowdown -and  other
losses, and in-line filtration is used between cycles.

Reuse of oil from spent emulsions used in rolling and drawing  is
practiced at some plants.   The free oil skimmed from gravity oil
and water separation,  following emulsion breaking,  is valuable.
This  free  oil  contains  some solids and water  which  must  be
removed before the oil can be reused.   The traditional treatment
involves acidifying the oil in a heated cooker, using steam coils
or live steam to heat the oil to a rolling boil.  When the oil is
sufficiently heated,  the steam is shut off and the oil and water
are permitted to separate.   The collected floating oil layer  is
suitable  for  use as supplemental boiler fuel or for some  other
type of in-house reuse.   Other plants choose to sell their  oily
wastes  to  oil  scavengers,   rather  than   reclaiming  the  oil
themselves. •  The  water phase from this operation is either sent
to treatment or,  if of a high enough quality, it can be recycled
and used to make up fresh emulsion.

Some   plants  collected  and  recycle  rolling  oils  via   mist
eliminators.   In the  rolling process, pils are sprayed as a fine
mist  on the  rollers for cooling and  lubricating  purposes,  and
some  of  this oil becomes airborne and may be lost  via  exhaust
fans  or volatilization.   With  the rising price of oils,   it  is
becoming a more  common practice  to prevent these losses.  Another
reason   for using hood and mist  eliminators is the improvement in
the working environment.

Using organic  solvents to deoil  or degrease nonferrous metals  is
usually  performed prior  to  sale or subsequent operations such as
coating.    Recycling  the   spent   solvent  can  be   conomically
attractive  along with its  environmental  advantages.   No   plants
are   known  to use distillation units  to  reclaim  spent solvent  for
recycling   in  this  category.   Most  plants  in   this   category
contract   haul  spent solvents or  sell  them to a   reclaimer.   No
nonferrous    metals  forming plants   currently  discharge   spent
solvents   as  a direct  discharge.    There  are  several  plants  that
discharge  spent  solvents  to a POTW;  however,  this  practice  is  not
widespread and  is  subject to  strict  controls by   the   POTW  for
 those  that  do  discharge.   The   Agency is   establishing   a  no
discharge requirement  for this  waste  stream.    This  is   discussed
more  fully in Sections IX through XIII.


                                1397

-------
 Dry Air Pollution Control Devices

 The   use  of  dry  air  pollution  control  devices  allows  the
 elimination of waste streams with high pollution potential,  i.e.,
 wastestreams  from wet air pollution control  devices.    However,
 the choice of air pollution control  equipment is complicated,  and
 sometimes  a wet system is the  necessary choice.   The   important
 difference  between  wet  and dry devices 'is  that  wet  devices
 control gaseous pollutants as well as particulates.

 Wet  devices  may  be  chosen over dry devices when  any  of  the
 following   factors  are  found:     (1)   the  particle   size   is
 predominantly under 20 microns,   (2)  flammable particles or  gases
 are to be treated and there is  minimal combustion risk,   (3) both
 vapors-  and particles are to be removed  from the  carrier medium
 and  (4)  the gases are corrosive  and may damage dry air  pollution
 control devices.

 Equipment for dry control of air  emissions  includes cyclones,  dry
 electrostatic precipitators,  fabric  filters,   and  afterburners.
 These   devices  remove  particulate  matter,   the first   three   by
 entrapment and the afterburners by combustion.

 Afterburner use  is limited to air  emissions  consisting mostly   of
 combustible particles.    Characteristics  of  the particulate-laden
 gas  which affect the design  and use  of  a device are gas density,
 temperature,   viscosity,   flammability,   cbrrosiveness,  toxicity,
 humidity,   and  dew  point.   Particulate characteristics  which
 affect  the design and use of  a device  are particle   size,  shape,
 density,   resistivity,   concentration,   and   other  physiochemical
 properties.

 Scrubbers   must  be  used  in  forging because of  the potential  fire
 hazard  of   baghouses  used  in  this   capacity.   The  oily  mist
 generated  in-this  operation  is highly  flammable  and  also tends  to
 plug and bind  fabric  filters, reducing their efficiency.

 Caustic  surface  treatment wet air pollution control  is  necessary
 due to  the  corrosive  nature of the gases.

 Proper  application  of   a  dry  control  device  can  result   in
 particulate  removal  efficiencies  greater than  99  percent   by
 weight  for  fabric  filters,  electrostatic  precipitators,  and
 afterburners, and up  to 95 percent for cyclones.

 Common  wet air pollution control devices are  wet  electrostatic
 precipitators,  venturi   scrubbers,  and packed tower  scrubbers.
 Collection  efficiency for gases will depend on the solubility of
 the  contaminant  in  the scrubbing  liquid.   Depending  on  the
 contaminant removed,  collection efficiencies usually approach 99
percent for particles and gases.

 Some nonferrous metals forming plants industry report the use  of
dry air pollution controls for forging.


                               1398

-------
Good Housekeeping

Good  housekeeping and proper equipment maintenance are necessary
factors  in  reducing  wastewater  loads  to  treatment  systems.
Control  of accidental spills of  oils,  process  chemicals,  and
wastewater  from washdown and filter cleaning or removal can  aid
in  maintaining  the segregation of wastewater  streams.   Curbed
areas should be used to contain ot control these wastes.

Leaks in pump casings,  process piping, etc., should be minimized
to maintain efficient water use.   One particular type of leakage
which may cause a water pollution problem is the contamination of
noncontact  cooling water by hydraulic oils,  especially if  this
type of water, is discharged without treatment.

Good housekeeping is also important in chemical, solvent, and oil
storage  areas  to  preclude a  catastrophic  failure  situation.
Storage areas should be isolated from high fire-hazard areas  and
arranged  so  that  if  a fire  or  explosion  occurs,  treatment
facilities  will  not be overwhelmed  nor  excessive  groundwater
pollution  caused  by  large quantities of  chemical-laden  fire-
protection water.

Bath or rinse waters that drip off the metal product while it  is
being  transferred  from one tank to another (dragout) should  be
collected and returned to their originating tanks.   This can  be
done with simple drain boards.

A conscientiously applied program of water use reduction can be a
very effective method of curtailing unnecessary wastewater flows.
Judicious  use  of  washdown water and  avoidance  of  unattended
running hoses can significantly reduce water use.
                               1399

-------
                            TABLE VII-1
               pH  CONTROL  EFFECT ON  METALS  REMOVAL
               Day  1
           In	     Out
                         Day 2
                    In	     Out
                                   Day 3
                              In        Out
pH Range  2.4-3.4    8.5-8.7    1.0-3.0'  -5.0-^6.0  "2.0-5.0    6.5-8.1

(mg/1)
TSS
Copper
Zinc
 39
 312
 250
 8
0.22
0.31
 16        19
 120      5.12
  32.5   25.0
           16
           107
            43.8
           7
          0.66
          0.66
                           TABLE VI1-2

      EFFECTIVENESS OF SODIUM HYDROXIDE  FOR  METALS REMOVAL
          In
               Day  1
          Out
          In
                         Day 2
          Out
          In
                                   Day 3
Cr
Cu
Fe

Pb
Mn
Ni

Zn
TSS
0.097
0.063
9.24

1 .0
0.11
0.077

.054
0.0
0.018
0.76

0.11
0.06
0.011
0.0
0.057
0.078
15.5

1 .36
0. 12
0.036
0.12
0.005
0.014
0. 92

0.13
0.044
0.009
0.0
0.068
0.053
9. 41

1 .45
0.1 1
0.069
0.19
          Out
pH Range  2.1-2.9   9.0-9.3    2.0-2.4    8.7-9.V-   2.0-2.4    8.6-9.1
(mg/1)                                    ~   •-••:-
0.005
0.019
0.95

0.11
0.044
0.011
0.037
         13
                   11
                             11
                               1400

-------
                         TABLE VII-5

                 SAMPLING DATA FROM SULFIDE
            PRECIPITATION-SEDIMENTATION SYSTEMS
Treatment
Lime, FeS, Poly-
electrolyte,
Settle, Filter
Lime, FeS, Poly-
electrolyte,
Settle, Filter
NaOH, Ferric
Chloride, Na2S
Clarify (1 stage)
pH
(mg/1
Cr+6
Cr
Cu
Fe
Ni
Zn
These
In

5 . 0-6 .
25.
32.
0.
39.
6
3
52
5
Out
8 8-9
<0.014
<0. 04
0.10
<0.07
data were obtained from
Summary Report,
Control
Metal Finishing Industry
In
7
0
2
108
0
33
three
.7
.022
.4
,68
.9

<0
<0
0
<0
0
Out
7.38
.020
.1
.6
.1
.01
In

1 1
18
0
0


.45
.35
.029
.060
Out

<,005
<.005
0.003
0.009
sources:
and Treatment
: Sulf
ide
Technology
Precipi tat ion ,
for
USEPA,
the
EPA
     No. 625/8/80-003, 1979,

     Industrial Finishing, Vol. 35, No.  11, November,  1979.

     Electroplating sampling data from plant 27045.
                               1402

-------
                            TABLE VI1-3
  EFFECTIVENESS  OF LIME AND SODIUM HYDROXIDE FOR METALS REMOVAL
                Day  1
                         Day 2
                                   Day  3

pH Range
(mg/1 /
Al
Co
Cu
Fe
Mn
Ni
Se .
Ti
Zn
In
9.2-9.6

37.3
3.92
0.65
137
175
6.86
28.6
143
18.5
Out
8.

0.
0.
0.
0.
0.
0.
*0.
0.
0.
3-9.8

35
0
003
49
12
0
0
0
027
In
9.2

38. 1
4.65
0.63
1 10
205
5.84
30.2
125
16.2
Out
7.

'o.
0.
0.
0.
0.
0.
0.
0.
0.
6-8. 1

35
0
003
57
012
0
0
0
044
In
9.6

29. 9
4 . 37
0.72
208
245
5.63
27.4
1 15
17.0
Out
7.

0.
0.
0.
.' 0.
0.
0.
0.
0.
0.
8-8. 2

35
0
003
58
12
0
0
0
01
TSS
4390
          3595
13
                                                   2805
                                                  13
Metal
                           TABLE VII-4

       THEORETICAL SOLUBILITIES OF  HYDROXIDES AND, SULFIDES
                OF SELECTED METALS  IN PURE WATER
Cadmium (Cd++)
Chromium
Cobalt
Copper (Cu •*"*•)
Iron (Fe-*-*-)
Lead (Pb-*-*-)

Manganese (Mn++)
Mercury (Hg++)
Nickel (Ni++)

Silver (Ag+)
Tin (Sn++)
Zinc (Zn++)
As Hydroxide

   2.3 x 10-s
   8.4 x 10-*
   2.2 x 10-»

   2.2 x TO-2
   8.9 x 10-*
   2.1

   1 .2
   3.9 x 10-«
   6.9 x 10-3

  13.3
   1.1 x 10~4
   1 .1
                                   Solubility of metal  ion, mq/1
                              As Carbonate
                              1 .0 x 10-*
                              7.0 x lO-3


                              3.9 x 10-2
                              1.9 x 10~l

                              2. 1 x 10-*

                              7.0 x 10-*
                                                                  As  Sulfide
                      6.7 x 10-»o
                    No precipitate
                      1.0 x 10-8

                      5.8 x 10-l»
                      3.4 x TO-5
                      3.8 x lO-9

                      2.1 x lO-3
                      9.0 x 10-20
                      6.9 x 10-8

                      7.4 x 10-* 2
                      3.8 x 10-s
                      2.3 x lO-7
                               1401

-------
                         TABLE VII-6

      SULFIDE PRECIPITATION-SEDIMENTATION PERFORMANCE

           Parameter               Treated Effluent
                                       (mg/1)

               Cd                     0.01
               Cr (T)                 0.05
               Cu                     0.05

               Pb                     0.01
               Hg                     0.03
               Ni                     0.05

               Ag                     0.05
               Zn                     0.01
Table VI1-6 is based on two reports:

     Summary  Report,  Control  and  Treatment Technology for the
     Metal Finishing Industry;  Sulfide Precipitation, USEPA, EPA
     No. 625/8/80-003,  1979.

     Addendum to Development Document  for  Effluent  Limitations
     Guidelines  and  New  Source  Performance  Standards,  Major
     Inorganic  Products  Segment  of  Inorganics  Point   Source
     Category, USEPA.,  EPA Contract No.  EPA-68-01-3281 (Task 7),
     June, 1978.
                               1403

-------
                           Table VII-7

              FERRITE CO-PRECIPITATION PERFORMANCE
Metal

Mercury
Cadmium
Copper

Zinc
Chromium
Manganese

Nickel
Iron
Bismuth

Lead
Influent(mg/1)

     7.4
   240
    10

    18
    10
    12

 1,000
   600
   240

   475
Effluent(mg/l)

     0.001
     0.008
     0.010  •

     0.016
    <0.010
     0.007

     0.200
     0.06
     0.100

     0.010
NOTE: These data are from:
Sources and Treatment of Wastewater in the Nonferrous
Metals Industry, USEPA, EPA No. 600/2-80-074, 1980.
Plant

1057



33056


12052

Mean
                           .TABLE VI1-8
                 CONCENTRATION OF TOTAL CYANIDE

Method
FeS04
FeSO*
ZnS04
(mg/1)
In
2.57
2.42
3.28
0.14
0.16
0.46
0.12

Out
0.024
0.015
0.032
0.09
0.09
0. 14
0.06
0.07
                               1404

-------
Plant ID t

  06097
  13924

  18538
  30172
  36048
     mean
          Table VI1-9

MULTIMEDIA FILTER PERFORMANCE

            TSS Effluent Concentration, mq/1
0.
1 .
3.
1 .
1 .
2.
2.
0,
8,
o,
0
4,
1,
61
0.
2.
2.

7.
2.

0,
2,
0,

o,
6,

0.
5.
5.

1 .
1 .

5
6, 4.'0- 4.0, 3.0, 2.
6, 3.6, 2.4, 3.4

0
5

                                            2,2.8
                        TABLE VII-10
        PERFORMANCE OF SELECTED SETTLING SYSTEMS
PLANT ID


01057
09025


11058
12075

19019

33617 .

40063
44062
46050

SETTLING
DEVICE

Lagoon
Clarifier &
Settling
Ponds
Clarifier
Settling
Pond
Settling
Tank
Clarifier &
Lagoon
Clarifier
Clarifier
Settling
Tank
SUSPENDED SOLIDS CONCENTRATION (mg/1)
Day 1
In
54
1100


451
284

170

—

4390
182
295


Out
6
9


17
6

1

_

9
13
10

Day
In
56
1900


-
242

50

1662

3595
1 18
42

2
Out
6
12


-
10

1

16

12
14
10

Day 3
In
50
1620


-
502

—

1298

2805
174
153


Out
5
5


- •
14

—

4

13
23
8

                              1405

-------
                          Table VII-11

                      SKIMMING PERFORMANCE

                              Oil & Grease
                                 mg/1
Plant     Skimmer Type

06058        API
06058        Belt
     In
224,669
     19.4
Out

17.9
 8.3
                              1406

-------
                          TABLE VII-12
                 SELECTED PARITION COEFFICIENTS
Priority Pollutant
Log Octanol/Water
Partition Coefficient
        1   Acenaphthene
       11   1, 1 ,.1-Trichloroethane
       13   1,1-Dichloroethane
       15   1,1,2,2-Tetrachloroethane
       18   Bis(2-chloroethyl)ether
       23   Chloroform
       29   1 ,1-Dichloroethylene
       39   Fluoranthene
       44   Methylene chloride
       64   Pentachlorophenol
       66   Bis(2-ethylhexyl)
            phthalate
       67   Butyl benzyl phthalate
       68   Di-n-butyl phthalate
       72   Benzo(a)anthracene
       73   Benzo(a)pyrene
       74   3,4-benzofluoranthene
       75   Benzo(k)fluoranthene
       76   Chrysene
       77   Acenaphthylene
       78   Anthracene
       79   Benzo(ghi)perylene
       80   Fluorene
       81   Phenanthrene
       82   Dibenzo(a,h)anthracene
       83   Indeno(1,2,3,cd)pyrene
       84   Pyrene
       85   Tetrachloroethylene
       86   Toluene
        4.33
        2. 17
        1  .79
        2.56
        1  .58
        1  .97
        1  .48
        5.33
        1  .25
        5.01

        8.73
        5,
        5
        5
        6,
        5,
        4.
  80
  20
  61
6.04
6.57
  84
  61
  07
4.45
7.23
4. 18
4.46
5.97
7.66
5.32
2.88
2.69
                               1407

-------
                           TABLE VII-13
                 TRACE ORGANIC REMOVAL BY  SKIMMING
                     API  PLUS BELT  SKIMMERS
                        (From Plant  06058)
Oil & Grease
Chloroform
Methylene Chloride

Naphthalene
N-nitrosodiphenylamine
Bis-2-ethylhexyl phthalate

Diethyl phthalate
Butylbenzyl phthalate
Di-n-octyl phthalate

Anthracene - phenanthrene
Toluene
                   225,000
                         0.023
                         0.013

                         2.31
                        59.0
                        11.0
                         0.005
                         0.019

                        16.4
                         0.02
                            Eff.
                            mg/1

                            14.6
                             0.007
                             0.012
                             0.004
                             0. 182
                             0.027
                             0.002
                             0.002

                             0.014
                             0.012
                          Table VII-14

           COMBINED METALS DATA EFFLUENT VALUES  (mg/1)
Cd
Cr
Cu

Pb
Ni
Zn

Fe
Mn
TSS
 Mean

 0.079
 0.084
 0.58

 0.12
 0.74
 0.33

 0.41
 0.16
12.0
 One Day
   Max.

 0.34
 0.44
 1 .90

 0.42
 1 .92
 1 .46

 1 .20
 0.68
41 .0
 10 Day Avg.
    Max.

 0.15
 0.18
 1 .00

 0.20
 1 .27
 0.61

 0.61
 0.29
19.5
                                                   30 Day Avg,
                                                      Max.
 0,
 0,
 0,

 0,
 1 ,
 0,

 0.
 0.
13
12
73

16
00
45

50
21
15.5
                               1408

-------
                          TABLE VII-15
                         L&S PERFORMANCE
                      ADDITIONAL POLLUTANTS
     Pollutant

     Sb
     As
     Be

     Hg
     Se
     Ag

     Tl
     Al
     Co
     F
                    Average Performance (mq/1
                         0.7
                         0.51
                         0.30

                         0.06
                         0.30
                         0. 10

                         0.50
                         2.24
                         0.05
                        14.5
                          TABLE VI1-16

         COMBINED METALS DATA SET - UNTREATED WASTEWATER
Pollutant

Cd
Cr
Cu

Pb
Ni
Zn

Fe
Mn
TSS
Min. Cone (mg/1)

     <0. 1
     <0. 1
     <0. 1
     <0. 1
     <0. 1
      4.6
Max.  Cone, (mq/1)

     3.83
   1 16
   108

    29.2
    27.5
   337.

   263
     5.98
  4390
                               1409

-------






























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-------
                    TABLE VII-18

PRECIPITATJON-SETTLING-FILTRATION (LS&F) PERFORMANCE
                       Plant A
Parameters No Pts
For 1 979-Treated
Cr
Cu
Ni
Zn
Fe
For 1978-freated
Cr
Cu
Ni
Zn
Fe
Raw Waste
Cr
Cu
Ni
Zn
Fe-
Range mq/1
Mean +_
std. dev.
Mean + 2
std. dev.
Wastewater
47
12
47
47

0.
0.
0.
0.

015 -
01 -
08 -
08 -

0.
0.
0.
0.

13
03
64
53

0
0
0
0

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.019
.22
. 17

+ 0.
+ 0.
+ 0.
+ 0.

029
006
13
09 ,

0.
0.
0.
0.

10
03
48
35

Wastewater
47
28
47
47
21

5
5
5
5
5
0.
0.
0.
0.
0.

32.
0.
1 .
33.
10.
01 -
005 -
10 -
08 -
26 -

0
08 -
65 -
2 _
0
0.
0.
0.
2.
1 .

72
0
20
32
95
07
055
92
35
1

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.45
.0
.0
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0
0
0
0
0






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10
010
14
34
18






0.
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0.
0.
0.






26
04
48
91
85






                         1411

-------
                    TABLE VII-19

PRECIPITATION-SETTLING-FILTRATION (LS&F) PERFORMANCE
                       Plant B
Parameters
For 1




.

For 1





Total





No Pts.
Range mq/1
Mean +_
std. dev.
Mean + 2
std. dev.
979-Treated Wastewater
Cr
Cu
Ni
Zn
Fe
TSS
175
176
175
175
174
2
0.0
0.0
0.01
0.01
0.01
1 .00
- 0
- 0
- 1
- 0
- 2
- 1
,40
.22
.49
.66
.40
.00
0
0
0
0
0

.068
.024
.219
.054
.303

+ 0.
+ 0.
+ 0.
+ 0.
+ 0.

075
021
234
064
398

0.
0.
0.
0.
1 .

22
07
69
18
10

978-Treated Wastewater
Cr
Cu
Ni
Zn
Fe
1974-1
Cr
Cu
Ni
Zn •
Fe
144
143
143
131
144
979-Treated'
1288
1290
1287
1273
1287
0.0
0.0
0.0
0.0
0.0
- 0
- 0
- 1
- 0
- 1
.70
.23
.03
.24
.76
0
0
0
0
0
.059
.017
. 147
.037
.200
+ 0.
+ 0.
+ 0.
+ 0.
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088
020
142
034
223
0.
0.
0.
0.
0.
24
06
43
11
47
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0.0
0.0
0.0
0.0
0.0
- 0
- 0
- 1
- 0
- 3
.56
.23
.88
.66
.15
0
0
0
0
0
.038
.011
.184
.035
.402
+ 0.
+0.
+ 0.
+ 0.
+0.
055
016
211
045
509
0.
0.
0.
0.
1 .
15
04
60
13
42
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Cr
Cu
Ni
Zn
Fe
TSS
3
3
3
2
3
2 1
2.80
0.09
1 .61
2.35
3.13
77
- 9
- 0
- 4
- 3
-35
-466
.15
.27
.89
.39
.9
•
5
0
3

22

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.17
.33

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                        1412

-------
                          TABLE VII-20

      PRECIPITATION-SETTLING-FILTRATION
                             Plant C
                         [LS&F) PERFORMANCE
For Treated Wastewater
Parameters     No Pts.
For Treated Wastewater
     Cd
     Zn
    TSS
     pH
103
103
103
103
For Untreated Wastewater
Cd
Zn
Fe
TSS
pH
103
103
3
103
' 103
           Range mg/1
               Mean +_
               std. dev.
0.010 - 0.500  0.049 +0.049
0.039 - 0.899  0.290 +.0.131
0.100 - 5.00   1.244 +1.043
7.1    - 7.9    9.2*
Mean + 2
std. dev.
  0. 147
  0.552
  3.33
0.
0.
0.
0.
6.
039
949
107
80
8
- 2
-29
- 0
-19
- 8
.319
.8
.46
.6
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0.
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0.
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7.
542
009
255
616
6*
+ 0.
+ 6.

±2-

381
933

896

1 .
24.

1 1 .

304
956

408

* pH value is median of 103 values.
                               1413

-------
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-------
                                         TABLE VI1-23
                         TREATABILITY RATING OF PRIORITY POLLUTANTS
                                  UTILIZING CARBON ADSORPTION
 Priority Pollutant                     Rati

  1.  acenaphthene                        H
  2.  acrolain                            r,
  3.  acrylonitrila                       L
  4.  benzene                             M
  5.  benzidine                           a
  6.  carbon tetrachlorida                M
      (tatrachloroMthane)
  7.  chlorohenzane                       H
  S.  1,2,3-trichlorobenzene              H
  9.  hexachlorobenzene                   a
 10.  1,2-dichloroethane                  H
 11.  1,1,1-trichloroethana               N
 12.  haxechloroethana                    H
 13.  1,1-dichloroethana                  M
 14.  1,1,2-trichloroethana               M
 IS.  1,1,2,2-tetrachlorathano            a
 16.  chloroathane                        L
 17.  bia(chlorcettthyl) ether
 IS.  bis(2-chloroethyl) ether            M
 19.   2-chloroethylvinyl ether            L
      (mixed)
 20.   2-chloronaphtha.lene                 H
 21.   2,4,6-trichlorophenol               a
 22.   parachloroatata erasol  •             a
 23.   chloroform (trichloroMthane)        L
 24.   2-chlorophanol                      a
 25.   1,2-dichlorobenzene                 H
 26.   1,3-dichlorobenzene                 a
 27.   1,4-dichlorobenzene                 n
 28.   3,3'-dichlorob«>nzldin«              a
 29.   1,1-dichloroethylene                L
 30.   1,2-trans-dichloroethylene          L
 31.   2,4-dichlorophcnol                  a
 32.   1,2-dichloropropane                 N
 33.   1,2-dichloropropylene               H
      (1,3-dichloropropene)
 34.   2,4-diaethylphenol                  H
 35.   2,4-dinitrotoluene                  a
 36.   2,6-dinitrcrtolu«n«         '         a
 37.   1,2-dlphanylhydrazina               a
 38-   •tbyUwnzana                         M
 39.   fluoranthan*                   -      a
 40.   4-chloroph«nyl ph«nyl  «th«r          a
 41.   <-broaoph«nyl phanyl «th«r          a
 42.   bifl(2-chloroi»opropyl)«th«r          H
 43.   bla(2-chloro*thox7)aathan«          H
 44.   Mtbyl«n* chlorid*                  L
      (dlchloroatathana)
 45.   awthyl chlorida (chloroaathana)      L
 46.   Mthyl broadda  (hrranmatliana)        L
 47.   brcanfoxm (tribroaeaathana)          H
 48.   dichloxobroaeatathan*                H
•Hota  Explanation of Haaoval Ratinga
Cataqory B (high raaoval)

   adsorba at lavala i 100 ag/g carbon at Cf « 10 rag/1
   adiorba at lavala >100 ag/g carbon at Cf < 1.0 ag/1
Catagory M (aodarata raaoral)

   adiorba at lavala >100 ag/g carbon at C  - 10 ag/1
   adaorba at l«v«l» £100 iig/g carbon at C. < 1.0 «g/l
Catagory L (low raaoval)

   adiorba at lavals < 100 mg/g carbon at c. • 10 mg/1
   adsorb* at laval* <10 ag/g carbon at C   < 1.0 ag/1

C. - final concentrations of priority pollutant at equilibrium
 Priority Pollutant
 49.   trichlorofluoronathana            M
 50.   dichlorodifluoromathana           L
 51.   chlorodibronoMthana              H
 52.   haxachlorobutadiana               R
 53.   haxachlorocyclopantadiana         H
 54.   isophoron*                        B
 55.   naphtfaalan*                       H
 56.   nitrobanzana                      H
 57.   2-nitrophenol                     R
 58.   4-aitrophanol                     a
 59.   2,4-dinitropnanol                 R
 60.   4,6-dinitro-o-crasol              a
 61.   N-nitrosodlaathylaBin*            M
 62.   H-nitrosodiphanylamina            a
 63.   W-nitrosodi-n-propylaHina         N
 64.   pantachlorophanol                 a
 65.   phanol                            H
 66.   bis(2~ethylhaxyl)phthalata        H
 67.   butyl banzyl phthalata            a
 68.   di-n-butyl phthalata              a
 69.   di-n-octyl phthalata             . a
 70.   diathyl phthalata                 a
 71.   disiathyl phthalata                a
 72.   1,2-oanzanthracana                a
      (banco(a)anthracan*)
 73.   banzo(a)pvrana  (3,4-banzo-        R
      pyrana)
 74.   3r4-banzofluoranthana             a
      (banco(b)fluoranthana)
 75.   11,12-banzofluoranthana           a
      (banzo(k)fluoranthan*)
 76.   ehrysana                          a
 77.  acanaphthylana                    H
 78.   anthracana                        a
 79.   1,12-bsnzoparylane (banzo         a
      (Thi)-parylana)
 80.  fluorana                          R
 81.  phananthrana                      a
 82.   1,2,3,6-dibanzanthrac-^a          B
      (dibanzo(a(h) anthracana)
 83.  indano (1,2,3-cd) pyrena          R
      (2<3-o-phanylana pyrana)
 84.  pyrana                            -
 85.  tatraehloroathylana               M
86.  toluana                           H
 87.  triehloroathylene                 L
88.  vinyl chloride                    L
      (chloroethy lene)
 106. PCS-1242 (Aroclor 1242)            R
107. PCB-1254 (Aroclor 1254)            R
 108. 9CB-1221 (Aroclor 1221)            R
109. PCB-1332 (Aroclor 1232)            a
110. PCB-I248 (Aroclor 1248)            R
111. PCB-1260 (Aroclor 1260)            a
112. PCB-1016 (Aroclor 1016)            H
                                        1416

-------
                                   Table  VII  - 24

             CLASSES OF  ORGANIC COMPOUNDS ADSORBED  'ON CARBON
Organic Chemical Class

Aromatic Hydrocarbons

Polynuclear Aromatics


Chlorinated Aromatics



Phenolics


Chlorinated Phenolics
High Molecular Weight Aliphatic  and
Branch Chain Hydrocarbons

Chlorinated Aliphatic Hydrocarbons
High Molecular Weight Aliphatic  Acids
and Aromatic Acids

High Molecular Weight Aliphatic  Amines
and Aromatic Amines

High Molecular Weight Ketones, Esters,
Ethers and Alcohols

Surfactants

Soluble Organic Dyes
Examples of Chesical Class

benzene, toluene, xylene

naphthalene, anthracene
bephenyls

chlorobenzene,  polychlorinated
biphenyls, aldrin, endrin,
toxaphene, DDT

phenol, cresol, fesor'ceriol
and polyphenyls

trichlorophenol,  pentachloro-
phenol

gasoline, kerosine
carbon tetrachloride,
perchloroethylene

tar acids, benzoic acid
aniline, toluene diamine


hydroquinone, polyethylene
glycol

alkyl benzene sulfonates

melkylene blue, Indigo carmine
High Molecular Weight includes  compounds  in  the  broad  range  of  from  4  to  20
carbon atoms.
                                       1417

-------
             Table VII-25



ACTIVATED CARBON PERFORMANCE (MERCURY)
Plant
A
B
C
Mercury 'levels -
In
28.0
0.36
0.008
Table VII-26
mg/1
Out
',0,9
6.015
0.0005

ION EXCHANGE PERFORMANCE
Parameter
All Values mg/1
Al
Cd
Cr+3
Cr+6
Cu
CN
Au
Fe
Pb
Mn
Ni
Ag
S04
Sn
Zn
Plant
Prior To
Pur if ir-
cation
5.6
5.7
3.1
7.1
4.5
9.8
7.4
4.4
6.2
1.5
1.7
14.8
A
After
Purifi-
cation
0.20
0.00
0.01
0.01
0.09
0.04
0.01
0.00
0.00
0.00
0.00
0.40
Plant
Prior To
Purifi-
cation
i-
43.0
3.40
2.30 '
1 .70,
1 .60
9.10
210.00
1.10
B
After
Purifi-
cation
-
0.10
0.09
0.10
0.01
0.01
0.01
2.00
0.10
                 1418

-------
                          Table VII-27

                  MEMBRANE FILTRATION SYSTEM EFFLUENT
Specific
Metal

Al
Cr, (+6)
Cr  (T)
Cu

Fe
Pb
CN

Ni
Zn
TSS
Manufacturers
Guarantee
0.
0.
0.
0.
0.
0,
0.
0.
0.
—
5
02
03
1
1
05
02
1
1
—
Plant
In

0.
4.
18.
288
0.
<0.
9.
2.
632

46
13
8

652
005
56
09

19066
Out

0.
0.
0.
0.
0.
<0.
0.
0.
0.

01
018
043
3
01
005
017
046
1
Plant
In

5.
98.
8.
21 .
o-.
<0.
194
5.
13.

25
4
00
1
288
005"

00
0
31022
Out

<0.
0.
0.
0.
0.
<0.
0.
0.
8.

005
057
222
263
01
005
352
051
0
                                                                 Predicted
                                                                 Performanc
                                                                    0.05
                                                                    0.20

                                                                    0.30
                                                                    0. 05
                                                                    0.02

                                                                    0.40
                                                                    0. 10
                                                                    1.0
Pollutant
(mg/1)

   Cr + 6
   Cu
   CN
   Pt>
   Hg
   Ni

   Ag
   Sb
   Zn
                          Table VII-28

                   PEAT ADSORPTION PERFORMANCE

                            In
                     35,000
                        250
                         36.0

                         20.0
                          1 .0
                          2.5

                          1 .0
                          2.5
                          1 .5
 Out
0.04
0.24
0.7

0.025
0.02
0.07

0.05
0.9
0.25
                               1419

-------
                           Table VII-29

                    ULTRAFILTRATION  PERFORMANCE
Parameter

•Oil  (freon extractable)
COD
TSS
Total Solids
Feed (mq/1)

   1230
   8920
   1380
   2900
Permeate (mg/1)

       4
     148
      13
     296
                               1420

-------
                          TABLE VI1-30

             CHEMICAL EMULSION BREAKING EFFICIENCIES
Parameter

O&G
TSS
O&G
TSS


O&G


TSS


O&G
Concentration (mq/1)
Influent    Effluent
  6,060
  2,612
 13,000
 18,400
 21,300
    540
    680
  1,060
  2,300
 12,500
 13,800
  1 ,650
  2,200
  3,470
  7,200
 98
 46
277

189
1 21
 59
140
 52
 27
 18
187
153
 63
 80
       Reference

Sampling data*

Sampling data*
Sampling data**
Katnick and Pavilcius, 197
  *0il  and grease  and  total suspended solids were taken as grab
   samples before  and  after batch emulsion  breaking  treatment which
   used alumn  and  polymer  on  emulsified  rolling oil  wastewater.

  •fOil  and grease  (grab) and  total  suspended solids  (grab) samples
   were taken  on three consecutive  days  from emulsified rolling
   oil  wastewater.   A  commercial demulsifier was used  in  this batch
   treatment.

 **0il  and grease  (grab) and  total  suspended solids  (composite)
   samples were taken  on three consecutive  days from emulsified
   rolling oil wastewater. A commercial demulsifier (polymer)
   was  used  in this batch  treatment.

 ++This result is  from a full-scale batch chemical  treatment system
   for  emulsified  oils from a .steel rolling mill.
                               1421

-------
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                               PH
10   tl    12   IS
FIGURE VIM. COMPARATIVE SOLUBILITIES OF METAL HYDROXIDES

              AND SULFIDE AS A FUNCTION OF pH
                               1422

-------
0.40
                                                    SODA ASH AND
                                                    CAUSTIC SODA
   e.o
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                              9.0
                                            8.5
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                                    PH
        FIGURE Vll-2. LEAD SOLUBILITY IN THREE ALKALIES
                                  1423

-------
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-------
                                                                INFLUENT
EFFLUENT
                              STORED
                             BACKWASH
                              WATER
                                     •—FILTER	
                                  nBACKWASH-*-
              COLLECTION CHAMBER
                                                    DRAIN
               FIGURE VIM4. GRANULAR BED FILTRATION
                                      1435

-------
PERFORATED
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\
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\
\
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METAL PLATE

FILTERED LIQUID OUTLET

                                  RECTANGULAR FRAME
      FIGURE VII-15. PRESSURE FILTRATION
                       1436

-------
SEDIMENTATION BASIN


          INLET ZONE
                               BAFFLES TO MAINTAIN
                               QUIESCENT CONDITIONS
                                         OUTLET ZONE
   INLET LIQUID
      *-*W»     *   SETTLING PARTICLf
      *   •  "**«»*.* •   TRAJECTORY . •
                                                                OUTLET LIQUID
  t
                                                  BELT-TYPE SOLIDS COLLECTION
                                                  MECHANISM
                         SETTLED PARTICLES COLLECTED
                         AND PERIODICALLY REMOVED
CIRCULAR CLARIFIER
 SETTLING ZONE.
                               INLET LIQUID
                                             , CIRCULAR BAFFLE
                                                     . ANNULAR OVERFLOW WEIR
—•  • •  •
 INLET ZONE
                                          .
                                        *-.•  •><*••
                    •  • • •-  •  •
                     «   • r- • •  " *   *
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OUTLET LIQUID
                                                         •SETTLING PARTICLES
            REVOLVING COLLECTION
            MECHANISM
                           SETTLED PARTICLES
                           COLLECTED AND PERIODICALLY
                           REMOVED
                             SLUDGE DRAWOFF
       FIGURE VII-16. REPRESENTATIVE TYPES OF SEDIMENTATION
                                    1437

-------
                                      FLANGE
WASTE WATCH
 WASH WATCW
                                          SURFACE WA»H
                                          MANIFOLD
  BACKWASH
        INFLUENT
        DISTRIBUTOR
                                               BACKWASH
                                               NEPbACKMENT CARBON
                                       CAMION REMOVAL VOMT
                                                TMCATCP WATEM
                                          •IWOWT PLATE
    FIGURE VI1-17. ACTIVATED CARBON ADSORPTION COLUMN
                           1438

-------
CONVEYOR DRIVE   L_ DRYING
                     'ZONE
   i—BOWL DRIVE
r
-LIQUID ZONE-
LIQUID
OUTLET
                                                                              SLUDGE
                                                                              INLFT
 CYCLOGEAR
 SLUDGE
 DISCHARGE
                                   CONVEYOR      BOWL
                REGULATING
                RING
                                                                          IMPELLER
                         FIGURE VII-18. CENTRIFUGATION
                                         1439

-------
                                         O
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                                         bl
                                         OC

                                         O
1440

-------
       CONTROLS
                        OZONE
                      GENERATOR
       DRY AIR
                             D
                    1	II    I
OZONE
REACTION
TANK
                                                         TREATED
                                                          WASTE
           X
        RAW WASTE-
FIGURE Vll-20. TYPICAL OZONE PLANT FOR WASTE TREATMENT
                               1441

-------
r
                                            MIXER
Fll
»T
SE
ST
WASTEWATER
FEED TANK

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-------
                                           LJ
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-------
OILY WATER
INFLUENT
            WATER
            DISCHARGE
                        -»
                        MOTOR
                        DRIVEN
                        RAKE
                        % i i t t  i
OVERFLOW
SHUTOFF
VALVE
                                                     AIR IN
                                                                 •ACK PRESS
                                                                 VALVE
      TO SLUDGE
      TANK    •"*
                                                                       EXCESS
                                                                       AIR OUT
                                                                       LEVEL
                                                                       CONTROLLER
                    FIGURE VII-23. DISSOLVED AIR FLOTATION
                                        1444

-------
   CONDUIT
   TO MOTOR
INFLUENT
 CONDUIT TO
 OVERLOAD
 ALARM
                                               COUNTERFLOW
                                               INFLUENT WELL
                                                     DRIVE UNIT
                         OVERLOAD ALARM

                            EFFLUENT WEIR
                                 DIRECTION OF ROTATION
     EFFLUENT PIPE
                                                           EFFLUENT CHANNEL
                                         PLAN
 INFLUENT
                                    TURNTABLE
                                    BASE
                  HANDRAIL
 CENTER COLUMN
 — CENTER CAGE
                                                                      WEIR
                   STILTS

                   CENTER SCRAPER
                                                                     SQUEEGEE
SLUDGE PIPE
                      FIGURE VII-24. GRAVITY THICKENING
                                     1445

-------
WASTE WATER CONTAINING
DISSOLVED METAL* OK
OTHER IONS
                                  /T
                 ,REGENERANT
                 "SOLUTION
                                               -DIVERTER VALVE
I  V
                                                     -DISTRIBUTOR
                                                      SUPPORT
    RECENERANT TO REUSE,
    TREATMENT. OR DISPOSAL'
                                                -DIVERTER VALVE
            MI:TAL-FREE WATER
            FOR REUSE OR DISCHARGE
               FIGURE VII-25. ION EXCHANGE WITH REGENERATION
                                         1446

-------
                      •              »
                        •   MOST
                         •  SALTS
                                      MACROMOLCCULES
                                      AND SOLIDS
MEMBRANE
                                                                - 490 PS I
                                     WATER
                                              /MEMBRANE CROSS SECTION.
                                              IN TUBULAR, HOLLOW FIBER,
                                              OR SPIRAL-WOUND CONFIGURATION



              9   I                 1    '•/            '    •
            *   «~» *  O        -»     ft  / ^   *      fi
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           .               .  o     .
t   i       y  »      i  r     _ *
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                                                       o  o
                                                  CONCENTRATE
                                                    (SALTS)
          O SALTS OR SOLIDS
          • WATER MOLECULES
           FIGURE VII-26. SfMPLIFIED REVERSE OSMOSIS SCHEMATIC
                                    1447

-------
                             PERMEATE
                             TUBE
                               ADHESIVE BOUND

                                       SPIRAL, MODULE
                                                               CONCENTRATE
                                                               FLOW
                                                     BACKING MATERIAL
                                             MESH SPACER
                                      MEMBRANE
                                 SPIRAL MEMBRANE MODULE
                                    PRODUCT WATER
             ^H°MEMUBRA°NRETTUBE   —EATE FLOW
»••* BRACKISH
    WATER
    FEED FLOW
                    !"•%:•"  "• ••<••>•>«•
                    \fO .V 0 «D H>0«°.>. • ,  *0»J
                          ^:'i
                                                                    BRINE
                                                                    CONCENTRATE
                                                                    FLOW
                                     PRODUCT WATER

                            TUBULAR REVERSE OSMOSIS MODULE
                                                       OPEN ENDS
                                                       OF FIBERS
                                                          . EPOXY
                                                           TUBE SHEET
   SNAP
   RING

"O" RING
SEAL
                                                              POROUS
                                                              BACK-UP DISC
CONCENTRATE
OUTLET
   END PLATE
                                          POROUS FEED
                                          DISTRIBUTOR TUBE •
                                                                                <=>
                                                                                PERMEATE
                                                                END PLATE
                                 HOLLOW FIBER MODULE

            FIGURE VII-27. REVERSE OSMOSIS MEMBRANE CONFIGURATIONS
                                           1448

-------











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                                   PLAN
                                       6-IN. FINE SAND
                                       3-IN. COARSE SAND
                                       3-IN. FINE GRAVEL
                                       3-IN. MEDIUM GRAVEL
                                       3 TO • IN. COARSE GRAVEL
v
     2-1 N. PLANK
     WALK
  PIPE COLUMN FOR
  GLASS-OVER
3-IN. MEDIUM GRAVEL
                                               6-IN. UNDERDRAIN LAID-
                                               WITH OPEN JOINTS
                                SECTION A-A
                     FIGURE Vll-28.  SLUDGE DRYING BED
                                        1449

-------
  ULTRAFILTRATION
                       MACROMOLECULES
 P» 10-50 PSI
MEMBRANE
                           ft       *

                           WATER     SALTS
                                  -MEMBRANE
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       0 DISSOLVED SALTS AND LOW-MOLECULAR-WEIGHT ORCANICS
   FIGURE VII-29. SIMPLIFIED ULTRAFILTRATION FLOW SCHEMATIC



                       1450

-------
           FABRIC OR WIRE
           FILTER MEDIA
           STRETCHED OVER
           REVOLVING DRUM
DIRECTION OF ROTATION
             ROLLER
SOLIDS SCRAPED
OFF FILTER MEDIA
    SOLIDS COLLECTION
    HOPPER
               INLET LIQUID
               TO BE
               FILTERED
                                      -TROUGH
                                                                FILTERED LIQUID
                           FIGURE Vll-30. VACUUM FILTRATION
                                              1451

-------
  >
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-------
                                 •OVERFLOW
                                  TROUGH
   (a)
30-40 in-
          INFLUENT
             I
         V-'-'SANO •'•:."
         ..-.y; COARSE
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EFFLUENT |
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UNOERORAIN
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                                   CHAMBER—A
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  COARSE MEDIA-

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                                                 INFLUENT
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                                                    28- 48 in
        UNDERORAIN
         CHAMBER —
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                                 UNDERDRAIN  I   f EFFLUENT
                                  CHAMBER—1
                                    Figure VII-32

                              FILTER CONFIGURATIONS
   (a)  Single-Media Conventional Filter.
   (b)  Single-Media Upflow Filter.
   (c)  Single-Media Biflow Filter.
                                    (d)  Dual-Media Filter.
                                    (e)  Mixed-Media  (Triple-
                                         Media)  Filter.
                                          1453

-------
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                            1455

-------
                                     
-------
                          EVAPORATION
CONTACT COOLING
WATER
COOLING

 TOWER
                                      SLOWDOWN
                                      DISCHARGE
    RECYCLED  FLOW
                                MAKE-UP WATER
                Figure VII-36

 FLOW DIAGRAM FOR RECYCLING WITH A COOLING TOWER
                    1457

-------
                          SINGLE RINSE
    OUTGOING WATER
                                        -•> WORK MOVEMENT

                                          INCOMING WATER
                     DOUBLE COUNTERFLOW
                             RINSE
OUTGOING WATER
                                                 WORK
                                              -•* MOVEMENT

                                                INCOMING WATER
                     TRIPLE COUNTERFLOW
                            RINSE
                                            WORK MOVEMENT
                                                 INCOMING
                                               r-  WATER
OUTGOING WATER
                        Figure VII-37
               COUNTER CURRENT RINSING (TANKS)
                              1458

-------
lOOOr—
                      Rinse Stages
                  Figure VII-38



   EFFECT OF ADDED RINSE  STAGES ON WATER USE






                      1459

-------

-------
                          SECTION VIII

            COST OF WASTEWATER TREATMENT AND CONTROL
This  section contains a summary of cost estimates,  a discussion
of  the  cost methodology used to develop  these  estimates,  and
descriptions of the equipment and assumptions for each individual
treatment technology.   These cost estimates,  together with  the
estimated  pollutant reduction performance for each treatment and
control option presented in Sections IX,  X, XI, and XII, provide
a  basis  for  evaluating  each  regulatory  option.    The  cost
estimates  also  provide the basis for determining  the  probable
economic  impact  of  regulation on  the  category  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.

SUMMARY OF COST ESTIMATES
                         - .     •              i

The total capital and annual costs of compliance associated  with
the final regulation are presented by subcategory in Tables VIII-
1  through  VIII-3 for regulatory options  BPT,  BAT,  and  PSES,
respectively.   The  number  of direct and - indirect  discharging
plants  in each subcategory is also shown.   The cost  estimation
methodology   used  to  obtain  these  plant  cost  estimates  is
described in the following subsection.

COST ESTIMATION METHODOLOGY

Two  general  approaches to. cost estimation  are  possible.   The
first  is a plant-by-plant approach in which costs are  estimated
for each individual plant in the category.   Alternatively,  in a
model  plant  approach,   costs  can be projected  for  an  entire
category   (or  subcategory)  based  on  cost  estimates  for  an
appropriately selected subset of plants.  The plant-by-plant cost
estimation procedure is  usually preferred compared with the model
plant  approach  because it maximizes the use of  plant  specific
data.
                             TBS:
To    implement   the   selected   approach,     the    wastewater
characteristics  and appropriate treatment technologies  for  the
category  are identified.   These are discussed in Section V  and
Section  VII  of  this  document,   respectively.     Based  on  a
preliminary   technical   and  economic  evaluation,   the   model
treatment  systems  are  developed for each regulatory option from
the  available set  of treatment processes.    When these  systems
are established, a cost  data base is developed containing capital
and  operating costs for each applicable  technology.   To  apply
this  data base to each  plant for cost estimation,  the following
steps are taken:
                               1461

-------
      1.   Define the components of  the treatment  system (e.g.,
          chemical  precipitation, multimedia  filtration)  that are
          applicable to the waste streams  under consideration at
          the plant and their sequence.

      2.   Define the flows  and pollutant concentrations of  the
          waste streams entering the  treatment system.

      3.   Estimate  capital  and annual costs for this  treatment
          system.

      4.   Estimate  the  actual compliance costs by accounting for
          and subtracting the costs for existing  treatment-in-
          place.

      5.   Repeat steps  1-4  for each regulatory option.

 In   this   subsection,   the changes made in   the  cost   estimation
 methodology   from  proposal are presented  first.   Following this,
 each of   the  elements of the cost estimation  procedure  are
 presented.    This  includes development of the cost data  base, the
 plant profile data base, and the wastewater  characterization data
 base.   The   subsection concludes  with a  discussion  of the  three
 methods used for treatment system  cost estimation-application  of
 a  computer   cost   estimation  model,  use   of   cost  curves  and
 equations, and scaling of  costs from similar plants.

 Cost  Data Base Development

 A  preliminary step   required prior  to cost  estimation is  the
 development   of a  cost data base,  which  includes the  compilation
 of   cost  data and  standardization  of  the  data to a common  dollar
 basis.    The   sources  of cost  data,   the  components  of   the  cost
 estimates,   and  the update factors  used  for standardization  (to
 March 1982 dollars  in  this  case) are  described below.

 Sources of Cost Data

 Capital and annual  cost data  for the  selected treatment  processes
 were  obtained from three  sources:    (1)  equipment manufacturers,
 (2) literature data, and (3) cost  data from existing plants.  The
 major  source  of   equipment costs was  contacts  with   equipment
 vendors,  while  the  majority  of annual  cost  information  was
 obtained  from the  literature.   Additional cost and design  data
 were obtained from  data collection portfolios when possible.

 Components of Costs

The components of the capital and annual costs and the   terminol-
ogy  used  in  this study are presented here in order  to  ensure
unambiguous interpretation of the cost .estimates and cost  curves
included in this section.
                               1462

-------
Capital  Costs.   The  total capital costs consist of  two  major
components:   direct, or total module capital costs and indirect,
or system capital costs.  The direct capital costs include:

     (1)  Purchased equipment cost,

     (2)  Delivery charges (based on shipping distance of 500
          miles), and

     (3)  Installation (including labor, excavation, site work,
          and materials).

The  direct  components  of the total capital  cost  are  derived
separately  for each unit process,  or treatment technology.   lA
this particular case,  each unit process cost includes individual
equipment costs (e.g.,  pumps,  tanks,  feed systems, etc.).  The
correlating  equations used to generate the individual  equipment
costs are presented in Table VIII-4.

Indirect capital costs consist of contingency,  engineering,  and
contractor fees.   These indirect costs are derived from factored
estimates,  i.e., they are estimated as percentages of a subtotal
of the total capital cost, as shown in Table VIII-5.

Annual Costs.   The total annualized costs also consist of both a
direct  and  a-system component as in the case of  total  capital
costs.    The components of the total annualized costs are  listed
in Table VIII-6.  Direct annual costs include the following:
                                                 9
     o  Raw materials - These costs are for chemicals and other
        materials used in the treatment processes,  which may
        include lime,  caustic,  sodium thiosulfate, sulfur diox-
        ide, ion exchange resins, sulfuric acid, hydrochloric
        acid,  ferrous sulfate, ferric chloride, and pdlyelectro-
        lyte.

     o  Operating labor and materials - These costs account for
        the  labor and materials directly associated with  opera-
        tion of the process equipment.  Labor requirements are
        estimated in terms of hours per year.  A labor rate of
        $21 per hour was used to convert the hour requirements
        into an annual cost.   This composite labor  rate included
        a base labor rate of $9 per hour for skilled labor, 15
        percent of the base labor rate for supervision and plant
        overhead at 100 percent of the total labor  rate.   The
        base labor rate was obtained from the "Monthly Labor
        Review," which is published by the Bureau of Labor
        Statistics of the U.S. Department of Labor.  For  the
        metals industry,  this wage rate was approximately $9 per
        hour in March of 1982.
                               1463

-------
      o  Maintenance labor and materials - These costs account for
         the labor and materials required for repair and routine
         maintenance of the equipment.   They are based on informa-
         tion gathered from the open literature and from equipment
         vendors.

      o  Energy -  Energy,  or power,  costs are calculated based on
         total energy requirements (in  kW-hrs), an electricity
         charge of $0.0483/kilowatt-hour and an operating schedule
         of  24 hours/day,  250 days/year unless specified  other-
         wise.  The electricity charge  rate (March 1982)  is  based
         on the average retail electricity prices charged for
         industrial service by selected Class A privately-owned
         utilities, as reported in the  Department of Energy's
         Monthly Energy Review.

 System   annual   costs   include   monitoring,    insurance   and
 amortization.  Monitoring  refers   to the periodic  analysis  of
 wastewater  effluent samples to ensure that discharge limitations
 are   being  met.    The annual cost  of  monitoring  was  calculated
 using an analytical lab  fee of $120 per wastewater sample  and a
 sampling  frequency based on the wastewater  discharge  rate,   as
 shown in Table yiII-7,  page    .  The  values shown in Table VIII-
 7  represent  typical requirements contained in NPDES permits.   For
 the    economic impact  analysis,    the  Agency  also   estimated
 monitoring  costs   based   on  10 samples  per  month,   which  is
 consistent with the statistical basis  for the monthly limit.

 The   cost of taxes and  insurance is  assumed to be  one percent   of
 the total depreciable capital investment.

 Amortization  costs,  which account  for  depreciation  and  the  cost
 of  financing,  were calculated using  a  capital   recovery  factor
 (CRF).    A  CRP value  of  0.177 was  used,   which  is based  on   an
 interest  rate of 12 percent,   and a  taxable lifetime  of 10  years.
 The   CRF   is   multiplied by the total  depreciable   investment   to
 obtain the annual  amortization costs.

 Standardization of  Cost Data

 All   capital  and annual cost  data were standardized by  adjusting
 to March  1982  dollars based on the following  cost  indices.

 Capital   Investment.    Investment costs were  adjusted  using   the
 EPA-Sewage Treatment Plant  Construction Cost  Index.  The  value  of
 this  index for March 1982 is  414.0.

 Chemicals.   The  Chemical  Engineering Producer Price Index   for
 industrial chemicals is used.   This index  is published  biweekly
 in  Chemical Engineering magazine.   The March 1982 value of this
 index is 362.6.

Energy.    Power  costs  are  adjusted  by  using  the  price  of
electricity on the desired date and multiplying it by the  energy
requirements for the treatment module in kW-hr equivalents.    The


                               1464

-------
industrial  charge rate for electricity for March 1982 is $0.0483
per kW-hr as mentioned previously in the annual costs discussion.

Labor.  Annual costs are adjusted by multiplying the hourly labor
rate by the labor requirements (in labor-hours), if the latter is
known.   The  labor rate for March 1982 was assumed to be $21 per
hour (see above).  In cases where the labor-hour requirements are
unknown,  the annual labor costs are updated using the EPA-Sewage
Treatment Plant Construction Cost Index.  The value of this index
for March 1982 is 414.0 as stated above.

Plant Specific Flowsheet

After  the cost data base have been developed,  the next step  of
the cost estimation procedure is the selection of the appropriate
treatment technologies and their sequence for a particular plant.
These  are determined for a given regulatory option  by  applying
the  general treatment diagram for that subcategory to the plant.
This general option diagram is modified as appropriate to reflect
the specific treatment technologies that the plant will  require.
For instance,  one plant in a subcategory may generate wastewater
from  a  certain  operation that requires  oil-water  separation.
Another plant in the same subcategory may not generate this waste
stream and thus may not require oil-water separation  technology.
The specific plant flowsheets will reflect this difference.

Wastewater Characteristics

Upon  establishing  the appropriate flowsheet for a given  plant,
the   next   step  is  to  define  the  influent   waste   stream
characteristics (flow and pollutant concentrations).

The  list of .pollutants which may influence the design (and  thus
the  cost)  of  the treatment system is shown  in  Table  VIII-8.
This list includes the conventional, priority metal, and selected
nonconventional  pollutants  that are generally found  in  metal-
bearing  waste  streams.   Varying influent  concentrations  will
affect the various wastewater treatment processes.   For example,
influent  waste  streams  with high  metals  loadings  require  a
greater  volume  of  precipitant (such as lime)  and  generate  a
greater  amount  of sludge than waste streams with  lower  metals
concentrations.

The  raw  waste  concentrations  of  pollutants  present  in  the
influent  waste streams for cost estimation were based  primarily
on field sampling data.   A production normalized raw waste value
in  milligrams  of  pollutant per metric ton  of  production  was
calculated   for  each  pollutant  by  multiplying  the  measured
concentration by the corresponding waste stream flow and dividing
this  result  by  the corresponding  production  associated  with
generation  of  the waste stream.   These raw  waste  values  are
averaged  across  all  sampled plants where the waste  stream  is
found.   These  final  raw  waste values are  used  in  the  cost
estimation  procedure to establish influent pollutant loadings to
each plant's treatment system.  The underlying assumption in this


                               1465

-------
 approach is that the amount of pollutant that is discharged by  a
 process is a function of the off-mass of product that is produced
 by  the  process.   The  amount of water used in the  process  is
 assumed  to not affect the mass of  pollutant  discharged.   This
 assumption  is also called the constant mass assumption since the
 mass of pollutant discharged remains the same even if the flow of
 water carrying the pollutant is changed.

 The individual flows for cost estimation are determined for  each
 waste  stream.   The  procedure used to derive these flows is  as
 follows:

      (1)  The production normalized flows (1/kkg) were determined
           for each waste stream based on production (kkg/yr)  and
           current flow (1/yr) data obtained from each plant's
           dcp or trip report data where possible.

      (2)  This flow was compared to the regulatory flow allowance
           (1/kkg) established by the Agency for each waste
           stream.

      (3)  The lower of the two flows was selected as the cost
           estimation flow.   The flow in 1/yr is calculated by
           multiplying the selected flow by  the production associ-
           ated with that waste stream.

      (4)   The regulatory flow was assigned  to waste streams for
           which actual flow rate data.were  unavailable for a
           plant.

 In  the nonferrous  metals forming category,   production and  flow
 information -was  not  available  for   all   plants.     For these
 facilities,   the  best approach is to use either  the  cost   curves
 (which   are   based   on  general  assumptions  of   the    pertinent
 wastewater   characteristics)  or scaling costs based on  analogous
 plants.  These  approaches,  and where each was used, are  discussed
 later in this section.

 Treatment  System  Cost Estimation

 Costs   for the  nonferrous metals forming category were   estimated
 in  one  of   three   ways:    (1)  through use  of  a  computer   cost
 estimation model,   (2)  through use of cost curves, or  (3)  through
 scaling  of  costs from other  similar facilities.   Selecting  the
 appropriate  method   for each  plant was based primarily   on  the
 quality  and  timeliness  of  the  information available   for   that
 plant.  Where complete  information (flows, production, analytical
 data,  in-place treatment technology) was available, the computer
 cost estimation model  or the cost  curves were selected.  The cost
 curves were generally  developed using the same algorithms used in
 the  cost  estimation model,  and  thus the   two  cost  estimation
methods give comparable results.   The cost  scaling procedure was
 selected  for  plants with nonferrous metals  forming  wastewater
 flows  of  less  than  5 percent of the plant's  total  wastewater
flow,  or  where available information was so sparse that use  of


                               1466

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 one of  the other  two procedures was precluded.   Each procedure  is
 discussed in detail below.

 Cost Estimation Model

 The computer-based cost estimation model was designed  to  provide
 conceptual  wastewater treatment design and cost estimates   based
 on wastewater flows, pollutant loadings, and unit operations that
 are  specified  by  the user.   The model was developed  using  a
 modular  approach;   that  is,  individual  wastewater  treatment
 processes  such   as  gravity  settling  are  contained  in   semi-
 independent entities known as modules.  These modules are used  as
 building blocks in the determination of the treatment system flow
 diagram.  Because this approach allows substantial flexibility  in
 treatment  system  cost estimation,  the model  did  not  require
 modification for  each regulatory option.

 Each module was developed by coupling design information from the
 technical  literature  with  actual design  data  from  operating
 plants.   This  results  in  a more realistic design  than   using
 either theoretical or actual data alone, and correspondingly more
 accurate cost estimates.   The fundamental units for cost estima-
 tion  are  not•the modules themselves but the  components  within
 each  module.   These  components range in configuration  from  a
 single  piece  of equipment,  such as a pump to  components   with
 several  individual pieces,  such as a lime  feed  system.    Each
 component  is sized based on one or more fundamental  parameters.
 For  instance,  the lime feed system is sized by calculating  the
 lime  dosage  required to adjust the pH of the influent to 9  and
precipitate 'dissolved pollutants.   Thus,  a larger feed  system
would  be  designed for a chemical  precipitation  unit  treating
wastewater  containing  high concentrations of  dissolved  metals
 than  for one. treating wastewater of the same flow rate but  lower
metals loadings.

The cost estimation model consists of four main parts, or catego-
 ries of programs:

     o  User input programs,
     o  Design and simulation programs,
     o  Cost estimation programs,  and
     o  Auxiliary programs.

A  general  logic  diagram depicting  the  overall  calculational
sequence is  shown in Figure VIII-1.

The  user input  programs allow entry of all data required by  the
model,    including  the  plant  specific  flowsheet,    flow   and
composition   data  for  each waste stream,   and  specification  of
recycle  loops.    The  design portion of the model calculates  the
design  parameter   for  each module of the flowsheet based on  the
user  input  and  material balances  performed around  each  module.
Figure'  VIII-2,   depicts  the logic  flow diagram for   the  design
portion of the model.
                               1467

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 The  design parameters  are  used as  input  to  the  cost   estimation
 programs   to  calculate  the   costs  for   each  module  equipment
 component   (individual  correlating  cost equations were  developed
 for  each   of  these  components).    The total direct  capital  and
 annual  costs   are   equal to  the sum  of the  module  capital  and
 annual  costs,   respectively.    System,   or  indirect costs  (e.g.,
 engineering, amortization)  are then calculated (see Table VIII-5,
 and  Table VIII-6,   and added to the  total .direct costs to  obtain
 the  total  system costs.   The logic flow  for the cost   estimation
 programs   is displayed  in Figure VIII-3.   The auxiliary  programs
 store and  transfer the  final  cost estimates  to data files,  which
 are  then  used to generate  final summary  tables (see Table  VIII-
 10,  for a  sample summary table).

 Cost Curves

 The  cost curves  were developed using  the  computer cost estimation
 model.   Therefore,  the design and cost assumptions  for  each
 treatment   option presented later in  this  section also  apply  to
 cost curve development.   Several flows  were selected for  each
 treatment  operation  and  the capital and annual costs were plotted
 against the flow or  other design  parameter.   In cases where  the
 cost was  a function of  two or  more independent variables   (e.g.,
 countercurrent   cascade   rinsing),  a combination of  curves  or
 curves and equations was used.  To  simplify  the calculations, the
 sludge handling  operations  (i.e.,   vacuum  filtration and contract
 hauling) cost curves were plotted as  a function of influent  flow
 to   the    sludge handling operation.    'This  necessitated   a
 calculation of   the ratio of  sludge produced  to  the  influent
 wastewater  flow.    This  ratio is  a  function of  the  wastewater
 pollutant   loadings.    Wastewater   characteristics   from   the
 subcategories  to be costed using the cost curves (nickel-cobalt,
 titanium,  zirconium-hafnium, uranium, and  refractory metals) were
 reviewed   to  determine how. many  sludge ratios were  required  to
 accurately  reflect  variation among   these   subcategories.   This
 resulted in the  identification  of the need for four ratios.   The
 subcategories represented by each ratio and  the ratios themselves
 appear  in Table VIII-9.    The  table  also presents the dry sludge
 ratios used in cost  estimation  for  contract hauling.

 To   calculate  the   sludge  generation  ratios,   a  model  plant
 representative  of   the  plants   in   the  subcategory  group  was
 developed.    This  plant included those waste streams within  the
 group that contained the highest pollutant loadings.    Next,  the
 computer  cost  estimation  model was  utilized  to  perform  the
 necessary  material  balances around a treatment  system  designed
 for  the model plant.    Flows based on BAT regulatory requirements
were used.   From this analysis, the sludge ratios  were calculated
as the volume of sludge produced divided by the influent flow  to
 treatment.     In  cases  where  the  waste  stream  mix  diverged
 substantially  from  the set of waste streams used  to develop  the
 ratio,   the  ratio was revised accordingly.   The  ratios used for
each  plant are documented  in the public record  supporting  this
rulemaking.
                               1468

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In  addition  to chemical precipitation,  the sludge  ratios  for
cyanide  precipitation  in the titanium forming subcategory  were
calculated.   The values are 0.72 1 sludge/1 influent and 0.11  1
sludge/1  influent  for  wet (3 percent) sludge and for  dry  (20
percent) sludge, respectively.

To  calculate  the  necessary flow to read  the  sludge  handling
curves,  the  influent  wastewater  flow  is  multiplied  by  the
corresponding sludge ratio.

After  the  curves  and  equations  were  developed,   they  were
validated  by comparing curve-derived costs with those  generated
by the computer model.   Average agreement within 25 percent  was
obtained for each treatment option.

Having  verified the cost curves,  the necessary flow and  design
data  were tabulated for each treatment operation at each  plant.
The   curves  were  then  read  to  obtain  individual  treatment
operation costs.   The results were summed and added to costs for
enclosures and segregation.   System capital costs  (engineering,
contractor's  fee,  contingency) were then applied as were system
annual costs (amortization,  taxes and insurance, and monitoring)
to arrive at the necessary totals for each plant.

Table   VIII-10   lists   each  treatment   operation   and ,  the
corresponding  figure  or table number where  the  specific  cost
correlation is displayed.

Cost Scaling

The  third method used to estimate compliance costs was to  scale
capital  and  operating costs from similar plants that  had  been
costed  by one of the other two methods.   As indicated  earlier,
this  technique  was utilized for plants for  which  insufficient
information was available to use one of the other two procedures,
and for plants whose nonferrous metals forming flow was less than
5  percent  of the total plant flow.   In the  latter  case,  the
impact  of  the  nonferrous metals forming  regulation  is  small
enough that a more sophisticated method is unwarranted.

Table VTII-12 lists the number of plants in each subcategory that
were addressed by the scaling procedure.

The  procedure used for scaling consists of four  steps.   First,
all  available information about the plant is  summarized.   This
includes  the  presence and wastewater flows of  each  nonferrous
metals  forming subcategory and other industrial categories,  the
type  of  wastewater  treatment present at  the  plant,  and  the
relative  production  of  each subcategory and  category  at  the
plant.   In the second step,  this profile was compared to plants
within  or outside of the nonferrous metals forming  category  to
identify  the  most  similar facility according  to  the  profile
factors given above.
                               1469

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 Third,  the  identified plant's total capital and operating costs
 were  scaled based on the flow and the six-tenths rule  for  cost
 estimation:
      Cost for
      Subject
       Plant
Cost for
Analogous
  Plant
      Plow for
x Subject Plant
      Flow for
   Analogous Plant
 The  six-tenths  rule  has been widely applied
 approximation of equipment costs.
0.6
                              for  first  order
 Finally,   the  costs  of  compliance  attributable  to  the  nonferrous
 metals  forming  regulation  are  calculated   by   apportioning   the
 total plant  costs on  a flow  basis.

 A greater  subjectivity is associated with this procedure  than  the
 other  two methods due to the  inherent uncertainties  in selecting
 and applying analogous plants.   However,  this  procedure yields
 costs  of  an acceptable  degree of accuracy when  examined  in light
 of  the availability  of  information and the minimal overall  cost
 impact of  these plants on the forming category.

 The  calculations   and selected analogous plants for  each  plant
 subjected   'to  this  procedure  are  contained  in   the   record
 supporting this rulemaking.

General Cost Assumptions

Regardless of the  cost methodology applied,   several general cost
assumptions were used throughout the category.  These include:

     (1)   Lime is used for pH adjustment and coagulation in all
          chemical precipitation and sedimentation systems except
          for the precious metals subcategory.  Caustic is used
          for precious metals forming wastewater to facilitate
          precious metals recovery from treatment sludges.  These
          sludges may be  recovered by, heating in a furnace. " If
          lime is used in chemical precipitation, the calcium
          ions present in the sludge would cause hot spots in the
          furnace.  This  will result in degradation of the
          furnace lining.  Therefore,  caustic is used for  the
          precious  metals  forming   subcategory  since  sodium  ions
          do  not cause this  condition  and  fluoride (which
          requires calcium for  removal  as  calcium fluoride)  is
          not found in significant quantities in precious  metals
          forming wastewater.
                              1470

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(2)   Sludges produced as a  result  of'chemical" precipitation
     and sedimentation which contain  excess  lime are consid-
     ered  to  be uonhazardous  waste,  industrial  facilities
     will have to test these sludges   Exceptions are sludges
     produced by treating uranium  forming  wastewater,  which
     are considered radioactive wastes.

(3)   Sludges produced as a  result  of  cyanide precipitation
     are considered to be hazardous.
(4)   Equalization tanks  prior  to  chemical  precipitation are
     not included for  plant  flows of  <100  1/hr.

(5)   For plant  flows less  than 50 gallons  per  week,  " compli-
     ance costs are estimated  based on  treatment  or  disposal
     by an off-site source,  i.e., contract disposal.

(6)   Enclosure  costs are assumed  to be  zero for all  modules
     except vacuum filters and, in some cases, chemical feed
     systems.

(7)   Combined treatment  of chemical precipitation, chromium
     reduction  (where  applicable), and  cyanide precipitation
     (where applicable)  is used for flow rates less  than
     2,200 1/hr.   If the costs calculated  for  combined
     treatment  are less  than the  costs  estimated  for  each
     separate treatment  operation, the  former  costs  are
     used.  Additional information is provided under  COST
     ESTIMATES  FOR INDIVIDUAL  TECHNOLOGIES - Combined
     Treatment, below.

(8)   In cases in which a single plant has  wastewater   gener-
     ating processes associated with  different nonferrous
     metals forming subcategories and or other industrial
     categories,  costs are estimated  for a single treatment
     system.  In most  cases, the  combined  treatment  system
     costs are  then apportioned between subcategories and
     categories on a flow-weighted basis since hydraulic
     flow is the primary determinant  of equipment size and
     cost.  It  is possible,  however,  for the combined
     treatment  system  to include  a treatment module  that is
     required by only  one  of the  associated subcategories.
     In this case, ~the total costs for  that particular
     module are included in  the costs for  the  subcategory
     which requires the  module.   Where  the module in
     question   involves  flow reduction, the costs are appor
     tioned based on  an influent flow-weighted basis.  Such
     cost apportioning is  essentially only a bookkeeping
     exercise to allocate  costs;  the  total costs  calculated
     for the plant remain  the  same.
                          1471

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Consideration of Existing Treatment

The cost estimates calculated by the model represent  "greenfield
costs"  that do not account for equipment that plants may already
have  in-place,  i.e.,  these  costs include  existing  treatment
equipment.   In order to estimate the actual compliance cost that
would  be  incurred by a plant to meet the  effluent  guidelines,
"credit"  should  be given to account for treatment in  place  at
that  plant.   This was accomplished by subtracting  capital  and
annual costs of treatment in place from the "greenfield costs" to
obtain  the  actual  or  required capital  and  annual  costs  of
compliance.


Existing treatment is considered as such only if the capacity arid
performance  of  the  existing equipment (measured  in  terms  of
estimated  ability to meet the proposed effluent limitations)  is
equivalent  to that of the technologies considered by the Agency.
The  primary source of information regarding  existing  treatment
was data collection portfolios (dcps).

General  assumptions  applying  to  all  subcategories  used  for
determining   treatment   in-place  qualifications  in   specific
instances include:

     (1)  In cases in which existing equipment has adequate
          performance but insufficient capacity, it is assumed
          that the plant would comply by either installing
          additional required capacity to supplement the existing
          equipment or disregard the existing equipment and
          install new equipment to treat the entire flow.   This
          selection was based on the lowest total annualized
          cost.

     (2)  When a plant reported processing treatment plant
          sludges for metal recovery,  capital and annual costs
          for sludge handling (vacuum filtration and contract
          hauling)  are not included in the compliance costs.  It
          is assumed that it is economical for the plant to
          practice recycle in this case,  and therefore,  the
          related costs are considered to be process associated,
          or a cost of doing business.

     (3)   Capital costs for flow reduction (via recycling)  were
          not included in the compliance costs whenever  the plant
          reported  recycle of the stream,   even if the  specific
          method of recycle was not reported.
                               1472

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      (4)  Settling lagoons were assumed to be equivalent to
          vacuum filtration for dewatering treatment plant
          sludges.  Thus, whenever a plant reported settling
          lagoons to be currently in use for treatment plant
          sludges, the capital costs of vacuum filtration were
          not included.  It was assumed that annual vacuum
          filtration costs were comparable to those for
          operation of settling lagoons and were used to
          approximate the annual operating cost for lagoons.

COST ESTIMATES FOR INDIVIDUAL TREATMENT TECHNOLOGIES

Treatment  technologies have been selected from among the  larger
set  of  available alternatives discussed in  Section .VII  after
considering  such factors as raw waste  characteristics,  typical
plant  characteristics  (e.g.,  location,  production  schedules,
product  mix,  and  land  availability),  and  present  treatment
practices.   Specific  rationales  for selection is addressed  in
Sections IX, X, XI, and XII .of this document.  Cost estimates for
each  technology  addressed in this  section  include  investment
costs   and   annual  costs  for  amortization,
maintenance, and energy.
        operation   and
The  specific  design and cost assumptions  for  each  wastewater
treatment  module  are  listed under the subheadings  to  follow.
Costs  are  presented as a function of influent  wastewater  flow
except where noted in the unit process assumptions.

Costs  are 'presented  for the following  control  and  treatment
technologies:

     -  Countercurrent cascade-spray rinsing,
        Cooling towers,
        Holding tanks,
        Flow equalization,
        Cyanide precipitation and gravity settling,
        Chromium reduction,
     -  Iron co-precipitation,
     -  Chemical emulsion breaking,
        Ammonia steam stripping,
     -  Oil-water separation,
     -  Chemical'precipitation and gravity settling,
        Combined treatment,
     -  Vacuum filtration,
     -  Multimedia filtration,
        Ion exchange, and
     -  Contract hauling.
In  addition,'  costs  for  the following
compliance costs are also discussed:

        Enclosures, and
     -  Segregation.
items  associated  with
                               1473

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 Countercurrent Cascade-Spray Rinsing

 Countercurrent  cascade  rinsing is used to reduce water  use  in
 rinsing operations.    In this process,  the cleanest water is used
 for  final  rinsing  of an item,   preceded by rinse  stages  using
 water with progressively more contaminates to partially rinse the
 item.  Fresh make-up water is added to  the final  rinse stage, and
 contaminated  rinse   water is discharged from the  initial  rinse
 stage.   The  make-up water for  all but the final rinse stage  is
 from the following stage.  The addition of overhead sprays to the
 rinsing  process also increases  rinsing  efficiency.    Therefore,
 countercurrent  cascade  rinsing  with   sprays was  costed  when
 appropriate as a flow reduction  technology for rinse  operations.

 The  costs  for countercurrent cascade-spray rinsing  apply  to a
 two-stage  rinse  system,   each  consisting  of   the   following

 equipment:

      o  Two fiberglass rectangular tanks (for existing sources,
         costs include only one additional tank since  the first
         tank was assumed to be in place).

      o  One spray rinsing system if not in place,

         —stainless  steel spray  nozzles
         —valves
         —Teflon-lined piping system
         —conductivity meter
         —strainer
         —splash guard.

      o  PVC spargers  (air diffuser)  for agitation,

         —one sparger/1.5 feet of  tank  length
         —4 cubic feet of air/min/sparger
         —8 hours installation
         —20  feet of  interconnecting piping.

      o  One blower (including motor) for  supplying  air  to  the
         sparger.

Retrofit capital costs   are estimated at   15  percent   of   the
installed equipment cost.

Information  reported  in  dcps was used  to estimate  the volume  of
countercurrent   rinse   tanks.    If  no information was  available,
tank   volume  was  assumed  to be  1,000  gallons.    When   it  was
determined   from  a  plant's  dcp  that  two-stage   countercurrent
cascade  rinsing  could   be achieved by converting  two  existing
adjacent rinse tanks,  only piping, pump, and spray rinsing costs
were accounted for.  A constant value of $1,000 was estimated for
the piping  costs.
                               1474

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Maintenance  .materials  are estimated at 2 percent  of  purchased
equipment  cost,  and maintenance labor is estimated at 5 percent
of the operating hours.

Capital  costs  for  the spray rinsing system  are  presented  in
Figure VIII-4,  and annual costs as an equation in Table VIII-11.
Capital  and  annual  costs may  be  determined  for  rectangular
fiberglass  tanks  with  spargers and interconnecting  piping  in
Figure VIII-5.   Capital and annual costs for pumps may be  found
in Figure VIII-6.

Cooling Towers

Cooling  towers  are used to reduce discharge flows by  .recycling
cooling water waste streams.   Holding tanks are used to  recycle
flows  less  than  3f400 liters per hour  (15  gpm).   This  flow
represents the effective minimum cooling tower capacity generally
available.

The  cooling  tower  capacity  is based on  the  amount  of  heat
removed,  which  takes into account both the design flow and  the
temperature  decrease  needed  across  the  cooling  tower.   The
influent flow to- the cooling tower and the recycle rate are based
on the assumptions given in Table VIII-13,  page    .   It should
be  noted that for BAT a cooling tower is not included for  cases
in which the actual flow is less than the reduced regulatory flow
(BAT flow) since flow reduction is not required.

The  temperature decrease is calculated as the difference between
the hot water (inlet) and cold water (outlet) temperatures.   The
cold water temperature was assumed to be 20C (85F) and an average
value  calculated  from  sampling data is used as the  hot  water
temperature for a particular waste stream.   When such data  were
unavailable,  or resulted in a temperature less than 35C (95F), a
value   of  35C  (95F)   was  assumed,   resulting  in  a  cooling
requirement  for  a 6C (10F) temperature  drop.   The  other  two
design parameters, namely the wet bulb temperature (i.e., ambient
temperature  at  100 percent relative humidity) and the  approach
(the difference between the outlet water temperature and the  wet
bulb  temperature),   were assumed to be constant at 25C (77F)  and
4C (8F), respectively.

For flow rates above 3,400 1/hr,  a cooling tower is assumed.  The
cooling  tower is sized by calculating the required  capacity  in
evaporative tons.   Cost data were gathered for cooling towers up
to 700 evaporative tons.

The  capital costs of .cooling tower systems include the following
equipment:

     -  Cooling tower (crossflow, mechanically-induced)  and
        typical accessories;

     -  Piping and valves (305 meters (1,000 ft.), carbon steel);
                               1475

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         Cold water storage tank (1-hour retention time);

      -  Recirculation pump, centrifugal; and

      -  Chemical treatment system (for pH, slime and corrosion
         control).

 For  heat  removal requirements exceeding ,700  evaporative  tons,
 multiple cooling towers are assumed.

 The  direct  capital  costs  include  purchased  equipment  cost,
 delivery,  and  installation.   Installation  costs  for  cooling
 towers  are assumed to be 200 percent of the cooling  tower  cost
 based on information supplied by vendors.

 Direct annual costs include raw chemicals  for water treatment and
 fan  energy  requirements.   Maintenance and operating labor  was
 assumed to be constant at 60 hours per year.  The water treatment
 chemical  cost is based on a rate  of $220/1,000 Iph  ($5/gpm)  of
 recirculated water.

 For  small recirculating flows (less than  15 gpm),   holding tanks
 were  used for recycling .cooling water.    A holding  tank  system
 consists of a steel tank,  61 meters (200  feet) of  piping,   and a
 recirculation pump.  The capacity  of the holding tank is based on
 the cooling requirements of the water to be cooled.    Calculation
 of  the  tank  volume is based on  a  surface area  requirement  of
 0.025  mVlph  (60   ftVgpm)   of  recirculated  flow  and
 constant relative  tank dimensions.

 Capital  costs  for  the holding tank system  include   purchased
 equipment  cost,  delivery and installation.   The annual costs are
 attributable   to  the operation of the pump  only  (i.e.,   annual
 costs for  tank and  piping are assumed to be negligible).

 Capital and   annual   costs   for cooling  towers and  tanks   are
 presented  in  Figure VIII-7.

 Holding Tanks-Recycle

 A  holding  tank  is  used to  recycle  water  back  to  a  process.
 Holding tanks are  usually used when  the recycled water  need   not
 be  cooled.   The equipment used to determine  capital costs are a
 tank,   pump,  and recycle  piping.  Fiberglass  tanks were used  for
 capacities  of   24,000 gallons  or less;  steel  tanks  for  larger
 capacities.  Annual costs  are associated only with the pump.   The
 tank  capital cost  is estimated on the basis of  required  volume.
 Required tank volume  is calculated on the basis of influent  flow
 rate,   20 percent excess capacity,  and four-hour retention time.
 The influent flow and the degree of recycle were derived from  the
 assumptions outlined  in Table VIII-13.

 Cost  curves for direct capital and annual costs are presented in
Figure VIII-8.
                               1476

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 Flow  Equalization

 Flow   equalization   is  accomplished   through   equalization   tanks
 which are  sized  based on  a  retention  time  of  8 or  16 hours  and an
 excess  capacity factor of  1.2.   Fiberglass  tanks were  used for
 capacities of   24,000  gallons or less;  steel tanks   for   larger
 capacities.   A  retention  time of 16 hours was assumed  only when
 the   equalization tank  preceded a chemical precipitation   system
 with   "low flow" mode,  and the operating  hours were greater than
 or  equal  to 16 hours  per  day.   In  this  case,   the  additional
 retention  time  is  required to  hold  wastewater  during   batch
 treatment,  since  treatment  is assumed to require 16 hours and
 only  one reaction tank  is included in the  "low flow" batch   mode.
 Cost   data were  available for steel equalization tank  up   to  a
 capacity   of 1,893,000  liters (500,000. gallons) ;  multiple   units
 were  required for volumes greater than 1,893,000 liters  (500,000
 gallons).   The  tanks are fitted with agitators with a horsepower
 requirement  of  0.006 kW/1,000 liters (0.03 hp/1,000 gallons)  of
 capacity to prevent  sedimentation.   An influent transfer pump is
 also. included in the equalization system.

 Annual  costs include electricity costs for the agitator and pump
 and 5 percent of. the installed tank cost for maintenance.

 Cost  curves for capital and annual costs are presented in   Figure
 VIII-9, for equalization at 8 hours and 16 hours retention  time.

 Cyanide Precipitation and Gravity Settling

 Cyanide precipitation is a  two-stage process to remove   complexed
 and uncomplexed cyanide as  a precipitate.  In  the first  step, the
 wastewater  is contacted with an excess of FeSC>4.7H20  at
 pH  9.0 to ensure that all  cyanide is converted to the   complexed
 form:
                    6CN~ -
                             Fe3(Fe(CN) 6) 2
21H20 + 3SO4
            2~
The  hexacyanoferrate is then routed to the second  stage,
additional FeSC-4.7H20 and acid are added.  In this stage,
the  pH is lowered to 4.0 or less,  causing the precipitation
Fe3(Fe(CN)6)2 (Turnbull's blue) and its analogues:
                                                            where
                                                               of
     3FeSO4.7H20
                       2Fe(CN)63 ->
Fe3(Fe(CN)6)2 + 21H20 + 3SO42~

The  blue  precipitate is settled and the overflow is  discharged
for further treatment.

Since the complexation step adjusts the pH to 9, metal- hydroxides
will  precipitate.   These hydroxides may either be  settled  and
                               1477

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 removed    at  pH  9  or   resolubilized  at  pH   4   in   the
 precipitation   step  and  removed  later  in a  downstream cnemicai
 precipitation   unit.   Advantages of preliminary removal  of   the
 metal  hydroxides  include teduced acid  requirements in  the  final
 precipitation   step,   since  the metals  will resolubilize when  the
 pH  is  adjusted  to 4.    However,  the hydroxide sludge  may  be
 classified as   hazardous due to  the  presence   of   cyanide.   In
 addition,  the   continuous mode operation requires  an   additional
 clarifier  between  the  complexation and  precipitation step.  These
 additional  costs  make the  settling  of   metal   hydroxides
 economically unattractive in the  continuous mode.    However,   the
 batch  mode  requires  no  extra  equipment.   Consequently,  metal
 hydroxide  sludge  removal in this case is desirable before   the
 precipitation step.    Therefore,  the batch cyanide  precipitation
 step settles two sludges:    metal hydroxide sludge  (at pH 9)   and
 cyanide sludge  (at pH  4).


 Costs  were estimated  for  both batch and continuous  systems  with
 the operating mode selected  on a  least  cost basis.   The equipment
and assumptions  used in each mode are detailed below.

Costs  for the complexation  step  in the continuous mode are based
on the following:

     (1)   Ferrous  sulfate  feed system

          -  ferrous sulfate steel storage hoppers with dust
             collectors (largest hopper size is 170 m3 (6,000
             ftd);  1.5 days storage)
          -  enclosure for storage tanks
          - •volumetric feeders (small installations)
          -  mechanical weigh belt feeders (large installations)
          -  dissolving tanks (5-minute detention time,  6 percent
             solution)  - dual-head diaphragm  metering pumps
          -  instrumentation and controls

     (2)   Lime  feed system

          -  hydrated lime
          -  feeder
          -  slurry mix tank (5-minute retention time)
          -  feed pump
          -  instrumentation (pH control)

     (3)   H2SC-4  feed system (used when influent  pH  is >9)

          -  93  percent ^804 delivered  in bulk  or  in drums
          -  acid storage  tank  (15 days  retention) when  delivered
             in  bulk
          -  metering pump (standby provided)
          -  pipe and valves
          -  instrumentation  and  controls
                               1478

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      (4)  Reaction  tank and agitator  (fiberglass,  60-minute
          retention time, 20 percent  excess capacity, agitator
          mount, concrete slab)                           ..

      (5)  Effluent  transfer pump.

Costs  for the second step (precipitation) in the  continuous mode
are based on the following equipment:

      (1)  FeSO4 feed system - as above

      (2)  H2SO4 feed system - as above

      (3)  Polymer feed system

             storage hopper
          -  chemical mix tank with agitator
          -  chemical metering pump

      (4)  Reaction  tank with agitator (fiberglass, 30-minute
          retention time, 20 percent excess capacity, agitator
          mount, concrete slab)

      (5)  Clarifier

          -  sized based on 709 lph/m2 (17.4 gph/ft2), 3 percent
             solids in underflow
             steel or concrete,  above ground - support
             structure, sludge scraper, and other
            'internals
             center feed

      (6)  Effluent transfer pump

      (7)  Sludge transfer pump.

Operation  and  maintenance  costs for  continuous  mode  cyanide
precipitation include labor requirements to operate and  maintain
the  system,   el.ectric  power for mixers,  pumps,  clarifier  and
controls,  and treatment chemicals.   Electrical requirements are
also  included for the chemical storage enclosures  for  lighting
and ventilation and in the case of caustic storage, heating.  The
following  assumptions are used in establishing O&M costs for the
complexation step in the continuous mode:

     (1)  Ferrous sulfate feed system

          -  stoichiometry of 1 mole FeSC>4.7H2O to 6 moles CN~
          -  1.5 times stoichiometric dosage to drive reaction to
             completion
          -  operating labor  at 10 min/feeder/shift
          -  maintenance labor at 8 hrs/yr for liquid metering
             pumps
             power based on agitators, metering pumps
          -  maintenance materials at 3 percent .of capital cost


                               1479

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          -  chemical cost  (sewage grade) at $0.1268 per kg
             ($0.0575 per Ib)

      (2)  Lime feed system

          -  dosage based on pH and metals content to raise pH to
             9
          -  operating and maintenance labor requirements are
             based on 20 min/day; in addition, 8 hrs/7,260 kg (8
             hrs/16,000 Ibs) are assumed for delivery of hydrated
             lime
          -  maintenance materials cost is estimated as 3 percent
             of the purchased equipment cost
          -  chemical cost of lime is based on $0.0474/kg
             ($0.0215 per Ib) for hydrated lime delivered in bags

      (3)  Acid feed system  (if required)

          -  dosage based on pH and metals to bring pH to 9
          -  labor unloading - 0.25 hr/drum acid
          -  labor operation - 15 min/day
          -  annual maintenance - 8 hrs
          -  power (includes metering pump)
          -  maintenance materials - 3 percent of capital cost
          -  chemical cost at $0.082 per kg ($0.037 per Ib)

      (4)  Reaction tank with agitator

          -  maintenance materials
             —  tank:  2 percent of tank capital cost
             .—  pump:  5 percent of pump capital cost
          -  power based on agitator (70 percent efficiency) at
             0.099 kW/1,000 liters (0.5 hp/1,000 gallons) of tank
             volume

      (5)  Pump

             operating labor at 0.04 hr/operating day
          -  maintenance labor at 0.005 hr/operating hour
          -  maintenance materials at 5 percent of capital cost
          -  power based on pump hp.

The  following  assumptions  were used for  the  continuous  mode
precipitation step:

      (1)  Ferrous sulfate feed system

          -  stoichiometric dosage based on 3 moles PeSO4.7H2O to
             2 moles of iron-complexed cyanide (Fe(CN)6~)
          -  total dosage is 10 times stoichiometric dosage based
             on data from an Agency treatability study
          -  other assumptions as above
                               1480

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     (2)  H2SO4 feed system

             dosage based on pH adjustment to 4 and resolubiliza-
             tion of the metal hydroxides from the complexation
             step
          -  other assumptions as above

     (3)  Polymer feed system

          -  2 mg/1 dosage
             operation labor at 134 hrs/yr, maintenance labor at
             32 hrs/yr
          -  maintenance materials at 3 percent of the capital
             cost
          -  power at 17,300 kW/yr
          -  chemical cost at $4.96/kg ($2.25/lb)


     (4)  Reaction tank with agitator

          -  see assumptions above

     (5)  Clarifier

          -  maintenance materials range from 0.8 percent to 2
             percent as a function of increasing size
          -  labor - 150 to 500 hrs/yr (depending on size)
          -  power - based on horsepower requirements for sludge
             pumping and sludge scraper drive unit

     (6)  Effluent transfer pump

          -  see assumptions above

     (7)  Sludge pump

             sized on underflow from clarifier
          -  operation and maintenance labor varies with flow
             rate
          -  maintenance materials - varies from 7 percent to 10
             percent of capital cost depending on flow rate.

The  batch  mode  cyanide precipitation  step  accomplishes  both
complexation  and precipitation in the same  vessel.   Costs  for
batch  mode  cyanide complexation and precipitation are based  on
the following equipment:

     (1)  Ferrous sulfate addition

          -  from bags
             added manually to reaction tank
                               1481

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      (2)   Lime addition

              from bags
           -   added manually  to  reaction  tank

      (3)   H2S04 addition

           -   from 208 liter  (55 gallon)  drums
           -   stainless  steel valve to control flow

      (4)   Reaction tank aip agitator (fiberglass, 8.5 hours
           minimum retention time, 20 percent excess capacity,
           agitator mount, concrete slab)

      (5)   Effluent transfer pump

      (6)   Sludge pump.

Operation^  and   maintenance  costs  for  batch   mode   cyanide
complexatzon  and  precipitation  include  costs  for  the  labor
required to operate and maintain the equipment;   electrical power
for  agitators,   pumps,   and  controls;   and  chemicals.   The
assumptions used in estimating costs are as follows:
     (1)  Ferrous sulfate addition

          -  stoichiometric dosage
             —complexation: 1 mole FeSO4.7H20 per 6 moles CN~
             —precipitation:   3 moles FeSO4.7H2O per 2 moles of
               the  iron  cyanide  complex  (Fe(CN)g)2
          -  actual dosage in  excess of stoichiometric
             —complexation:  1.5 times stoichiometric dosaqe
               added
             —precipitation:   10 times stoichiometric dosaqe
               added
          -  operating  labor at 0.25 hr/batch
          -  chemical cost (sewage grade)  at S0.1268/ka
             ($0.0575/lb)                            '  y
          -  no maintenance  labor or materials, or power costs

     (2)   Lime  addition

          -  dosage  based  on pH and  metals content to  raise pH to

          -  operating labor at 0.25  hr/batch
          -  chemical cost at $0.0474/kg ($0.0215/lb)
          -  no maintenance  labor or materials, or power costs

     (3)  H2SO4 addition

         -  dosage based on pH and metals content to lower pH to
            9  (for complexation if required) and/or to lower pH
            to 4 (for precipitation)


                              1482

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          -.  operating labor at 0.25 hr/batch
          -  chemical cost at $0.082/kg ($0.037/lb)
          -  no maintenance labor or materials, or power costs

     (4)  Reaction tank with agitator

          -  maintenance materials
             —tank:  2 percent of tank capital cost
             —pump:  5 percent of pump capital cost
             power based on agitator (70 percent efficiency) at
             0.099 kW/1,000 liters (0.5 hp/1,000 gallons) of tank
             volume

     (5)  Effluent transfer pump

          -  operating labor at 0.04 hr/operating day
          -  maintenance   labor   at  0.005   hr/operating   day
          -  maintenance materials at 5 percent of capital cost
          -  pow.er based on pump hp

     (6)  Sludge pump

          -  operation and maintenance costs vary with flow rate
             maintenance materials costs vary from 7 to 10
             percent of capital cost depending on flow rate.

Capital  and annual costs for continuous and batch  mode  cyanide
precipitation are presented in Figure VIII-10.

At  plants  where the total flow requiring cyanide  treatment  is
low,  cyanide  precipitation and settling may be accomplished  in
the  same unit as chemical precipitation and settling.   This  is
called combined treatment and is discussed later in this section.

Chromium Reduction

Chromium reduction refers to the reduction of hexavalent chromium
to the trivalent form.  Chromium in the hexavalent state will not
precipitate as a hydroxide; it must first be reduced to trivalent
chromium.   For  large  flows  (greater than  2,000  1/hr)  which
undergo  continuous  treatment,  the waste stream is  treated  by
addition  of acid (to lower pH to 2.5) and gaseous sulfur dioxide
(SC-2) dissolved in water in an agitated reaction vessel.  The
SC-2  is  oxidized to sulfate (804) while it  reduces  the
chromium.   For smaller flows (less than 2,000 1/hr),  for  which
batch treatment is more appropriate,  the waste stream is treated
by  manual addition of sodium metabisulfite in the same  reaction
vessel  used for chemical precipitation.   The chemistry of  this
operation  is  similar  to that for  SO2 addition.   This  is
referred  to  as combined treatment,  and is discussed more fully
later in this section.

The  equipment  required  for the continuous  stream  includes  a
g02 feed system (sulfonator), a H2SO4 feed system, an
acid resistant reactor vessel and agitator, and.a stainless steel'


                               1483

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  pump.    The  reaction  pH  is 2.5 and the  SO2  dosage  is  a
  SSSni?"  °f  fc?f  influ

 Iron  Co-Precipitation
Molybdenum  is  effectively  precipitated  by  addition  of  high
X2?SS  °f ^°n Sa*tS at low PH'   ^though  the  precipitation
chemistry  and  precise iron-molybdenum compounds formed are  not
«f Ji-i •   e?stood£ „ comPlexation  and  physical  adsorption  onto
settling  iron  hydroxide  floe  have  both  been  postulated  as
mechanisms for molybdenum removal.   This technolog? is described
in more detail in Section VII.                          aescrioea


              ironnsalt dosage has been determined empirically as
               a 10:1 weight ratio of iron to the summed mass  of
                               1484

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 molybdenum    To  alleviate  scaling  problems,  FeCl3  is  selected
 over   Fe2(SO4)3   as   the iron  "source.    The  pH   for
 optimum precipitation is 4.0.    Hydrochloric acid  is  added  as the
 acid    source.    Removal   of 'the  insoluble  precipitates    is
 accomplished  during  chemical precipitation and sedimentation.

 Capital  and operating   costs ' have   been   estimated   for  both
 continuous, batch and low  flow operating  modes.  However, for the
 nonferrous metals forming  industry,  all plants requiring iron co-
 precipitation generated flows in the batch and low flow  treatment
 ranges.   Assumptions for  cost estimation of the batch   Fed?
 feed  system are  as follows:

 Capital

      o   Flow  between  100 1/hr and  10,500  1/hr

      o   Influent  molybdenum concentration is assumed  as  150 mg/1

      o   FeCl3 (40 weight percent solution) is  added at 10:1 iron
         to molybdenum ratio
     o  FeCl3 storage hopper:

     o
                               2-week supply
        Mix tank of 8 hrs retention, 20 percent excess, 50 gal
        minimum

     o  Agitator at 0.5 hp/1,000 gal., 0.25 hp minimum

     o  Pump at 3 gpm feed

Annual

  ...  o  Operating labor at 0.75 hour/batch
     o  Maintenance, labor at 1 hour/week
     o  Batch is 8 hrs of flow
     o  FeCl3 (sewage grade) at $174/ton

Assumptions for the low flow FeCl3 feed system include:

Capital

     o  Flow less than 2,200 1/hr

     o  Manual addition of FeCl3 from bags (hopper included at
        $2,360 for flows greater than 500 1/hr)

     o  10,000 gallons of wastewater accumulated prior to  treat-
        ment
Annual
         10,000 gallons of wastewater accumulated prior to treat-
         ment
                               1485

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      o   Operating  labor  and  maintenance  labor  are  calculated  by
         0.25  hr/batch  +  0.0025  hr/lb  FeCl3

      o   PeCl3 cost is  $0.21/lb  for  flow  < 500  1/hr;  $0.087/lb for
         flows >  500 1/hr

Assumptions   for the batch and  low  flow  pH adjustment system   are
as follows:
Capital

     o
     o
     o

Annual
Manual addition from drum
$250 capital cost for acid valve
Dosage based on 100 mg CaCC>3/l alkalinity
     o  0.25 hr/batch for operation labor
     o  1 hr/7 batches for maintenance labor
     o  HC1 (22° Baume) is $85/ton

The  sludge  generation  .from iron  co-precipitation  is  0.05  1
sludge/1  of  influent  flow from  molybdenum-containing  streams
(0.0075 1 sludge/1 influent for dewatered sludge).   This  sludge
is in addition to the sludge ratios presented earlier.

Capital  costs for iron co-precipitation are presented in  Figure
VIII-12, while annual costs are presented in Figure VIII-13.

Chemical Emulsion Breaking

Chemical  emulsion breaking involves the separation of relatively
stable oil-water mixtures by chemical addition.   Alum,  polymer,
and  sulfuric  acid are commonly used  to  destabilize  oil-water
mixtures.  In the determination of capital and annual costs based
on  continuous operation,  400 mg/1 of alum and 2 mg/1 of polymer
are  added to waste streams containing emulsified  oil.   In  the
continuous system,  no sulfuric acid is required.   The equipment
included  in the capital and annual costs for continuous chemical
emulsion breaking are as follows:

     (1)  Alum and polymer feed systems

          —  storage units
          -  dilution tanks
             conveyors and chemical feed lines
          -  chemical feed pumps

     (2)  Rapid mix tank (retention time of 15 minutes;  mixer
          velocity gradient is 300/sec,  20 percent excess capac-
          ity)

     (3)  Flocculation tank (retention time of 45 minutes; mixer
          velocity gradient is 100/sec,  20 percent excess capac-
          ity)
                               1486

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      (4)   Pump.

 Following   the   flocculation   tank.,
 mixture  is routed  to  oil  skimming.
the  destabilized  oil-water
 In  the  determination  of  capital and  annual  costs  based  on   batch
 operation,   sulfuric   acid  is  added to waste  streams  containing
 emulsified  oil  until a pH of 3 is  reached.   No alum  or polymer  is
 required.    The following equipment is included in the determina-
 tion of  capital and annual  costs based on batch operation:

      (1)  Sulfuric acid feed systems

             storage tanks  or  drums
             chemical  feed  lines
             chemical  feed  pumps

      (2)  Two.tanks equipped with  agitators  (retention time  of  8
          hrs,  mixer velocity  gradient is 300/sec, 20 percent
          excess capacity)

      (3)  Two belt oil skimmers

      (4)  Two waste oil pumps

      (5)  Two effluent water pumps

      (6)  One waste oil storage tank  (sized  to  retain the waste
         . oil from eight  batches,  20 percent excess  capacity).

The  capital  and annual  costs for continuous and  batch  chemical
emulsion  breaking were determined by summing the  costs  from  the
above equipment.   Alum,  polymer,  and sulfuric acid costs  were
assumed  to  be $0.257 per kg  ($0.118 per pound),  $4.95  per  kg
 ($2.25  per pound),  and  $0.08 per kg of 93 percent  acid  ($0.037
per pound of 93 percent acid),  respectively.

Operation  and  maintenance  and energy costs for  the  different
types  of  equipment  which comprise  the  batch   and  continuous
systems  were  drawn  from  various literature  sources  and  are
included in the annual costs.

The  cutoff  flow for determining the operation  mode  (batch  or
continuous)   is 1,000 liters per hour (264 gal/hr),  above  which
the continuous  system is costed; at lower flows, the batch system
is costed.

For  annual  influent  flows to the  chemical  emulsion  breaking
system of 92,100 liters/year (24,000 gallons/year)  or less, it is
more  economical to directly contract haul rather  than treat  the
waste stream.  The breakpoint  flow is based on a total annualized
cost  comparison and a contract hauling rate of $0.40/gallon  (no
credit was  given for oil resale).
                               1487

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Capital  and  annual  costs for chemical  emulsion  breaking  are
presented  in Figure VIII-14.

Ammonia Steam Stripping

Ammonia removal using steam is a proven technology that is in use
in many industries.   Ammonia is "more volatile than water and may
be  removed  using steam to raise the temperature  and  preferen-
tially evaporate the ammonia.   This process is most economically
done  in a plate or packed tower,  where the method of contacting
the liquid and vapor phases reduces the steam requirement.

The  .pH of the influent wastewater is raised to approximately  12
by  the  addition of lime to convert almost all  of  the  ammonia
present  to molecular ammonia (NH3).   The water is preheated
before  it is sent to the column.   This process takes  place  by
indirectly  contacting the influent with the column effluent  and
with  the gaseous product via heat exchangers.   The water enters
the  top  of  the column and  travels  downward.   The  steam  is
injected  at the bottom and rises through the column,  contacting
the water in a countercurrent fashion.   The source of the  steam
may  be  either  boiled wastewater or  another  steam  generation
system, such as the plant boiler system.

The  presence of solids in the wastewater,  both those present in
the influent and those which may be generated by adjusting the pH
(such as metal hydroxides), necessitates periodic cleaning of the
column.   This requires an acid cleaning system and a surge  tank
to hold wastewater while the column is being cleaned.  The column
is  assumed to require cleaning approximately once per week based
on the demonstrated long-term cleaning requirements of an ammonia
stripping  facility.   The volume of cleaning solution  used  per
cleaning  operation is assumed to be equal to the total volume of
the empty column (i.e., without packing).

For  the estimation of capital and annual  costs,  the  following
pieces  of  equipment  were included in the design of  the  steam
stripper:

     (1)  Packed tower
          -  3-inch Rashig rings
          -  hydraulic loading rate = 2 gpm/ft2
          -  height equivalent to a theoretical plate

     (2)  pH adjustment system
= 3 ft
          -  lime feed system (continuous) - see chemical precip-
             itation section for discussion
          -  rapid mix tank, fiberglass (5-minute retention time)
          -  agitator (velocity gradient is 300 ft/sec/ft)
          -  control system
          -  pump

     (3)  Heat exchangers (stainless steel)
                               1488

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     (4)   Reboiler  (gas-fired)

     (5)   Acid cleaning system

          -  batch  tank, fiberglass
          -  agitator (velocity gradient is 60/sec)
          -  metering pump

     (6)   Surge tank (8-hour retention time).


The direct capital  cost of the lime feed system was based on  the
chemical feed rate  as noted in the discussion on chemical precip-
itation.    Sulfuric  acid  used in the acid cleaning  system  was
assumed  to  be added manually,  requiring no special  equipment.
Other  equipment costs were direct or indirect functions  of  the
influent  flow rate.   Direct annual costs include operation  and
maintenance  labor  for the lime feed system,  heat exchangers and
reboiler; the cost  of lime and sulfuric acid, maintenance materi-
als,  energy costs  required to run the agitators and  pumps;  and
natural  gas costs  to operate the reboiler.   The cost of natural
gas  is  $6.70/1,000 scf.   The total direct capital  and  annual
costs are presented in Figure VIII-15.  .

Oil-Water Separation

Oil skimming costs apply to the removal of free  (non-emulsified)
oil using either a coalescent plate oil-water separator or a belt
skimmer located on the equalization tank.  The latter is applica-
ble  to  low  oil removal rates (less than 189  liters  per  day)
whereas  the  coalescent plate separator is used for oil  removal
rates greater than 189 liters/day  (50 gpd).

Although  the  required coalescent plate  separator  capacity  is
dependent on many factors,  the sizing was based primarily on the
influent  wastewater flow rate,  with the following design values
assumed for the remaining parameters of importance:
                 Parameter

      Specific gravity of oil
      Operating  temperature  (°F)
      Effluent oil concentration  (mg/1)
Design Value

    0.85
   68
   10.0
 Extreme  operating  conditions,  such as  influent  oil  concentrations
 greater   than  30,000 mg/1,   or temperatures much  lower   than   20C
 (68F)  were  accounted   for   in  the   sizing  of  the   separator.
 Additional   capacity  for  such extreme  conditions   was  provided
 using    correlations    developed from   actual  oil    separator
 performance  data.

 The capital and annual costs of oil-water  separation  include the
 following equipment:
                                1489

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      -  Coalescent plate separator with automatic shutoff valve
         and level sensor
      -  Oily waste storage tanks (2-week retention time)
      -  Oily waste discharge pump
      -  Effluent discharge pump

 Influent flow rates up to 159,100 1/hr  (700  gpm)  are  treated in a
 single unit; flows greater than this  require multiple units.

 The direct annual costs for oil-water separation  include  the cost
 of operating and maintenance labor and  replacement parts.   Annual
 costs  for the coalescent plate separators alone  are  minimal   and
 involve only periodic  cleaning  and replacement  of the plates.

 If  the  amount of oil discharged is  189 liters/day (50   gpd)   or
 less,  it is more economical to use a belt skimmer rather  than  a
 coalescent plate separator.   This belt  skimmer  may be attached to
 the  equalization  basin which  is usually necessary  to   equalize
 flow  surges.    The belt skimmer-equalization basin configuration
 is assumed to achieve  10 mg/1 oil in  the effluent.

 The  equipment  included in the belt  oil skimmer   and associated
 design parameters and  assumptions are presented below.

      (1)   Belt oil skimmer

           -  12-inch width
           -  6-foot length

      (2)   Oily waste storage  tank

           -  2-week storage
           -  fiberglass

 Capital   costs  for  belt  skimmers were   obtained   from  published
 vendor  quotes.    Annual  costs  were estimated from  the energy  and
 operation and  maintenance requirements.    Energy  requirements  are
 calculated from the  skimmer motor horsepower.  Operating labor  is
 assumed   constant   at  26  hours  per year.   Maintenance  labor   is
 assumed   to require  24 labor hours per year and belt  replacement
 once  a year.

 Capital and annual  costs  for oil-water separation are $2,600  and
 $1,300, respectively, based on  these assumptions.

 Chemical  Precipitation and Gravity Settling

Chemical  precipitation using lime or caustic followed by gravity
settling   is  a fundamental technology for  metals  removal.    In
practice,   quicklime  (CaO),  hydrated  lime   (Ca(OH)2)/   or
caustic (NaOH) can be used to precipitate toxic and other  metals.
Where  lime  is  selected,   hydrated  lime  is  generally   more
economical  for  low lime requirements since the use of  slakers,
which  are necessary for quicklime usage,  is practical only  for
large volume applications of lime (greater than 50 Ibs/hr).   The
                               1490

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chemical precipitant used for compliance costs estimation depends
on a variety of factors and the subcategory being considered.

Lime  or caustic is used to adjust the pH of the  influent  waste
stream  to a value of approximately 9,  at which optimum  overall
precipitation  of  the metals as metal hydroxides is  assumed  to
occur.   The  chemical  precipitant  dosage is  calculated  as  a
theoretical  stoichiometric  requirement based on the pH and  the
influent metals concentrations.   In addition,  particular  waste
streams  may  contain  significant  amounts  of  fluoride.    The
fluoride will form calcium fluoride (CaF2) when combined with
free  calcium  ions  which  are present if lime is  used  as  the
chemical  precipitant.   The  additional sludge  due  to  calcium
fluoride   formation   is  included  in  the  sludge   generation
calculations.   In  cases where the calcium consumed  by  calcium
fluoride  formation  exceeds  the calcium  level  resulting  from
dosing  for  pH  adjustment and metal  hydroxide  formation,  the
additional  lime  needed  to consume the  remaining  fluoride  is
included in the total theoretical dosage calculation.   The total
chemical dosage requirement is obtained by assuming an excess  of
10   percent.   of   the   theoretical   dosage.    The   effluent
concentrations  are  generally  based on  the  Agency's  combined
metals  data  base  treatment effectiveness values  for  chemical
precipitation technology described in Section VII.

The  costs  of chemical precipitation and  gravity  settling  are
based on one of three operating modes,  depending on the influent
flow:   continuous, "normal" batch, or "low flow" batch.  The use
of  a particular mode for cost estimation purposes is  determined
on  a least cost (total annualized) basis.   The economic;  break-
point  between  continuous and normal batch was estimated  to  be
10,600 1/hr (46.7 gpm).   Below 2,200 1/hr, it was found that the
low  flow batch was the most economical.   The direct capital and
annual  costs  are  presented in Figure  VIII-16  for .all  three
operating modes.

Continuous  Mode.    For  continuous  operation,   the  following
equipment is included in the determination of capital and  annual
costs:

     (1)  Chemical precipitant feed system (continuous)

          -  lime
             —bags (for hydrated lime) or storage units (30-day
               storage capacity) for quicklime
             —slurry mix tank (5-minute retention time) or
               slaker
             —feed pumps (for hydrated lime slurry) or gravity
               feed (for quicklime slurry)
             —instrumentation (pH control)
             caustic
             —day tanks (2) with mixers and feeders for feed
               rates less than 200 Ibs/day; fiberglass tank with
               15-day storage capacity otherwise
             —chemical metering pumps


                               1491

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             —pipe and valves
             —instrumentation  (pH control)

      (2)  Polymer feed system

          -  storage hopper
          -  chemical mix tank with agitator
          -  chemical metering pump

      (3)  Reaction system

          -  rapid mix tank, fiberglass (5-minute retention time)
          -  agitator (velocity gradient is 300 ft/sec/ft)
          -  instrumentation and control

      (4)  Gravity settling system

          -  clarifier, circular, steel (overflow rate is 560
             gpd/ft2; underflow solids is 3 percent)

      (5)  Sludge pump

Ten  percent of the clarifier underflow stream is recycled to the
pH  adjustment  tank to serve as seed material for  the  incoming
waste stream.

The direct capital costs of the chemical precipitant and  polymer
feed  are based on the respective feed rates (dry Ibs/hr),  which
are dependent on the influent waste stream characteristics.   The
flexibility of this feature (i.e., costs are independent of other
module components) was previously noted in the description of the
cost estimation model.   The remaining equipment costs (e.g., for
tanks,  agitators,  pumps)  were developed as a function  of  the
influent  flow (either directly or indirectly,  when coupled with
the design assumptions).

Direct  annual costs for the continuous system are based  on  the
following assumptions:

      (1)  Lime feed system

          -  operating and maintenance labor requirements are
             based on 3 hrs/day for the quicklime feed system and
             20 min/day for the hydrated lime feed system; in
             addition, 5 hrs/50,000 Ibs are required for bulk
             delivery of quicklime and 8 hrs/16,000 Ibs are
             assumed for delivery of hydrated lime
          -  maintenance materials cost is estimated as 3 percent
             of the purchased equipment cost
          -  chemical cost of lime is based on $47.40/kkg
             ($43.00/ton)  for hydrated lime delivered in bags and
             $34.50/kkg ($31.30/ton)  for quicklime delivered on a
             bulk basis (these costs were obtained from the
             Chemical Marketing Reporter)
                               1492

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(2)  Caustic feed system

     -  labor  for unloading of dry NaOH requires 8  hours/
        16,000 Ibs delivered; liquid 50 percent NaOH
        requires 5 hours/50,000 Ibs
     -  operating labor for dry NaOH feeders is 10 min/day/
        feeder                                           ,
     -  operating labor for metering pump is 15 jnin/day
     -  maintenance materials cost is assumed to be 3
        percent of the purchased equipment cost
     -  maintenance labor requires 8 hours/year
        energy cost is based on the horsepower requirements
        for the feed pumps and mixers;  energy requirements
        generally represent less than 5 percent .of the total
        annual costs for the caustic feed system
        chemical cost is $0.183 per Ib

(3)  Polymer feed system

     -  polymer requirements are based on a dosage of 2 mg/1
        the operating labor is assumed to be 134 hrs/yr,
        which includes delivery and solution preparation
        requirements; maintenance labor is estimated at 32
        hrs/yr
     -  energy costs for the feed pump and mixer are based
        on 17,300 kW-hr/yr
     -  chemical cost for polymer is based on $5.00/kkg
        ($2.25/lb)

(4)  Reaction system

     -  operating and maintenance labor requirements are 120
        hrs/yr
     -  pumps  are  assumed to require  .0.005 hrs of,  mainte-
        nance/operating hr (for flows less than 100 gpm) or
        0.01 hrs/operating hr (flows greater than 100 gpm),
        in addition to 0.05 hrs/pperating day for pump
        operation
     -'  maintenance materials costs are estimated as 5
        percent of the purchased equipment cost
        energy costs are based on the power requirements for
        the pump (function of flow) and agitator (0.06
        hp/1,000 gal); an agitator efficiency of 70 percent
        was assumed

(5)  Gravity settling system

        annual operating and maintenance labor requirements
        range from 150 hrs for the minimum size clarifier
        (3QO  ft^)  to 500 hrs for a clarifier of  30,000
        ft_; in addition,  labor hours  for operation and
        maintenance of the sludge pumps were assumed to range
        from 55 to 420 hrs/yr, depending on the pump capacity
        (10 to 1,500 gpm)
                          1493

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          -  maintenance material costs are estimated as 3
             percent of the purchased equipment cost
          -  energy costs are based on power requirements for the
             sludge pump and rake mechanism.

Normal Batch Mode.   The normal batch treatment system,  which is
used  for  flows between 2,200 and 10,600 1/yr,  consists of  the
following equipment:

     (1)  Chemical precipitant feed system

          -  lime (batch)
             —slurry tank (5-minute retention time)
             —agitator
             —feed pump ,
          -  caustic  (batch)
             —fiberglass  tank  (1-week storage)
             —chemical metering pump

     (2)  Polymer feed system (batch)

          -  chemical mix tank (5-day retention time)
          -  agitator        .      '
          -  chemical metering pump

     (3)  Reaction system

          -  reaction tanks (minimum pf 2) (8-hour retention time
             each)
          -  agitators (2) (velocity gradient is 300 ft/sec/ft)
          -  pH control system

The  reaction tanks used for pH adjustment are sized to hold  the
wastewater volume accumulated for one batch period (assumed to be
8  hours).   The tanks are arranged in a parallel setup to  allow
treatment  in  one tank while wastewater is  accumulated  in  the
other  tank.   A separate gravity settler is not necessary  since
settling  can occur'in the reaction tank after precipitation  has
taken place.  The settled sludge is then pumped to the dewatering
stage if necessary.

Direct  annual  costs for the normal batch treatment  system  are
based on the following assumptions:

     (1)  Lime feed system (batch)

          -  operating labor requirements range from 15 to 60
             min/batch, depending on the feed rate (5 to 1,000
             Ibs of hydrated lime/batch)
          -  maintenance labor is assumed to be constant at 52
             hrs/yr (1 hr/week)
          -  energy costs for the agitator and feed pump are
             assumed to be negligible
          -  chemical costs are based on the use of hydrated lime
             (see continuous feed system assumptions)


                               1494

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     (2)  Caustic feed system (batch)

             operating  labor requirements are based on 30  min/
             metering pump/shift
          -  maintenance labor requirements are 16, hrs/metering
             pump/year
             energy costs are assumed to be negligible
             chemical costs are based on the use of 50 percent
             liquid caustic solution (see continuous feed system)

     (3)  Polymer feed system (batch)

          -  polymer requirements are based on a dosage of 2 mg/1
             operating and maintenance labor are assumed to
             require 50 hrs/year
             chemical cost for polymer is based on $5.00/kkg
             ($2.25/lb)

     (4)  Reaction system

             required operating labor is assumed to be 1 hr/batch
             (for pH control, sampling, valve operation, etc.)
          -  maintenance labor requirements are 52 hrs/yr
             energy costs are based on power requirements for
             operation of the sludge pump and agitators.

Low-Flow  Batch Mode.
  	    For small influent flows (less than 2r200
it is more economical on a total annualized cost basis to
the "low flow" batch treatment system.   The lower  flows
1/hr),
select
allow an assumption of up to five days for the batch duration, or
holding  time,  as  opposed to eight hours for the  normal  batch
system.   However,  whenever  the total batch volume (based on  a
five-day  holding  time) exceeds 10,000  gallons,  which  is  the
maximum single batch tank capacity, the holding time is decreased
accordingly  to  maintain  the  batch volume  under  this  level.
Capital costs for the low flow system are based on the  following
equipment:

     (1)  Reaction system

             reaction/holding tank (5-day or less retention time)
             agitator
             transfer pump

     (2)  Polymer feed system (batch)

          -  chemical mix tank (5-day retention time)
             agitator
          -  chemical metering pump.

The  polymer feed system is included for the low flow system  for
manufacturing  processes operating in excess of 16 hours per day.
The addition of polymer for plants operating 16 hours or less per
                               1495

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 day  is assumed to be unnecessary due to the additional  settling
 time available.

 Only  one  tank is required for both equalization  and  treatment
 since sedimentation is assumed to be accomplished during  nonpro-
 duction  hours  (since the holding time is greater than the  time
 required for treatment).   Costs 'for a chemical precipitant  feed
 system  are  not included since lime or caustic addition  at  low
 application  rates  can  be assumed to be done  manually  by  the
 operator.   A common pump is used for transfer of both the super-
 natant and sludge through an appropriate valving arrangement.

 As in the normal batch case, annual costs consist mainly of labor
 costs  for  the  low flow system and are based on  the  following
 assumptions:

      (1)  Reaction system

           -  operating labor is assumed to be constant at 1
              hr/batch (for pH control,  sampling, filling, etc.);
              additional labor is also required for the manual
              addition of lime or caustic,  ranging from 15 minutes
              to 1.5 hrs/batch depending on the feed requirement
              (1 to 500 Ibs/batch)
           -  maintenance labor is 52 hrs/year (1 hr/week)
           -  energy costs are based on  power  requirements associ-
              ated  with the agitator and pump
           -  chemical costs are based on the  use of hydrated lime
              or liquid caustic (50  percent)

      (2)   Polymer  feed system (batch)

           -  see assumptions  for  normal  batch treatment.

 Combined Treatment

 For small  treatment  systems  (i.e.,   flow is less  than  2,200. 1/hr)
 where one  or  more pretreatment  steps  is  required   (e.g.,  cyanide
 precipitation  or chromium reduction),   significant  cost  savings
 can  be   realized by  using a  single  reactor vessel   and  multiple
 treatment  steps  versus  treatment in  several separate tanks.   For
 the  nonferrous  metals  forming  industry,  this combined treatment
 approach   was_ used,  where applicable,  in the  precious  metals
 forming  and  iron,  copper and  aluminum metal powders  subcatego-
 ries.

 The  treatment steps  that may be performed in combined  treatment
 include chemical emulsion  breaking, oil-water separation, cyanide
 precipitation, chromium reduction, and chemical precipitation and
 settling.   Only  those steps specifically required by the  waste
 streams at the plant are included in the design.

 The design basis for combined treatment begins with the  chemical
precipitation  unit.   This  unit is designed to hold  wastewater
 from the plant for a period up to five days, based on the optimal
                               1496

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 cost  of  capital  equipment and  operating  costs.   The  total  reten-
 tion   time   required   is calculated  by  summing   the  individual
 retention   times associated with each  treatment step.   The  tank
 size   is then calculated based on  the  larger of either  the  holdup
 time  or  the total  retention time.

 The equipment that may be used in  combined treatment  includes:

      (1)  Manual lime  or caustic addition
      (2)  Batch  reactor tank
      (3)  Pump
      (4)  Agitator
      (5)  Polymer  feed system  (if  required)
      (6)  FeSO4  feed system (if required)
      (7)  H2SO4  feed system (if required)
      (8)  Na2S2Os  feed system  (if  required)
      (9)  Belt skimmer (if required).

 The design  bases such  as dosages and feed equipment are identical
 to  those presented in the respective  treatment  discussions  for
 batch operation, with  the following exceptions:
     (1)  Annual costs for chemical addition are adjusted by the
          number of days of holdup

     (2)  Batch reactor tank annual costs are recalculated as
          follows:

          -  one  hour/batch for operating labor for each  treat-
             ment step except chromium reduction, where 0.5
             hour/batch is used
          -  52 hours/year total maintenance

     (3)  The chemical feed rates for identical chemicals
          required in separate treatment steps are additive.

The capital and annual costs calculated by combined treatment are
apportioned to each treatment step as follows:
           Treatment Step

     Chemical Precipitation
     Cyanide Precipitation
     Chromium Reduction
    Cost Items

Batch reactor tank
Lime addition
Pump
Agitator
Polymer feed system

FeSC-4 feed system
H2SO4 feed system
        feed system
H2SC-4 feed system (if cyanide
  precipitation is not
  present)
                               1497

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     Chemical Emulsion Breaking
Vacuum Filtration
                                     Belt  skimmer
                                     H2SO4 feed system (if  cyanide
                                       precipitation or chromium
                                       reduction is  not present)
The underflow from the clarifier at 3 percent solids is routed to
a  rotary precoat vacuum filter,  which dewaters sludge to a cake
of 20 percent dry solids.  The dewatered sludge is disposed of by
contract  hauling  and the filtrate is recycled to  the  chemical
precipitation step.

                                                               of
                  is based on a yield of 14.6 kg of dry solids/hr
                  : of filter area (3  lbs/hr/ft2),  a  solids
 The   capacity  of  the  vacuum filter,   expressed  as  square  feet
 filtration  area,
 per   square meter
 capture  of  95  percent and  an excess  capacity  of 30 percent.    It
 was   assumed   that  the filter was  operated  eight  hours/operating
 day.

 Cost  data  were compiled for vacuum  filters ranging from   0.9   to
 69.7  m2  (9.4  to  750  ft2) 'of filter  surface area.   Based
 on a  total  annualized cost comparison,  it was assumed  that  it was
 more  economical  to  directly contract  haul   clarifier  underflow
 streams  which were  less  than  50  1/hr  (0.23  gpm),  rather  than
 dewater by  vacuum filtration before  hauling.

 The costs for  the vacuum filtration  system  include the  following
 equipment:

      (1)  Vacuum  filter with precoat  but no sludge conditioning
      (2)  Housing
      (3)  "Influent  transfer  pump
      (4)  Slurry  holding tank
      (5)  Sludge  pumps.

 The  vacuum filter is sized  based on 8 hrs/day  operation.   The
 slurry  holding   tank and  pump are excluded   when  the  treatment
 system  operates  8 hrs/day or less.   It was  assumed in this case
 that the underflow from the  clarifier directly enters the  vacuum
 filter and  that holding tank  volume for the slurry in addition to
 the clarifier holding capacity was unnecessary.    For cases where
 the  treatment  system is  operated for more than 8  hrs/day,  the
 under-flow  is stored during vacuum filter  non-operating  hours.
Accordingly,  the  filter  is  sized to filter  the stored slurry in
 an 8 hour period  each day.  The holding tank  capacity is based on
 the  difference   between the plant and  vacuum  filter  operating
 hours plus an excess capacity of 20 percent.

Cost  curves for direct capital and annual costs are presented in
Figures  VIII-17 and VIII-18,  for vacuum filtration.    Two  cost
 curves are presented,  one for stainless steel filter systems and
one for carbon steel filter systems.    The stainless steel filter
and   appurtenances   are   used   for   sludges   from   cyanide
                               1498

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 precipitation,   carbon   steel   filters   for   all   other   sludges.
 Annual  cost  for  both  designs are  presented in Figure VIII-19.

 The   following assumptions  were made  for developing  capital   and
 annual  costs:

      (1)  Annual costs associated with  the vacuum  filter  were
          developed based on continuous operation  (24 hrs/day,
          365 days/year).   These  costs were adjusted for  a
          plant's  individual operating schedule by assuming that
          annual costs are  proportional to the hours the  vacuum
          filter actually operates.   Thus, annual  costs were
          adjusted by the ratio of actual vacuum filter operating
          hours  per year (8 hrs/day x number  days/year) to the
          number  of hours  in continuous operation (8,760  hrs/
          year).

      (2)  Annual vacuum filter costs  include  operating and
          maintenance labor (ranging  from 200 to 3,000 hrs/year
          as a function of  filter size), maintenance materials
          (generally less than 5  percent of capital cost), and
          energy requirements (mainly for the vacuum pumps).

      (3)  Enclosure costs for vacuum  filtration were based on
          applying rates of $45/ft2 and $5/ft2/year for capital
          and annual costs, respectively to- the estimated floor
          area required by  the vacuum filter  system.  The capital
          cost rate for enclosure is  the standard  value as
          discussed below in the  costs for enclosures discussion.
         . The annual cost rate accounts for electrical energy
          requirements for  the filter housing.  Floor area for
          the enclosure is based  on equipment dimensions reported
          in vendor literature,  ranging from  300 ft2 for the
          minimum size filter (9.4 ft2) to 1,400 ft2 for a vacuum
          filtration capacity of  1,320 ft2.

Multimedia Filtration

Multimedia filtration is used as a wastewater treatment polishing
device  to remove suspended solids not removed in previous treat-
ment  processes.    The  filter beds consist of graded  layers  of
coarse  anthracite  coal and fine sand.   The equipment  used  to
determine capital and annual costs are as follows:

      (1)  Gravity flow,  vertical steel cylindrical filters with
          media  (anthracite and  sand)

      (2)  Influent storage  tank  sized for one backwash volume

      (3)  Backwash tank  sized for one backwash volume

      (4)  Backwash pump  to  provide necessary  flow and  head for
          backwash operations

          -   air  scour system


                              1499

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      (5)  Influent transfer pump

           -  piping, valves, and a c"  Irol system.

 The hydraulic loading rate is 7,335 lph/m2 (180  gph/ft2)
 and   the  backwash  loading  rate  is  29,340  lph/m2   (720
 gph/ft^).   The filter is backwashed once per 24 hours for 10
 minutes.   The  backwash  volume  is  provided  from  the   stored
 filtrate.

 Effluent  pollutant  concentrations  are based  on   the Agency's
 combined  metals  data  base for treatability  of  pollutants  by
 filtration technology.

 Cartridge-type  filters are used instead of multimedia filters  to
 treat small flows  (less than 800 liters/hour)  since they are  more
 economical  than  multimedia filters at  these flows (based on   a
 least  total annualized cost comparison).    The effluent   quality
 achieved by these  filters was equivalent to the level  attained  by
 multimedia  filters.    The  equipment  items  used   to determine
 capital and annual costs for membrane  filtration are as follows:

      (1)   Influent holding tank  sized  for  8 hours retention

      (2)   Pump

      (3)   Prefilter

           -  prefilter cartridges
           -  prefilter housings

      (4)   Membrane filter

           -  membrane  filter  cartridges
           - .housing

 The majority  of annual  cost  is attributable  to  replacement of the
 spent  prefilter   and membrane filter  cartridges.   The  maximum
 loading   for   the  prefilter and membrane  filter  cartridges  was
 assumed   to  be 0.225  kg per  0.254 m units length  of  cartridge.
 The  annual energy and maintenance costs associated with the pump
 are  also  included in  the  total annual costs.   Cost  curves  for
 direct  capital  and annual costs for multimedia  filtration  and
 capital  costs  for cartridge filtration are presented in  Figure
VIII-20.  Annual costs for cartridge filtration are obtained from
 Table VIII-11.

 Ion Exchange

This  technology   is applicable to precious metals  recovery  and
 final effluent polishing in the precious  metals subcategory.   It
operates  by  absorption of charged precious metal  ions  onto  a
strongly  anionic  resin,  which  replaces the  metal  ions  with
chloride  or hydroxide ions.   It has been found that loading  of


                               1500

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the resin to exhaustion and recovery of metals through combustion
is  preferred  over regeneration;  separation efficiency  of  the
desired metals during regeneration is not usually adequate.

EPA has determined that removal of precious metal ions is achiev-
able  at no net cost,  since the annual value of recovered  metal
exceeds  the annualized cost of column operation.   This analysis
was  based on median flows and concentrations of precious  metals
at  a model plant.   The mass of metal recovered  was  calculated
using  a treatability value for each metal (Au,  Pt,  Pd) of 0.01
mg/1 (0.007 mg/1 for silver).   The metal value was determined by
assuming  2/3  of  the market price for  each  metal.   This  was
compared  to  the  cost of operating  and  depreciating  the  ion
exchange column.

Contract Hauling

Concentrated  sludge  and  waste oils are removed on  a  contract
basis  for  off-site  disposal.   The cost  of  contract  hauling
depends  on  the  classification of the  waste  as  being  either
hazardous  or nonhazardous.   For nonhazardous wastes,  a rate of
$0.106/liter  ($0.40/gallon)  was used  in  determining  contract
hauling  costs.    The cost for contract hauling hazardous  wastes
was developed from a survey of waste disposal services and varies
with the amount of waste hauled.  No capital costs are associated
with  contract hauling.    Annual cost curves for contract hauling
nonhazardous  and hazardous wastes are presented in Figure  VIII-
£ J. •

Enclosures
The  costs  of  enclosures for equipment  considered  to  require
protection  from inclement weather were accounted for  separately
from the module costs (except for vacuum filtration).
ular,  chemical  feed systems were generally assumed
enclosure.
                                                       In partic-
                                                      to  require
                                                              the
                                                              the
Costs  for  enclosures  were  obtained by  first  estimating
required  enclosure area and then multiplying this value  by
$/ft2   unit  cost.    A  capital  cost  of  $45/ft2  was
estimated, based on the following:

     -  structure (including roofing, materials, insulation,-
        etc.)

     -  site work (masonry, installation, etc.)

        electrical and plumbing.

The  rate for  annual costs of enclosures is  $5/ft2/yr  which
accounts  for   energy requirements for heating and  lighting  the
enclosure.

The  required  enclosure area is determined as the amount of total
required  enclosure area which exceeds the enclosure  area  esti-
                               1501

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 mated to be available at a particular plant.  It was assumed that
 a common structure could be used to enclose all equipment needing
 housing  unless information was available to indicate that  sepa-
 rate  enclosures  are needed (e.g.,  due to plant  layout).   The
 individual  areas  are estimated at 50 ft2 per  feed  system.
 The  available  enclosure areas associated with each  plant  site
 were  based  on experience from site visits at  numerous  plants.
 For  plant  flows less than 1,100 1/hr,  between 1,100  1/hr  and
 10,800 1/hr,  and over 10,800 1/hr, the estimated available areas
 are 150 ft^, 200 ft% and 250 ft%  respectively.

 The  estimated available area did not exceed the required  enclo-
 sure area at any plant in this category.

 Segregation

 Estimation  of costs for segregation of process  wastewaters  for
 the  nonferrous  metals forming category is required by the  fre-
 quency of multiple subcategories and categories present at plants
 covered by this regulation.    Eighty-two of the approximately 150
 plants  for  which costs were estimated for this  regulation  are
 such  plants.    Because the  subcategories and  categories  repre-
 sented  at  these plants may have different arrays  of  regulated
 pollutants,  the  possibility  exists for mass  allowances  to  be
 incorporated  into a plant's permit that  are in fact not required
 from a treatment standpoint.   EPA seeks to avoid such a situation
 due  to  its potential for allowing additional  pollutants  to  be
 discharged into the environment.    As. discussed in Section X,  EPA
 took  steps to minimize monitoring  difficulties that could  arise
 from this situation.   However,  segregation of wastewater contain-
 ing different  pollutants may be required  for  optimal  environmen-
 tal benefit.    EPA does not  seek  to discourage  combined treatment
 of   process wastewater where such  treatment  provides   effective
 removal  of regulated pollutants.

 Segregation costs,   which   are essentially  the  costs   associated
 with transporting  wastewater  from its  point of  generation to   the
 treatment  system,   are therefore a  function  of  the  subcategories
 and  categories  present  at the  plant.   In case  I,   which is   the
 most_  common,   the   nonferrous  metals  forming  flow   is   a  small
 portion  _of  the  total  process wastewater  flow.    The   cost  of
 segregating  the  flow  from each  nonferrous metals forming  process
 at   a particular plant  was estimated by multiplying  a per  stream
 segregation  cost by  the  number of waste streams in  each  subcate-
 gory that are present at  the plant.  These costs are then attrib-
 uted to  each forming  subcategory.

 In case  II, the  nonferrous metals forming wastewater is the major
wastewater flow.   Here the cost is also calculated by using  the
per  stream cost,  however,  the number of wastewater streams not
associated  with the major nonferrous metals forming  subcategory
were used.   The costs were then assigned to the major nonferrous
metals  forming  subcategory to reflect the cost of compliance  by
the major subcategory with its effluent limitations.
                               1502

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The  per stream segregation costs and assumptions are
Table VIII-14.
listed  in
Finally,  an additional cost for segregation must be included for
separation  of  process wastewaters that are discharged from  the
same  equipment,  where this equipment is used to process  metals
that  are  in separate subcategories.   For  instance,  the  same
surface  treatment  rinse tank may rinse titanium  parts  over  a
certain period and then be used for rinsing of nickel parts.  The
cost for this segregation is represented by the cost of a holding
tank of 4 hours retention,  a pump,  and connecting piping.   The
resulting  cost  was assigned to each nonferrous  metals  forming
subcategory  for  which wastewater is discharged from the  common
equipment.

For the purpose of evaluating the economic impact of the  nonfer-
rous metals forming regulation,  the Agency estimated the compli-
ance  cost  for each plant on the basis of a combined  wastewater
treatment system.  Nonferrous metals forming plants that generate
process wastewater which is regulated by more than one nonferrous
metals  forming  subcategory  with  different  model  end-of-pipe
treatment requirements may be able to comply with permit require-
ments  using a less costly treatment system than a  system  which
will  treat  all  process wastewater to meet the  most  stringent
limitations.

Costs for segregation of wastewaters not included in this regula-
tion (e.g.,  noncontact cooling water) were also included in  the
compliance cost estimates.  The capital costs for segregating the
above  streams  were determined using a rate of $6,900  for  each
stream requiring segregation.  This rate is based on the purchase
and  installation of 50 feet of 4-inch piping (with valves,  pipe
racks, and elbows) for each stream.  Annual costs associated with
segregation are assumed to be negligible.

Where  a common stormwater-process wastewater piping  system  was
used at a plant, costs were included for both segregation of each
process  waste stream to treatment (based on the above rate)  and
segregation  of  stormwater  for rerouting around  the  treatment
system.   Stormwater  segregation  cost is $8,800  based  on  the
underground installation of 300 feet of 24-inch diameter concrete
pipe.

COMPLIANCE COST ESTIMATION

A  cost summary was prepared for each plant.   An example of this
summary for plants that were costed by the computer model may  be
found in Table VIII-15,  page    .  Referring to this table, five
types  of data are included for each option:   run number,  total
capital costs,  required capital costs,  total annual costs,  and
required annual costs.   Run number refers to which computer  run
the costs were derived from.

Total  capital  costs include the capital cost estimate for  each
piece  of wastewater treatment equipment necessary to  meet  mass
                               1503

-------
 Limitations.    Required capital costs are determined by consider-
 ing  the  equipment and wastewater treatment system a plant  cur-
 rently  has  in place.    As discussed  previously,   the  required
 capital  costs reflect  the estimates of the actual   capital  cost
 the  facility  will incur to purchase and install  the  necessary
 treatment  equipment by accounting for what that facility already
 has installed.

 For plants that discharge wastewater in more than one subcategory
 in  the nonferrous metals forming category,  or in  more than  one
 category, the compliance costs must be allocated to the different
 subcategories  and categories.   In general,  this  allocation  is
 done  based  on  the flow contribution of  each  subcategory  and
 category.  For instance, if 33 percent of the flow came from the
 nickel  and  cobalt forming  subcategory,  the  titanium  forming
 subcategory,   and  the  electroplating category each,   the capital
 and annual costs allocated to each of the two forming  subcatego-
 ries and the  other category would be 33 percent.

 An exception  to this rule occurs when preliminary treatment steps
 such as chromium reduction are performed on only a  portion of the
 total plant wastewater  flow.    In this case, the costs associated
 with  the preliminary step are allocated solely to  the subcatego-
 ries  and categories that discharge water requiring  that  treat-
 ment.    Where  flow reduction is included,   the costs are  appor-
 tioned as above keeping constant the portion(s)  borne by subcate-
 gories where  flow is not reduced.   This prevents  compliance costs
 from  increasing for a  subcategory from option to option when  no
 regulatory flow  change  has  been  established.   Examples  and
 detailed  calculation  sheets for  the apportionment of  costs  at
 each   plant   are  contained   in  the  public  record  for    this
 rulemaking.

 NONWATER QUALITY ASPECTS

 The   elimination or  reduction of one form of pollution may  aggra-
 vate other  environmental problems.    Therefore,   Sections   304(b)
 and   306  of the  Act  require EPA to consider  the nonwater  quality
 environmental   impacts  (including  energy  requirements)  of certain
 regulations.    In compliance  With  these   provisions,   EPA has
 considered  the  effect of this regulation  on  air pollution,   solid
 waste  generation,  water scarcity,   and energy consumption.   This
 regulation  was   circulated   to and  reviewed  by   EPA personnel
 responsible   for  nonwater  quality  environmental programs.    While
 it is  difficult  to balance pollution problems against  each   other
 and  against energy utilization,  the Administrator  has  determined
 that   the  impacts identified  below are  justified by the  benefits
 associated  with  compliance  with  the  limitations and   standards.
 The  following  are  the  nonwater   quality  environmental  impacts
 associated with compliance with  BPT,  BAT, NSPS, PSES,  and PSNS.

Air Pollution, Radiation,  and Noise

 In general, none of  the  wastewater  treatment or control processes
 causes air pollution.  Steam  stripping of ammonia has a potential
                               1504

-------
to   generate atmospheric  emissions;   however,   with proper design
and  operation,  air pollution  impacts are  prevented.   None of the
wastewater  treatment processes cause  objectionable  noise  or  have
any  potential for  radiation  hazards.

Solid Waste Disposal                   .

As shown  in Section V,  the waste  streams being  discharged contain
large  quantities  of   toxic and  other metals;   the most  common
method  of  removing  the metals  is   by  chemical   precipitation.
Consequently, significant volumes of  heavy metal-laden sludge are
generated that must be  disposed of properly.

The  technologies that directly generate sludge  are:

     1.   Cyanide precipitation,
     2.   Chemical precipitation (lime or caustic),
     3.   Multimedia filtration, and
     4.   Oil water separation.

Table VIII-15 presents  the sludge volumes  generated by plants  for
each regulatory option  in each subcategory, page

The estimated sludge volumes generated from wastewater  treatment
were  obtained  from material balances performed by the   computer
model and extrapolated  to the entire  category.   Generally,   the
solid  waste  requiring disposal is .a dewatered.sludge  resulting
from  vacuum  filtration,  which contains  20 percent   solids   (by
weight).   The solids content will be lower in cases where  it  is
more economical to contract haul a waste stream directly  from  the
process without undergoing treatment.

A  major concern in the disposal of sludges, is the  contamination
of - soils,  plants,  and animals by the heavy metals contained in
the sludge.    The leaching of heavy metals from sludge and  subse-
quent  movement through soils is enhanced by  acidic  conditions.
Sludges  formed by chemical precipitation possess  high pH  values
and  thus  are resistant to acid  leaching.   Since  the  largest
amount  of sludge that results from the alternatives is generated
by chemical  precipitation, it is not expected that metals will be
readily leached from the sludge.   Disposal of sludges in a lined
sanitary  landfill will further reduce the possibility  of  heavy
metals contamination of soils,  plants, and animals.

Other  methods  of treating and disposing sludge  are  available.
One method currently being used at a number of plants is reuse or
recycle, usually to recover metals.   This is especially common at
plants  in  the precious metals forming subcategory.   Since  the
metal concentrations in some sludges may be substantial,  it  may
be  cost-effective for some plants to recover the metal  fraction
of their sludges prior to,disposal.

Wastes  generated  by  nonferrous  metal formers  are  subject  to
regulation  under  Subtitle  C  of  the Resource  Conservation  and
Recovery Act (RCRA) if they are hazardous.    However,   the Agency


                               1505

-------
examined solid wastes similar to those that would be generated at
nonferrous  metals  forming  plants by  the  suggested  treatment
technologies  (that is,  the sludges from lime and settle  treat-
ment)  and  believes  they are not  hazardous  wastes  under  the
Agency]s  regulations implementing Subtitle C of RCRA.   The  one
exception to this is solid  waste generated by cyanide precipita-
tion.  This sludge is expected to be hazardous and this judgement
was  included in this study.   None of the noncyanide wastes  are
specifically listed as hazardous,  nor are they likely to exhibit
one  of  the four characteristics of hazardous waste (see 40  CFR
Part^ 261)  based  on  the  recommended  technology  of  chemical
precipitation  and  sedimentation,  preceded where  necessary  by
hexavalent chromium reduction.  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  nonferrous metals forming wastewater treatment sludges will
similarly  not  be  EP toxic if  the  recommended  technology  is
applied.

The  Agency is not proposing an allowance for discharge of  spent
solvents  from  the solvent degreasing operations  at  nonferrous
metals  forming  plants.   Disposal of the spent solvent  may  be
subject  to  regulation under RCRA.   However,  no plant  in  the
nonferrous  metals  forming industry is known to  currently  dis-
charge  the spent solvents.   Therefore,  the cost of disposal of
the  spent solvents has not been included in estimating the  cost
of this proposed regulation because all plants which use  solvent
degreasing already incur those costs.

Although  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 charac-
teristics  of  hazardous waste (see 40 CFR 261.10).    The  Agency
also may list these wastes as hazardous under 40 CFR 261.11.

If these wastes are hazardous, as defined by RCRA, 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  require  generators  of  hazardous  nonferrous  metals
forming wastes to meet containerization,  labelling,   recordkeep-
ing,  and reporting requirements;  if plants dispose of hazardous
wastes off-site, they have to prepare a manifest which tracks the
movement of the wastes from the generator's premises to a permit-
ted off-site treatment, storage, or disposal facility (see 40 CFR
262.20).   The  transporter  regulations require transporters  of
hazardous  wastes  to comply with the manifest system  to  assure
that the wastes are delivered to a permitted facility (see 40 CFR
263.20).   Finally,  RCRA  regulations  establish  standards   for
hazardous  waste  treatment,   storage,  and  disposal  facilities
allowed to receive such wastes (see 40,CFR Part 264).
                               1506

-------
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 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.

Consumptive Water Loss

Treatment  and control technologies that require extensive  recy-
cling and reuse of water may require cooling mechanisms.   Evapo-
rative  cooling mechanisms can cause water loss and contribute to
water  scarcity problems-a primary concern in arid and  semi-arid
regions.   While this regulation assumes water reuse, the overall
amount of reuse through evaporative cooling mechanisms is low and
the quantity of water involved is not significant.   In addition,
most  nonferrous  metals forming plants are located east  of  the
Mississippi  where water scarcity is not a problem.   The  Agency
has  concluded that consumptive water loss is  insignificant  and
that  the  pollution reduction benefits of  recycle  technologies
outweigh their impact on consumptive water loss.

Energy Requirements                ...

The  incremental  energy requirements of a  wastewater  treatment
system  have  been determined in order to consider the impact  of
this  regulation  on natural resource depletion  and  on  various
national  economic  factors associated with  energy  consumption.
The  calculation of energy requirements for wastewater  treatment
facilities proceeded in two steps.  First, the portion of operat-
ing  costs  which  were attributable to energy  requirements  was
estimated  for each wastewater  treatment  module.   Then,  these
fractions,  or energy factors, were applied to each module in all
plants  to  obtain  the energy costs associated  with  wastewater
treatment  for  each plant.   These costs were  summed  for  each
subcategory  and converted to kW-hrs using the electricity charge
rate  previously mentioned ($0.0483/kW-hr for March  1982).   The
total plant energy usage was calculated based on the data collec-
tion portfolios.

Table  VIII-16,  presents  these  energy  requirements  for  each
regulatory  option  in each subcategory.   From the data in  this
table,  the Agency has concluded that the energy requirements  of
the  proposed tr-eatment options will not significantly affect the
natural  resource base nor energy distribution or consumption  in
communities where plants are located.
                               1507

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1517

-------
                          Table VIII-5

              COMPONENTS OF TOTAL CAPITAL INVESTMENT
 Number                Item

    1      Bare Module Capital  Costs

    2        Electrical &  instrumentation
    3        Yard piping
    4        Enclosure
    5        Pumping
    6        Retrofit  allowance
    7      Total Module Cost
    8         Engineering/admin.  &  legal
    9         Construction/yardwork
   10      Total Plant Cost
  11        Contingency
  12        Contractor's fee
  13      Total Construction Cost
  14        Interest during construction
  15      Total Depreciable Investment

  16        Land
  17        Working capital

  18      Total Capital Investment
       Cost

Direct capital costs3

Included in item 1
Included in item 1
Included in item 1
Included in item 1
Included in item 1
Item 1 + items 2
  through 6

10% of item 7
0% of item 7
Item 7 + items 8
  through 9

15% of item 10
10% of item 10
Item 10 + items 11
  through 12

0% of item 13
Item 13 + item 14

0% of item 15
0% of item 15

Item 15 + items 16
  through 17
aDirect capital costs include costs of equipment and required
 accessories, installation, and delivery.
                               1518

-------
                          Table VII1-6

             COMPONENTS OF TOTAL ANNUALIZED INVESTMENT
 Number                Item

   19      Bare Module Annual Costs

   20        Overhead
   21        Monitoring
   22        Taxes and Insurance
   23        Amortization

   24      Total Annualized Costs
       "Cost

Direct annual costsa

0% of item 15b
See footenote c
1% of item 15
CRF x item 15d

Item 19 + items 20
  through 23
aDirect annual costs include costs of raw materials, energy,
 operating labor, maintenance and repair.

      15 is the total depreciable investment obtained from Table
     """ «j •

GSee page     for an explanation of the determination of
 monitoring costs.

dThe capital recovery factor (CRF) was used to account for
 depreciation and the cost of financing.
                              1519

-------
                Table VIII-7
        WASTEWATER SAMPLING FREQUENCY
Wastewater Discharge
  (liters per day)
       0  -  37,850
  37,851  - 189,250
 189,251  - 378,500
 378,501  - 946,250
 946,250+
Sampling Frequency
Once per month
Twice per month
Once per week
Twice per week
Three times per week
                     1520

-------
                      Table VIII-8

POLLUTANT PARAMETERS IMPORTANT TO TREATMENT SYSTEM DESIGN
               Parameter

         Flow rate
         pH
         Temperature
         Total suspended solids
         Acidity (as CaCO3)
         Aluminum
         Ammonia
         Antimony
         Arsenic
         Beryllium
         Cadmium
         Chromium (trivalent)
         Chromium (hexavalent)
         Cobalt
         Columbium
         Copper
         Cyanide (free)
         Cyanide (total)
         Fluoride
         Iron
         Lead
         Magnesium
         Manganese
         Mercury
         Molybdenum
         Nickel
         Oil  and grease
         Phosphorus
         Selenium
         Silver
         Sulfate
         Tantalum
         Thallium
         Tin
         Titanium
         Tungsten
         Uranium
         Vanadium
         Zinc
         Zirconium
    Units

 liters/hour
 pH  units
 6F
 mg/1
 mg/1
 mg/1
 mg/1
 mg/1
 mg/1
 mg/1
 mg/1
 mg/1
 mg/1
 mg/1
 mg/1
 mg/1
 mg/1
 mg/1
 mg/1
 mg/1
 mg/1
 mg/1
 mg/1
 mg/1
 mg/1
 mg/1
 mg/1
 mg/1
 mg/1
 mg/1
 mg/1
 mg/1
 mg/1
mg/1
mg/1
mg/1
mg/1
mg/1
mg/1
mg/1
                          1521

-------
                               Table VII1-9
            THE RATIO OF SLUDGE TO INFLUENT WASTEWATER FLOW
                      FOR COST CURVE DEVELOPMENT
  Subcategory Group
Ni-Cof U, Zr
Ti
Refractory Metals - Ia
Refractory Metals - IIb
Wet (3%) Sludge
    Ratio
     0.14
     0.66
     0.05
     0.89
Dry (20%) Sludge
     Ratio
     0.02
     0.10
     0.007
     0.13
aThese include plants with surface treatment baths and rinses,
 sawing and grinding lubricants, and alkaline cleaning baths and
 rinses.
bThese include plants with tumbling wastewater and sawing and
 grinding lubricants.
                              1522

-------
                          Table VIII-10

                KEY TO COST CURVES AND EQUATIONS
Module

Spray Rinsing
  Equipment
  Pump

Countercurrent Rinsing
  Tank, Rectangular
    Fiberglass
  Pump

Cyanide Precipitation

Chromium Reduction
  Batch
  Continuous

Holding Tanks

Cooling Towers

Equalization

Chemical Emulsion Breaking

Oil Skimming

Chemical Precipitation and
  and Settling

Vacuum Filtration
  Carbon Steel
  Stainless Steel*

Multimedia Filtration


Contract Hauling

Iron Co-Precipitation
  Low-Flow
    Flow < 499 1/hr
    500 1/hr < Flow <
      2,200 1/hr
  Batch and Continuous
 Capital Cost
Figure VIII-4
Figure VIII-6
Figure VIII-5

Figure VIII-6

Figure VIII-10


Figure VIII-11
Figure VIII-11

Figure VIII-8

Figure VIII-7

Figure VIII-9

Figure VIII-14

   $2,600

Figure VIII-16
Figure VIII-17
Figure VIII-18

Figure VIII-20
   $  250
   $2,510

Figure VIII-12
 Annual  Cost
Table VIII-11
Figure VIII-6
Figure VIII-5

Figure VIII-6

Figure VIII-10


Table VIII-11
Figure VIII-11

Figure VIII-8

Figure VIII-7

Figure VIII-9

Figure VIII-14

   $1,300

Figure VIII-16
Figure VIII-19
Figure VIli-19

Figure VIII-20
Table VIII-11

Figure VIII-21
Figure VIII-13
Figure VIII-13

Figure' VIII-13
*Used for sludges from cyanide precipitation,
                              1523

-------
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                                                                     1524

-------
                                   Table  VII1-12

                  NUMBER  OF  PLANTS FOR WHICH COSTS WERE SCALED.
                                FROM SIMILAR  PLANTS
        Subcategory

Lead-Tin-Bismuth Forming

Magnesium Forming

Nickel-Cobalt Forming

Precious Metals Forming

Refractory Metals Forming

Titanium Forming

Uranium Forming

Zinc Forming

Zirconium-Hafnium Forming

Metal Powders
Number of Plants

       12

        1

        5

        9

       10

        6

        0

        0

        0

        5
                              1525

-------
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1527

-------
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                       A ••- V   A E A
                                                    1528

-------
                            Table VIII-15
                      NONFERROUS METALS FORMING
                   SOLID WASTE GENERATION  (kkg/yr)
   Subcategory

Lead-Tin-Bismuth Forming

Magnesium Forming

Nickel-Cobalt Forming

Precious Metals Forming

Refractory Metals Forming

Titanium Forming

Uranium Forming

Zinc Forming

Zirconium-Hafnium Forming

Metal Powders
 BPT

  9.68

189

 81.7

 19.0

162

705

150

 99.6

 65.6

 27.4
 BAT

 11.2

191

113

 22.3

196

901

153

101

 80.3

 27.4
 PSES

   22.2

   33.2

3,800

   58.7

1,130

1,710

    0

    0

    2.23

  273
                         1529

-------
                                Table VIII-16
                          NONFERROUS METALS FORMING
                        ENERGY CONSUMPTION (1000 kW-hr/yr)
   Subcategory
Lead-Tin-Bismuth Forming
Magnesium Forming
Nickel-Cobalt Forming
Precious Metals Forming
Refractory Metals Forming
Titanium Forming
Uranium Forming
Zinc Forming
Zirconium-Hafnium Forming
Metal  Powders
BPT
330
110
880
440.
330
880
220
110
440
330
BAT
330
110
880
440
330
880
220
110
440
330
PSES
890
50
950
1,160
1,260
580

50
110
1,310
                              1530

-------
CREATE DATA FILES
 FOR AUTOMATIC
   DATA ENTRY
                        (   START   J
                          USER INPUT
                      MAIN DESIGN ROUTINE
                       TO CALL REQUIRED
                           MODULES
             DESIGN
            MODULE 2
 DESIGN
MODULE 3
 DESIGN
MODULE N
                                                       J
                        OUTPUT DESIGN
                           VALUES &
                       MATERIAL BALANCE
                          (OPTIONAL)
                      MAIN COST ROUTINE
                       TO CAU. REQUIRED
                          MODULES
                       CALCULATE SYSTEM
                            COSTS
                      rSINT COST RESULTS
                             ±
TRANSFER RESULTS
TO DISK DATA FILES
1
r
                       C
                     Figure VIII-1

  GENERAL LOGIC  DIAGRAM OF COMPUTER COST MODEL

                         1531

-------
             Figure VIII-2



LOGIC DIAGRAM OF MODULE DESIGN PROCEDURE






                 1532

-------
                    DESIGN VALUES
                  AND CONFIGURATION
                    TOOM MATERIAL
                   BALANCE PROGRAM
                 Figure VIII-3

LOGIC  DIAGRAM OF THE  COST ESTIMATION ROUTINE

                     1533

-------
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-------
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                                      1551

-------

-------
                           SECTION IX

               BEST PRACTICABLE CONTROL TECHNOLOGY
                      .CURRENTLY AVAILABLE


This  section  defines  the effluent  characteristics  attainable
through  the application of best practicable  control  technology
currently  available (BPT),  Section 301(b)(1)(A).    BPT reflects
the average of the best existing performance by plants of various
sizes,  ages,  and manufacturing processes within the  nonferrous
metals forming category.

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 facili-
ties  involved,  the manufacturing processes  employed,  nonwatef
quality  environmental  impacts (including energy  requirements)/
and  other factors the Administrator considers  appropriate.   In
general,  the BPT level represents the average of the best exist-
ing 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.   See Tanner's Council of America v. Train, 540 F..2d 1188
(4th  Cir.  1976).   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  forming  category  to
identify  the manufacturing processes used and wastewaters gener-
ated during nonferrous metals forming.  Information was collected
from industry using data collection portfolios,  and  wastewaters
from specific plants were sampled and analyzed.   The Agency used
these  data  to  subcategorize the category  and  determine  what
constitutes  an  appropriate BPT.   The factors which  were  con-
sidered  in  establishing  subcategories are' discussed  fully  in
Section IV.  Nonwater quality impacts and energy requirements are
considered in Section VIII.

The category has been subcategorized,  for the purpose of regula-
tion,  on  the basis of metal type formed.   Each subcategory  is
further divided into specific wastewater sources associated  with
specific  manufacturing operations.   The regulation  establishes
pollutant  discharge  limitations  for  each  source  of  process
wastewater  identified within the subcategory.   This approach to
regulation  is  referred to as the building block  approach  with
each  waste stream being a building block.   Compliance with  the
regulation  is determined on an overall plant basis  rather  than
for  individual building blocks.   The building block approach is


                               1553

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         useful for this category since many nonferrous  metals

           *
    «





show  that  thS tfeatment scheme detailed below will  remove  all

^llutantB present in significant concentrations to an acceptable

level.
SSara     Separate  preliminary  treatment   steps  for  chromium
reduction,   lmu?sionl breaking,  cyanide  removal,  and  ammonia


asrvs.
inarv
                steps (when necessary) and chemical
                                                             -

                                                           ion
                              1554

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 prior   to  combined wastewater  treatment.    The  basis  for   perfor-
 mance  of these  treatment  technologies  is  set  forth  in substantial
 detail in  Section VII.

 For  each  of  the subcategories,  a  specific approach  was  followed
 for  the   development of  BPT mass limitations.    To  account   for
 production and flow variability from  plant to  plant,  a  unit   of
 production or production normalizing  parameter  (PNP)  was deter-
 mined  for  each operation  which could then be  related  to the  flow
 from the operation to determine a production  normalized flow.   As
 discussed   in  Section  IV,  the PNP for  the   nonferrous metals
 forming  category  is  off-metric ton  (the  metric tons of  metal
 removed  from a forming operation or associated  operation at   the
 end of a process cycle),  with one  exception.    Laundry washwater
 in the uranium forming subcategory  is  normalized to employee-day.

 Each subcategory was analyzed to determine:   (1)  which operations
 included generated wastewater, (2)  specific flow rates generated,
 and (3) specific production normalized flows for  each  operation.
 The  normalized flows were then analyzed to determine  which  flow
 was  to  be used as the basis for BPT mass  limitations for  that
 operation.   The selected flow (referred to as the  BPT regulatory
 flow), reflects the water use controls which are  common practices
 within the industry.   The overall effectiveness of   end-of-pipe
 treatment  for the removal of wastewater pollutants  is  improved  by
 the  application  of  water flow controls within  the   process   to
 limit  the  volume of wastewater requiring treatment.  However, the
 controls or in-process technologies recommended under  BPT include
 only   those  measures  which are commonly  practiced   within  the
 category   or  subcategory.   Except for  recycle  of   lubricating
 emulsions,  most  plants  in  this  category  do  not  have  flow
 reduction  in place.    Therefore,  flow reduction  is not generally
 included as part of the BPT technology.

 In general,  the BPT regulatory flows are based on the average of
 all  applicable  data.    However,  for some waste streams with  a
 large  range of production normalized flows the median was used as
 the basis  for the BPT regulatory flow.    The Agency believes  the
median  is  more representative of the current typical water  use
 for these waste streams than the average.    Plants with  existing
 flows  above  the  average or median may have to  implement  some
method of  flow reduction to achieve the BPT limitations.   In most
 cases,   this  will  involve  improving  house-keeping  practices,
better   maintenance  to limit water leakage,   or  reducing  excess
 flow by turning down a flow valve.   It is  not believed that these
modifications will generate any significant costs for the plants.
 In  fact,   these  plants  should save  money  by  reducing  water
consumption.

Pollutant  discharge limitations for this  category are  expressed
as mass loadings,  i.e.,  allowable mass  of  pollutant discharge per
off-kilogram  of  production  (mg/off-kg).    Mass  loadings  were
calculated  for 'each  operation  (building  block)   within  each
subcategory.   The  mass loadings were  calculated by  multiplying
the  BPT  regulatory  flow (1/off-kkg)  for the operation   by  the


                               1555

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effluent concentration achievable  by  the  BPT  treatment,  technology
(mg/1).    Table  VII-21  presents  the   effluent   concentrations
achievable  by  the BPT model  treatment train  for   the   pollutants
regulated in each subcategory.  These concentrations are  based on
the performance of chemical precipitation and sedimentation  (lime
and settle) when applied  to a broad range of  metal-bearing waste-
waters,  with preliminary treatment, when necessary.  The deriva-
tion  of these  achievable effluent concentrations  is discussed in
substantial detail in Section VII.

In  deriving mass limitations from the BPT model treatment   tech-
nology,  the Agency assumed that all wastewaters generated within
a  subcategory  were combined  for treatment in a single  or common
treatment  system  for that subcategory,  even though  flow and
sometimes pollutant characteristics of process wastewater 'streams
vary within the subcategory.   A disadvantage of common treatment
is  that some loss in pollutant removal effectiveness will result
where  waste streams containing specific  pollutants at  treatable
levels  are  combined  with other streams in which  these  same
pollutants  are absent   or present at very   low   concentrations.
Under  these circumstances a  plant may prefer to segregate   these
waste  streams  and bypass treatment.   Since treatment  systems
considered  under BPT are primarily for metals,  oil and  grease,
and  suspended  solids removal,  and many  existing  plants  usually
had one common  treatment  system in place  for  these pollutants, it
is  reasonable  to  assume a  common  treatment  system  for  each
subcategory to  calculate  the  system's cost and effectiveness.

Regulated Pollutant Parameters

In  Section  VI,  priority pollutant parameters are selected  for
consideration   for  regulation in the nonferrous  metals  forming
subcategories   because  of their frequent presence  at  treatable
concentrations  in  raw  wastewaters.      The   selected  pollutant
parameters include total suspended solids- oil and grease, and pH
which  are regulated in every subcategory,    i'rJ.writy metals  are
also  regulated in every subcategory,   though  the specific metals
regulated   vary.    Nonconventional  pollutants   selected   for
regulation    also    vary   . with    different    subcategories.
Nonconventional pollutants regulated in one or more subcategories
include  ammonia,   fluoride,  and  molybdenum.   The  basis  for
regulating  total  suspended solids,  oil and grease,   and pH  is
discussed  below.   Selection  of  priority   and  nonconventional
pollutants  for  regulation  will be included  in  the  individual
subcategory  discussions  presented later in  this  section  since
regulated priority metal and nonconventional pollutants vary with
the different subcategories.

Total  suspended  solids,   in addition to being present  at  high
concentrations  in raw wastewater from nonferrous metals  forming
operations,   is an important control parameter for metals removal
in chemical precipitation  and settling treatment systems.   Metals
are  precipitated as  insoluble metal  hydroxides,   and  effective
solids  removal is required in order to ensure reduced levels  of
regulated  metals in  the treatment system  effluent.   Therefore, '
                           i

                               1556

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 total  suspended solids are regulated as a conventional pollutant
 to be removed from the wastewater prior to discharge.

 Oil  and grease is regulated under BPT since a number of  nonfer-
 rous^metals forming operations (i.e.,  rolling, sawing, grinding,
 drawing,  extrusion) generate emulsified wastewater streams which
 may  be  discharged.   In addition,   the equipment used  to  form
 nonferrous metals use significant quantities of oil as  machinery
 lubricant or hydraulic fluid,   these oils frequently get into the
 process wastewater as tramp oils.

 The importance of pH control is documented in Section VII and its
 importance in metals removal technology cannot be  overemphasized.
 Even  small  excursions from the optimum pH level  can  result  in
 less than optimum functioning  of the treatment system and inabil-
 ity  to achieve specified results.    The optimum operating  level
 for  removal of most metals is usually  pH 8.8 to  9.3.    However
 nickel,   cadmium,   and  silver  require  higher pH  for  optimal
 removal.    To allow a reasonable operating margin  and to preclude
 the need for final  pH adjustment,  the effluent pH  is  specified  to
 be  within the range of 7.5  to  10.

 The  remainder   of  this  section describes  the development  of  BPT
 mass   loadings   for each subcategory.    The  development  of  BPT
 regulatory   flows  for  each  operation  in each  subcategory is   pre-
 sented  in   detail.    The pollutants  selected and   excluded   from
 regulation,  and  the cost and benefit  of  the regulation at  BPT are
 also presented.

 LEAD-TIN-BISMUTH FORMING SUBCATEGORY

 Production Operations  and Discharge Flows

 Production   operations that generate wastewater in the   lead-tin-
 bismuth forming subcategory include rolling,  drawing, extrusion,
 swaging, continuous strip casting, semi-continuous ingot casting
 shot casting,  shot forming,  alkaline cleaning,  and degreasing.
Water use practices, wastewater streams, and wastewater discharge
 flows  from  these operations were discussed in Section  V.   This
 information provided the basis for development of the BPT regula-
tory  flow allowances summarized in Table IX-11.'   The  following
paragraphs discuss the basis for the BPT flow allowances for each
waste stream.
                                                              The
Rolling

Rolling  is  performed  at 26 plants in  this  subcategory.
following information is available from these plants:

Number  of  plants and operations using  emulsion  lubricant:   7
Number  of plants and operations using soap  solution  lubricant:
X •

No  lubricants were reported to be used in over 15 rolling opera-
tions.
                               1557

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Lead-Tin-Bismuth Rolling Spent Emulsions.   All of the operations
usingrollingemulsions completely recycle  the  emulsions  and
periodically  batch dump them when they become spent.   The spent
emulsion  from one operation is incinerated;  the spent  emulsion
from  one operation is applied to land;  and the  spent  emulsion
from  five operations is contract hauled.   Spent emulsions which
are  contract  hauled  off-site typically receive  some  type  of
emulsion  breaking (chemical or thermal) and oil skimming  treat-
ment.   After this treatment the water fraction is discharged and
the  oil  fraction is either sent to a  reclaiming  operation  or
landfilled directly.  Since spent emulsions are often treated on-
site  and  the water discharged (with the oil  fraction  contract
hauled),  EPA is allowing a discharge for this waste stream.  The
BPT discharge allowance is 23.4 1/kkg (5.60 gal/ton),.the average
of the six reported production normalized discharge flows.

Lead-Tin-Bismuth Rolling Spent Soap Solutions.  The one operation
usingrollingsoap solutions applies and discharges 43.0  1/kkg
(10.3 gal/ton).   Therefore,  the BPT discharge allowance is 43.0
1/kkg (10.3 gal/ton).

Drawing

Drawing is performed at 26 plants in the- lead-tin-bismuth forming
subcategory.   The following information is available from  these
plants:

Number  of  plants and operations using neat  oil  lubricant:   3
Number  of  plants and operations using  emulsion  lubricant:   6
plants, 8 operations.
Number  of plants and operations using soap solution   lubricant-
coolant:  2.
No lubricants were reported, to be used in over five operations.

Lead-Tin-Bismuth  Drawing  Spent Neat Oils.   None of  the  three
operations using neat oils discharge any of the  lubricant.   Two
achieve  zero  discharge through total recycle and  one  contract
hauls  batches of the spent neat oils periodically.   Since  neat
oils are pure oil streams,  with no water fraction,  it is better
to   remove  the oil directly by contract hauling and not to  dis-
charge  the stream than to commingle the oil with  water  streams
and  then remove it later using an oil-water separation  process.
Therefore, this waste stream should not be discharged.

Lead-Tin-Bismuth  Drawing  Spent  Emulsions.   Six of  the  eight
operations  using  emulsion  lubricants do  not  discharge  spent
emulsion.    Two  operations  periodically  discharge  the  spent
emulsion.  Information sufficient to calculate production normal-
ized discharge flows was available for only one of the operations
which  discharge the spent emulsion.   Four of the six  remaining
operations achieve zero discharge through 100 percent recycle  of
the  emulsions with drag-out on the product surface being the only
loss,  while  two  operations report contract hauling  the  spent
emulsions after periodic batch dumps.   Information sufficient to


                               1558

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calculate production normalized discharge flows was not available
for the operations which contract haul the spent emulsion.  Spent
emulsions  which  are contract hauled off-site typically  receive
some  type  of emulsion breaking (chemical or  thermal)  and  oil
skimming treatment.   After this treatment, the water fraction is
discharged  and  the oil fraction is either sent to a  reclaiming
operation  or  landfilled directly.   Since spent  emulsions  are
often  treated  on-site and the water discharged  (with  the  oil
fraction  contract hauled),  EPA is allowing a discharge for this
waste  stream.   The BPT discharge allowance is 26.3 1/kkg  (6.30
gal/ton),   the  only  reported  non-zero  production  normalized
discharge flow.
Lead-Tin-Bismuth
	  Drawing Spent Soap Solutions.
using soap solutions as a drawing lubricant
                                                  One of the  two
                                                         periodi-
operations
cally discharges the solution.  The other operation achieves zero
discharge through total recycle.   The BPT discharge allowance is
7.46 1/kkg (1.79 gal/ton),  the one reported non-zero  production
normalized discharge flow.

Extrusion

Extrusion  is  performed at 43 plants in this  subcategory.   The
following information is available from these plants:

Number of plants and operations using contact cooling water:   14
plants, 17 operations
Number  of  plants  and  operations  reporting  hydraulic   fluid
leakage:  2.
None  of  the  plants reported using  water-based  lubricants  in
extrusion operations.

Lead-Tin-Bismuth  Extrusion  Press  and Solution  Heat  Treatment
Contact  Cooling Water.   As discussed in  Section  III,contact
cooling water is used in extrusion operations, either by spraying
water  onto the metal as it emerges from the die or press,  or by
direct quenching in a contact water bath.    Three operations were
reported to achieve zero discharge by 100 percent recycle and one
operation  reported  achieving  zero  discharge  by  100  percent
recycle  with  periodic contract hauling.    A discharge  with  no
recycle  is reported for 11 extrusion operations.   No water  use
data were reported for one of these operations.  A discharge with
an unknown recycle rate was reported by two plants.  The BPT dis-
charge  allowance  is  the average of the  10  reported  non-zero
production normalized discharge flows, 1,440 1/kkg (346 gal/ton).
Production normalized discharge flows for the two operations with
unknown recycle ratios were not included in the average.

Lead-Tin-Bismuth Extrusion Press Hydraulic Fluid Leakage.  One of
the  43  plants with extrusion  operations  discharges  hydraulic
fluid leakage from an extrusion press. Another plant reported 100
percent recycle of hydraulic fluid leakage.    The Agency believes
that other plants in the lead-tin-bismuth forming subcategory use
similar  extrusion  presses and may have leakage.   The BPT  dis-
                               1559

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charge  allowance  is  based  on  the  one  reported
normalized discharge f'ow, 55.0 1/kkg (13,2 gal/ton).

Swaging
production
Swaging  is performed at five plants in this subcategory.   Emul-
sions  are used for lubrication in a total or four operations  at
three plants.  Two plants did not report the use of lubricants in
swaging operations.

Lead-Tin-Bismuth  Swaging  Spent Emulsions.   Three of  the  four
swaging operations which use lubricants achieve zero discharge by
100 percent recycle, with evaporation and drag-out on the product
surface  being  the only losses.   Spent emulsion is  batch  dis-
charged  from  the other operation.   Spent emulsions  which  are
contract hauled off-site typically receive some type of  emulsion
breaking (chemical or thermal) and oil skimming treatment.  After
this  treatment,  the  water fraction is discharged and  the  oil
fraction  is either sent to a reclaiming operation or  landfilled
directly.   Since  the spent emulsions are often treated  on-site
and  the water discharged (with the oil fraction contract hauled)
by plants in this category and other categories,  EPA is allowing
a discharge for this waste stream.   The BPT discharge  allowance
is 1.77 1/kkg (0.424 gal/ton), the only reported non-zero produc-
tion normalized discharge flow.

Casting

The  following information was reported on casting operations  in
this subcategory:

Total number of plants:  34

Number of plants and operations with continuous strip casting:  6
LV.mbar using contact cooling water:  5
Number  of  plants  and operations  using  sern.l-continuous  ingot
casting:  3
Number using contact cooling water:  3

Number  of  plants and operations with shot  casting:   3  Number
using contact cooling water:  3
Number of plants and operations with continuous wheel casting:  1
Number using contact cooling water:  0

Number of plants and operations with continuous sheet
casting:  1 Number using contact cooling water:  0

Number  of  plants and operations with stationary  casting  (also
referred to as chill casting and mold casting):   26 plants,   28
operations
Number using contact cooling water:  0
Number  or  plants and operations with shot pressing:   2  Number
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  Lead-Tin-Bismuth  Continuous  Strip Casting  Contact  Cooling  Water.
  in   rive   of   the six  continuous  strip   casting  operations" - the
                          is c°»letel  recycled9  and   periSSicaSj
                 n          .
  K   ™        °ne °Perati°n  uses  only  noncontact  cooling  water
 The  BPT discharge allowance is  the average  of  the  five   reported
 production  normalized  discharges  flows,    1.00   1/kkg    (0.240
 y d -L / L \J li j m

 Lead-Tin-Bismuth  Semi-Continuous   ingot Casting Contact  Cooling
 Water    Water use and discharge data were-^p^te^TToT-only— £E§
 operation.   Contact  cooling  water from this operation  is  dis-
 charged  on  a once-through basis.   Based on  the  one   Sported
                                                               fc
 Lead-Tin-Bismuth Shot Casting Contact Cooling Water.   in two  of
 H,^LJ   e™Perati°nS'  the contact cooling wateT-Js periodically
 dumped.   The  average of the two reported production  normalized
 gal/tSn"??       1S ""* BPT dischar^e allowance,  37.3 1/kkg (S 95


 Lead-Tin-Bismuth Shot Forming Wet Air Pollution Control Slowdown.
 One  plant  provided information on shot  forming - ft •"reported
 using  a  wet  scrubber to control air pollution9 from  thl  lead
 polishing and drying unit operations of a shot forming line   The
 scrubber  water is discharged on a once-through basiJ?   The  BPT
                                       norm.li.ed water use of  the
 Alkaline  Cleaning

            provided  information on  six  alkaline  cleaning   opera-
Spent baths are
       The  BP?
 the averlge of
     Average or
Lead-Tin-Bismuth Alkaline Cleaning Spent Baths
discharged  from  six_ alkiTTHe— ^leinTSg-^i
discharge  allowance  is 120 1/kkg (28.7 gal/ton) ,
the six production normalized discharge flows.
Lead-Tin-Bismuth Alkaline Cleaning Rinse.  Four alkaline cleanina
operationS< discharge rinse with no-T¥c7cle.   The BPT  dischargl
allowance is 2,360 1/kkg (565 gal/ton)/ the average of the  four
production normalized water use from the four operations.

Degreasing

Lead-Tin-Bismuth  Degreasing Spent Solvents.   A small number  of
surveyed  plants with solventde^Feasing operations have  process
wastewater  streams associated with the operation.   Because most
plants practice solvent degreasing without wastewater  discharge,
the Agency believes zero discharge of wastewater is the
ate discharge limitation.
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Regulated Pollutants

The  priority pollutants considered for regulation under BPT  are
listed in Section VI,  along with an explanation of why they were
considered.   The only priority pollutants considered for regula-
tion  are  antimony  and lead.   These two pollutants  have  been
selected  for  regulation under BPT along  with  total  suspended
solids,  oil and grease,  and pH.  The basis for regulating total
suspended solids,  oil and grease, and pH under BPT was discussed
earlier  in this section.   The basis for regulating antimony and
lead is discussed below.

Antimony  has been selected for regulation under BPT since it  is
frequently  found  at treatable concentrations in process  waste-
water streams from this subcategory.   Treatable antimony concen-
trations  were  found  in shot  casting  contact  cooling  water,
alkaline cleaning spent baths, and alkaline cleaning rinse.

Lead  has  been  selected for regulation under BPT since  it  was
found  at  treatable  concentrations in  all  process  wastewater
samples  analyzed  from this subcategory and because  it  is  the
metal  being processed.   The Agency believes that when  antimony
and  lead are controlled with the application of lime and  settle
technology, control of other priority metals which may be present
in process wastewater is assured.

Treatment Train

The  BPT  model treatment train  for the lead-tin-bismuth  forming
subcategory  consists  of preliminary treatment  when  necessary,
specifically  emulsion breaking  and oil skimming.   The  effluent
from preliminary treatment  is combined with other wastewater  for
common  treatment  by oil skimming and lime  and  settle.   Waste
streams  potentially needing preliminary chemical emulsion break-
ing are listed in Table IX-1.    Figure IX-1 presents a  schematic
of  the  general  BPT treatment-train for the  nonferrous  metals
forming category.

Effluent Limitations

The pollutant mass discharge  limitations  (milligrams of pollutant
per  off-kilogram of PNP) were calculated by multiplying the  BPT
regulatory  flows summarized in Table  IX-11  (1/kkg) by the concen-
tration  achievable  by  the  BPT model  treatment system  summarized
in  Table   VII-21  (mg/1)  for  each pollutant parameter  considered
for regulation at BPT  (1/off-kkg x mg/1 x kkg/1,000 kg =  mg/off-
kg).   The   results  of  this computation for all waste streams-and
regulated  pollutants in  the lead-tin-bismuth forming  subcategory
are   summarized  in Table  IX-13.   This limitation  table lists all
the  pollutants  which  were   considered  for   regulation;   those
specifically regulated  are  marked with an asterisk.
                                1562

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Costs and Benefits

In  establishing  BPT,  EPA considered the cost of treatment  and
control and the pollutant reduction benefits to evaluate economic
achievability.   As shown in Table X-3 (page xxxx), the application
of  BPT  to the total lead-tin-bismuth forming  subcategory  will
remove  approximately 5,730 kg/yr (12f610 Ibs/yr)  of  pollutants
including  235  kg/yr (520 Ibs/yr) of toxic pollutants.   As shown
in  Table  X-13  (page xxxx),  the application of  BPT  to  direct
dischargers  only  will remove approximately 1,450  kg/yr  (3,190
Ibs/yr)  of pollutants including 45 kg/yr (100 Ibs/yr)  of  toxic
pollutants.   Since  there are only three direct discharge plants
in this subcategory,  total subcategory capital and annual  costs
will  not be reported in this document in order to protect confi-
dentiality  claims.   The Agency concludes that  these  pollutant
removals   justify   the  costs  incurred  by  plants   in   this
subcategory.

MAGNESIUM FORMING SUBCATEGORY

Production Operations and Discharge Flows

Production  operations that generate wastewater in the  magnesium
forming  subcategory  include  rolling,   forging,  direct  chill
casting,  surface treatment,  sawing,  grinding,  and degreasing.
Water use practices, wastewater streams, and wastewater discharge
flows  from these operations were discussed in Section  V.   This
information provided the basis for development of the BPT regula-
tory  flow allowances summarized in Table IX-13.   The  following
paragraphs discuss the basis for the BPT flow allowances for each
waste stream.

Rolling

The  following  information was reported on rolling operations  in
this subcategory:

Number of plants:  1                            .
Number of operations using emulsion lubricant:  2.

Magnesium  Rolling  Spent  Emulsions.   The emulsions  from  both
operations  are  batch  dumped and hauled  off-site  by  a  waste
contractor.  The quantity of emulsion hauled was not reported for
either operation.  Spent emulsions which are .contract hauled off-
site  typically receive some type of emulsion breaking  (chemical
or  thermal) and oil skimming treatment.   After this  treatment,
the  water fraction is discharged and the oil fraction is  either
sent  to  a reclaiming operation or landfilled  directly.   Since
spent   emulsions  are  often  treated  on-site  and  the   water
discharged  (with  the  oil fraction  contract  hauled),  EPA  is
allowing  a discharge for this waste stream.   The BPT  flow  has
been  set equal to the BPT flow given for spent aluminum  rolling
emulsions,  74.6 1/kkg (17.9 gal/ton).  The Agency believes that,
because  aluminum  and magnesium have similar melting points  and
                               1563

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other metallurgical properties, similar arac=,-Ls ot waste emulsion
will be generated in rolling the two metals..

Forging

The  following information was reported on  Corging operations   in
this subcategory:

Number of plants:  4                       .,--,,
Number of plants and operations using  lubricants:  j  plants,
4  operations  Number  of plants  and  operations  using   contact

3°°piants?te4* operations Number of  equipment  cleaning operations:
2.


Magnesium Forging Spent Lubricants.    The  ou-.y loss  of  iub,- Leant
from  any   of  the   foUr operations is through  drag-out   on   the
product  surface.    Consequently,   there   is  no  BPT  discharge
allowance for forming  spent  lubricants.   Since,  magnesium  forging
?ub?icants  are not water based, they should be kept  separate  from
other  process wastewater  streams and therefore,   should  not   be
discharged.

Magnesium   Forging Contact  Cooling  Water.    One operation  has   no
water  dischaTgi~dSe~tc~IOO  percent  recycle and evaporation.   The
BPT   flow  is the average of the two reported non-zero  production
normalized  discharge flows,  2,890  1/kkg  (693 gal/ton).

Magnesium   Forging   Equipment Cleaning   Wastewater.   One  plant
 reported "  using   water  to  clean  equipment in  its   two  forging
operations.   The equipment cleaning wastewater from these opera-
 tions is not recycled.  The BPT discharge allowance, based on the
 average  production normalized water use  from the two  operations,
 is 39.9  1/kkg (9.59  gal/ton).

 Casting

 Magnesium   Direct  Chill  Casting   Contact  Co^Unc,   Water..   One
 Honfefrous  metals  forming plant  casts  magnesium by  t-.fe  direct
 chill  method.    The  cooling  water used in  this  operation  _ is
 completely  recycled.    Another  plant has a direct chill  casting
 operation   which is *n integral  part of  3 ^gnes-,- srnelcing  and
 refining   (nonferrous  metals manufacturing pnase LL}  operation.
 Once-through  contact  cooling  water  is  discharged  from  tnis
 operation.   The BPT flow of 3,9.50 1/kkg (947 gal/ton) is based on
 the  production  normalized water use for the  nonferrous  metals
 manufacturing operation.

 Surface Treatment

 Three ulants supplied information on magnesium surface,  treatment
 operations.   Information  was provided on the discharge of  nine
 surface  treatment  baths  and on seven sui-faci   creal.me.it  rinse
 operations.
                                 1564

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 Magnesium Surface Treatment Spent Baths.   An unreported amount of
 wastewater  is   contract   hauled  from  two  of  the  operations.
 Wastewater discharge flows were reported  for three of the remain-
 ing seven operations.   The BPT discharge  allowance is the average
 of   production  normalized discharge  flow  from  three  operations,
 466 1/kkg (112  gal/ton).

 Magnesium  Surface  Treatment   Rinse.   One  operation  uses   100
 percent  recycle with a  periodic batch  discharge of rinse.   Of  the
 remaining six operations,   two operations  consist  of single stage
 overflow^  rinses  with  no recycle,   two operations consist of  a
 spray  rinse followed by  an overflow rinse with no  recycle,   and
 two operations consist of non-cascade sequential  rinsing  stages.
 The average of  the seven  production  normalized  discharge flows is
 the BPT  flow, 18,900 1/kkg (4,520 gal/ton).
 Sawing or Grinding

 The  use of emulsion lubricants was reported for a total
 operations at two plants.
of  two
Magnesium  Sawing  or Grinding Spent  Emulsions.   One  operation
achieves  zero discharge by 100 percent recycle.   Some  emulsion
from  this  operation is lost due to evaporation and drag-out  on
the product.   In the other operation,  the emulsion is  recycled
with  periodic batch discharges contract hauled to treatment  and
disposal  off-site.   Since spent emulsions are often treated on-
site  and  the water discharged (with the oil  fraction  contract
hauled),  EPA is allowing a discharge for this waste stream.  The
BPT  allowance  has been set equal to the  production  normalized
discharge  flow  of contract hauled emulsion,  19.5  1/kkg  (4.68
gal/ton).

Degreasing

Magnesium  Degreasing  Spent Solvents.   Only a small  number  of
surveyed  plants with solvent degreasing operations have  process
wastewater streams associated with the operation.   Because  most
plants  practice solvent degreasing without wastewater discharge,
the Agency believes zero discharge of wastewater is an  appropri-
ate discharge limitation.

Wet Air Pollution Control

Magnesium Wet Air Pollution Control Slowdown.    Slowdown from the
wet  air pollution control devices used to control air  pollution
from  forging,  sanding and repairing,  and surface treatment  is
included under this building block.   The Agency believes that the
water  requirements for scrubbing  air emissions from these  areas
are  similar.    Three of the four  operations practice 90  percent
recycle  or   greater of the scrubber liquor while no  recycle  is
used  in the remaining operation.    Flow reduction is  considered
BPT technology for wet air pollution control blowdown since three
of  the  four   plants  practice 90 percent  or  greater  recycle.
                               1565

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 presents   a  schematic  of  the  general  BPT treatment  train  for   the
 nonferrous metals  forming category.

 Effluent  Limitations

 The  pollutant  mass discharge  limitations (milligrams  of pollutant
 per   off-kilogram  of PNP)  were  calculated by  multiplying  the   BPT
 regulatory flows summarized in  Table  IX-13 (1/kkg)  by the concen-
 tration   achievable by the BPT  model  treatment  system summarized
 in   Table VII-21 (mg/1) for each  pollutant parameter considered
 for   regulation  at BPT   (1/off-kkg  x  mg/1 x 1  kkg/1,000 kg  =
 mg/off-kg).    The   results of  this  computation  for all waste
 streams   and  regulated  pollutants as  well as  magnesium   in   the
^magnesium forming subcategory are summarized   in  Table  IX-14.
 Although   no  limitations have been  established  for magnesium,
 Table  IX-14  includes  magnesium mass  discharge   limitations
 attainable using the BPT  model  technology. These limitations  are
 presented for  the  guidance of permit  writers.  Only daily maximum
 limitations  are   presented,  based on  the detection limit   for
 magnesium (0.10   mg/1),   because lime  and settle  treatment   was
 determined  to remove  magnesium to below the  level  of analytical
 quantification.    The   attainable monthly average  discharge   is
 expected   to  be lower than the one day maximum  limitation^   but
 since it would be impossible  to monitor for compliance   with  a
 lower level, no monthly average has been presented.

 The   limitation table  lists all the pollutants  which  were consid-
 ered for  regulation; those specifically regulated are marked with
 an asterisk.

 Costs and Benefits

 In   establishing BPT,   EPA considered the cost  of  trsatment   and
 control and  the pollutant reduction benefits  to evaluate  economic
 achievability.  As shown  in Table X-4 (page xxxx),  the application
 of   BPT   to  the.total  magnesium forming subcategory  will  remove
 approximately  33,570  kg/yr (73,855 Ibs/yr) of  pollutants includ-
 ing  16,900 kg/yr (37,180  Ibs/yr)  of toxic pollutants.   As shown
 in   Table X-l (page xxxx),   the  corresponding  capital and annual
 costs  (1982 dollars)  for this  removal  are $218,000 and   $146,000
 per  year, respectively.   As shown in  Table  X-14 (page xxxx),  the
 application  of BPT to  direct  dischargers only will  remove approx-
 imately   28,615  kg/yr (62,950  Ibs/yr)   of pollutants including
 14,790 kg/yr  (32,540  Ibs/yr) of  toxic  pollutants.    As shown   in
 Table X-2 (page xxxx), the corresponding capital and annual costs
 (1982 dollars)  for   this removal are  $148,200 and  $95,700   per
 year, respectively.    The Agency concludes that  these pollutant
 removals  justify the costs incurred by  the plants in  this subcat-
 egory.  .
                                1567

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NICKEL-COBALT FORMING SUBCATEGORY

Production Operations and Discharge Flows

Production  operations  which generate process wastewater in  the
nickel-cobalt forming subcategory include rolling, tube reducing,
drawing,  extrusion, forging, metal powder production, stationary
casting,  vacuum  melting,  heat  treatment,  surface  treatment,
cleaning,  sawing,  grinding,  product testing,  and  degreasing.
Water use practices,  wastewater streams and wastewater discharge
flows  from these operations were discussed in Section  V.   This
information provided the basis for development of the BPT regula-
tory  flow allowances summarized in Table IX-15.   The  following
paragraphs discuss "the basis for the BPT flow allowances for each
waste stream.

Rolling

Rolling  is  performed at 30 plants in the nickel-cobalt  forming
subcategory.   The following information is available from  these
plants:

Number  of  plants and operations using neat  oil  lubricant:   5
plants, 6 operations
Number  of  plants  and operations using  emulsion  lubricant:  5
plants, 7 operations
Number of plants and operations using contact cooling  water:   6
plants, 9 operations.
Approximately  15 plants reported no use of lubricants or contact
cooling water for their rolling operations.

Nickel-Cobalt Rolling Spent Neat Oils.   The neat oils in four of
the operations are consumed during the rolling  operation,  while
the  neat  oils in the other two operations are contract  hauled.
Since neat oils are pure oil streams,  with no water fraction, it
is better to remove the oil directly by contract hauling and  not
to  discharge  the  stream than to commingle the oil  with  water
streams  and then remove it later using an  oil-water  separation
process.    Consequently,   this   waste  stream  should  not  be
discharged.

Nickel-Cobalt Rolling Spent Emulsions.   Spent rolling  emulsions
are  either treated on-site or contract hauled for treatment  and
disposal  off-site.    Production  normalized discharge flows  are
available  for  three of the seven rolling operations  which  use
spent  emulsions.   Spent emulsions from two of these  operations
are  treated on-site while emulsion from the third  operation  is
contract  hauled.   A BPT discharge allowance of 170 1/kkg  (40.9
gal/ton)  has been established for this stream since spent  emul-
sion  is sometimes treated on-site and the water discharged (with
the oil fraction contract hauled).   The BPT flow is based on the
average  of  the three reported production  normalized  discharge
flows.
                               1568

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...Nick el-Cobalt   Rolling  Contact  Cooling Water.    Plow  information
 was available  for  eight of the  nine rolling operations which  use
 contact  cooling water.    Two operations achieve zero discharge by
 completely   recycling   the  contact  cooling  water   stream.   No
 information  regarding   the amount of water used in  these  opera-
 tions  was  available.    The other  operations use  widely  varying
 amounts   of water for  contact   cooling.    Production  normalized
 water  uses for these operations vary from 72.8 to 43,400  1/kkg.
 The  BPT flow  of 3,770  1/kkg (905  gal/ton)  is  based  on the median
 of  the   six reported production normalized cooling   water  uses.
 The  median  is believed to be a  better   representation  of  the
 current   typical  water use for this operation than   the  average
 (arithmetic mean)  because of the large range of reported  produc-
 tion normalized water uses.

 Tube Reducing

 Three  plants   reported information on three tube reducing  (also
 referred to as pilgering)  operations.    Lubricants  are  used  in
 these operations.

 Nickel-Cobalt   Tube Reducing Spent Lubricant.    There shall be no
 discharge  allowance for the discharge of  pollutants . from  tube
 reducing spent lubricants if once  each month for six  consecutive
 months the  facility owner or operator demonstrates the absence of
 N-nitrosodi-n-propylamine,    N-nitrosodimethylamine,    and   N-
 nitrosodiphenylamine   by  sampling  and   analyzing   spent   tube
 reducing lubricants.      If the   facility  complies  with  this
 requirement for six months  then the frequency of sampling may be
 reduced  to  once each quarter.    A  facility  shall be  considered in
 compliance   with  this  requirement if the concentrations  of  the
 three  nitrosamine  compounds  does  not   exceed  the  analytical
 quantification  levels   set  forth  in 40 CFR Part  13fi  which  are
 0.020  mg/1 for N-nitrosodiphenylamine,   0.020 for N-nitrosodi-n-
 propylamine, and 0.050  mg/1  for N-nitrosodimethylamine.

 Drawing

 Drawing   is performed at 32  plants in the  nickel-cobalt  forming
 subcategory.    The  following information is available from these
 plants:

 Number   of   plants and  operations  using neat  oil lubricant:    8
 plants,  11  operations

 Number   of   plants and  operations  using  emulsion lubricant:    8
 plants,  9 operations.
 No lubricants  were reported  to  be  used  at over 15 plants.

 Nickel-Cobalt   Drawing  Spent Neat  Oils.   Neat oils  from nine  of
 the 11 operations  are contract  hauled;  the only loss of neat oil
 from one operation is by evaporation and  drag-out; no information
 regarding  spent  neat  oils  is  available  for  the other  drawing
 operation  which uses a neat oil lubricant.    As discussed previ-
 ously  for  rolling spent neat oils,   it is  better to  remove  the


                                1569

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neat  oils  directly  and  not to discharge the  stream  than  to
commingle  the oil wita water streams and then remove  it  later.
Therefore, this waste stream should not be discharged.
Nickel-Cobalt  Drawing
3ent  Emulsions.    Spent   emulsions   from
eight of the nine plants reporting the use ,of emulsion lubricants
are  periodically contract hauled to treatment and disposal  off-
site.   One operation periodically discharges the spent emulsion.
Information   sufficient   to  calculate  production   normalized
discharge  flows  was available for two of the  operations  which
haul the emulsion and the one which discharges it.   As discussed
previously  for drawing spent emulsions in  the  lead-tin-bismuth
forming  subcategory,  spent emulsions are often treated  on-site
and  the water discharged (with the oil fraction contract hauled)
by plants in this category and other categories.   Therefore, the
BPT  discharge  allowance is the average of  the  three  reported
production normalized discharge flows, 95.4 1/kkg (22.9 gal/ton).
Extrusion

Extrusion is performed at eight plants in this subcategory.
following information is available from these plants:
                                    The
Number of plants and operations using lubricants:  4
Number  of  plants and operations using press and  solution  heat
treatment contact cooling water: 2
Number   of  plants  and  operations  recording  hydraulic  fluid
leakage:  1.

Nickel-Cobalt  Extrusion Spent Lubricants.   Lubricants are  com-
pletely recycled in all operations,  with the only loss occurring
through evaporation and drag-out.  The extrusion lubricants which
are used are typically neat oils.   Since neat oils are pure  oil
streams,  with no water fraction,  it is better to remove the oil
directly  and  not to discharge the stream than to commingle  the
oil with water streams and then remove it later.  Therefore, this
waste stream should not be discharged.

Nickel-Cobalt Extrusion Press and Solution Heat Treatment Contact
Cooling  Water.    As discussed in Section  III,  contact  cooling
water  is  used  in  extrusion operations to  accomplish  a  heat
treatment effect,  either by spraying water onto the metal as  it
emerges from the die or press,  or by direct quenching in a water
bath.  Contact cooling water in one of the operations is recycled
and  periodically  batch dumped;  the other operation  discharges
with  no  recycle.   The average of the two  reported  production
normalized discharge flows is the BPT discharge  allowance,  83.2
1/kkg (20.0 gal/ton).

Nickel-Cobalt Extrusion Press Hydraulic Fluid Leakage.  Discharge
of  hydraulic  fluid  leakage  was reported  from  one  extrusion
operation.   The  BPT  discharge  allowance of  232  1/kkg  (55.6
gal/ton)  is  based on the production normalized  discharge  flow
from this operation.
                               1570

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Forging

Forging  is performed aj: 31 plants in the  nickel-cobalt  forming
subcategory.   The  following information is available from these
plants:

Number of plants and operations using lubricants:   5 plants,   6
operations
Number of plants and operations using contact cooling water:  6
Number  of  plants  and  operations  reporting  hydraulic   fluid
leakage:  1
Number of equipment cleaning operations:   1 plant, 2 operations.
Approximately 20 dry forging operations were reported.

Nickel-Cobalt Forging Spent Lubricants.   The lubricants from the
six  operations are either contract hauled directly or only  lost
through  evaporation  and drag-out.   It is better to remove  the
neat oil and graphite-based lubricants typically used in  forging
operations  from this subcategory and not to discharge the stream
than  to  commingle the lubricants with other water  streams  and
then remove them later.   Therefore, this waste stream should not
be discharged.

Nickel-Cobalt  Forging Contact Cooling Water.   Five of  the  six
plants that reported this waste stream provided flow information.
Four plants discharge the cooling water without any recycle while
one  plant recycles over 95 percent of the water.   The BPT  dis-
charge of 474 1/kkg (114 gal/ton) is based on the average produc-
tion  normalized  water  use for the five plants  providing  flow
information.

Nickel-Cobalt Forging Equipment Cleaning Wastewater.   One  plant
reported  using  water to clean the equipment in its two  forging
operations.  The BPT discharge allowance, based on the average of
the  two production normalized water uses,  is 40.0  1/kkg  (9.57
gal/ton).

Nickel-Cobalt  Forging Press Hydraulic Fluid Leakage.   One plant
reported  a discharge of forging press hydraulic  fluid  leakage.
The  BPT discharge allowance of 187 1/kkg (44.8 gal/ton) is based
on the production normalized discharge flow of hydraulic  leakage
from this operation.

Casting

The  following information was reported on casting operations  in
this subcategory:

Total number of plants:  12

Number  of plants and operations with stationary  casting:     10
plants, 12 operations
Number using contact cooling water:  2
Number dry:  10
                               1571

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Number  of plants and operations with vacuum melting and casting:
3
Number of plants with vacuum melting steam condensate:  2
Number dry:  1

Number of plants and operations with electroflux remelting:  2
Number dry:  2.
                                                     Water.   Two
                                                           In one
Nickel-Cobalt  Stationary  Casting Contact  Cooling  	
stationary casting operations use contact cooling water.
operation the cooling water is completely reused in other nonfer-
rous forming operations at the plant.   The cooling water is  not
recycled in the other operation but some is lost through evapora-
tion  and  drag-out.   The BPT allowance of 12,100  1/kkg  (2,900
gal/ton)  is based on the average production normalized water use
for the two operations.

Nickel-Cobalt Vacuum Melting Steam Condensate.   Information  was
reported  on two vacuum melting operations which generate a steam
condensate waste stream.   In one operation the entire volume  of
steam  condensate  is reused for surface  treatment  rinse.   The
other  operation  recycles  98 percent of  the  steam  condensate
through  a  cooling  tower.   Analysis of a sample of  the  bleed
stream from the cooling tower indicated that there are no  pollu-
tants  present  above treatable concentrations.   In  fact,  some
pollutants  were found at concentrations lower than source  water
concentrations.   Vacuum melting steam condensate can, therefore,
be  reused  in the generation of steam for vacuum melting  or  in
other processes present at the forming plant.  The feasibility of
reusing  the  condensate is demonstrated by the  operation  which
currently  reuses  the condensate for  surface  treatment  rinse.
Therefore,  since  analysis  of the condensate indicates that  no
pollutants  are present at treatable concentrations,  and  it  is
current  industry  practice  to  reuse the  condensate  in  other
forming operations, no allowance is provided for this stream.

Metal Powder Production

Metal  powder production operations are performed at  15  plants.
Atomization  wastewater  is generated in a total of seven  opera-
tions at six plants.  No wastewater is generated from atomization
processes at nine plants.

Nickel-Cobalt  Metal  Powder Production  Atomization  Wastewater.
Production normalized discharge flows for this waste stream  vary
widely from 1,280 1/kkg to 75,300 1/kkg.   The BPT flow allowance
of  2,620  1/kkg  (629 gal/ton) is based on the median  of  seven
production  normalized  discharge flows.   Because of  the  large
range  of production normalized discharge flows,  the  median  is
believed  to  be a better representation of the  current  typical
water use for this operation than the average (arithmetic mean).
                               1572

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Solution Heat Treatment

Heat  treatment operations are performed at 31  plants.   Contact
cooling  water is used in a total of 22 operations at 17  plants.
No water is used at 14 plants.

Nickel-Cobalt  Annealing  and  Solution  Heat  Treatment  Contact
Cooling  Water.   No BPT discharge allowance is provided for this
stream.   The  zero discharge allowance is based on  100  percent
reuse  of  the wastewater,  either as annealing  contact  cooling
water  or  in  other  processes present at  the  forming  plants.
Analysis of a sample of this wastewater indicates that there  are
no  pollutants present above treatable concentrations and  there-
fore, reuse is possible.  Furthermore, three operations which use
annealing contact cooling water recycle all of the cooling water.
In one operation the cooling water is treated by oil skimming and
recycled to the cooling process.   In two operations, the cooling
water is recycled without treatment.

Surface Treatment

Thirty  plants  provided information on surface treatment  opera-
tions in the nickel-cobalt forming subcategory.

Nickel-Cobalt  Surface  Treatment Spent Baths.   A  total  of  39
surface  treatment bath operations were identified.   Spent baths
from  six operations are discharged to evaporation  ponds,  baths
from 10 operations are contract hauled to treatment and  disposal
off-site  and 23 baths are discharged to either a POTW or surface
water.   The  BPT regulatory flow of 935 1/kkg (224  gal/ton)  is
based  on  the average of the 24 reported  production  normalized
flows.  Information sufficient to calculate production normalized
flows  was provided for 25 baths that are discharge:! or  contract
hauled.

Nickel-Cobalt  Surface  Treatment  Rinse.   Thirty-three  surface
treatment  rinse  operations were identified.   Rinse from  seven
operations   is  discharged  to  evaporation  ponds  or   surface
impoundments,  and rinse from two operations is contract  hauled.
In one process, the rinse is treated and reused.  The BPT flow of
23,600  1/kkg  (5,640 gal/ton) is based on the average of the  24
production normalized water uses reported for this operation.

Ammonia Rinse Treatment

Two  plants  reported  using an ammonia rinse in  a  total  of  3
operations.

Nickel-Cobalt  Ammonia Rinse.   All three operations are stagnant
rinses with batch discharges.   The BPT flow of 14.8 1/kkg  (3.54
gal/ton)  is based on the average production normalized discharge
flow from the three operations.
                               1573

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Alkaline Cleaning

Eighteen plants provided information on alkaline cleaning  opera-
tions in the nickel-cobalt subcategory.   The reported operations
include 23 baths and 22 rinses.

Nickel-Cobalt  Alkaline  Cleaning Spent Baths.   Seven baths  are
dischargedto  evaporation ponds or impoundments,  and  two  are
contract  hauled to treatment and disposal off-site.   Flow  data
were  available for 15 baths.   Production  normalized  discharge
flows for these baths vary from 1.2 1/kkg to 231 1/kkg.   The BPT
flow  of 33.9 1/kkg (8.13 gal/ton) is based on the median produc-
tion normalized discharge flow from the 15 baths.   The median is
believed  to  be a better representation of,the  current  typical
flow  for  this  operation than  the  average  (arithmetic  mean)
because  of  the large range of production  normalized  discharge
flows.   The  production normalized water use for a combined bath
and rinse was not included in the average because the  individual
discharges could not be discerned.

Nickel-Cobalt   Alkaline  Cleaning  Rinse.    Rinse  from   eight
operations is discharged to evaporation ponds,  impoundments,  or
applied to land.  Rinse from one operation is treated and reused.
Water  use data are available for a total of 12 alkaline cleaning
rinse operations.   The BPT flow of 2,330 1/kkg (559 gal/ton)  is
the  average  production normalized water use for 11  operations.
The production normalized water use for a combined bath and rinse
was not included in the average because the individual discharges
could not be discerned.

Molten Salt Treatment

Six  plants  reported using molten salt treatment in a  total  of
eight operations.

Nickel-Cobalt Molten Salt Rinse.  The BPT flow for this stream is
8,440 1/kkg (2,020 gal/ton).  This flow is the average production
normalized water use for six nonrecycled overflowing rinses.  The
water  uses  for  two stagnant rinses were not  included  in  the
average  because  flow  reduction  through  stagnant  rinsing  is
considered to be part of the BAT technology.

Sawing or Grinding

Twenty-one  plants reported using emulsion lubricants in a  total
of  25 sawing or grinding operations.   One rinse  operation  was
also reported.

Nickel-Cobalt  Sawing or Grinding Spent  Emulsions.    Information
sufficient to calculate production normalized discharge flows was
reported  for  five operations. '  The BPT flow allowance of  39.4
1/kkg  (9.45 gal/ton)  is based on the average production  normal-
ized discharge flow from the five operations.
                               1574

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Nickel-Cobalt  Sawing  or Grinding  Rinse.   One  plant  reported
generating  this waste stream.   The BPT regulatory flow of 1,810
1/kkg  (435 gal/ton) is based on the production  normalized  dis-
charge flow from this plant.

Steam Cleaning

Nickel-Cobalt Steam Cleaning Condensate.  Two plants reported the
discharge  of  contact  steam condensate  from  product  cleaning
operations.   Neither  plant recycles the condensate.   Only  one
plant  reported  information sufficient to  calculate  production
normalized  flows.   The  BPT  discharge  allowance  is  the  one
reported  production normalized discharge flow,  30.1 1/kkg (7.22
gal/ton).
Product Testing
                            Tube Testing and  Ultrasonic
Nickel-Cobalt  Hydrostatic  	  	
              The  Agency believes that hydrostatic tube
Wastewater.
   Testing
   testing
reused  in
and  ultrasonic testing wastewater can be recycled or
other processes present at the forming plant.   Also, some plants
in  this category discharge wastewater from these operations less
than once per year,  which is effectively zero discharge.  There-
fore,  no  allowance  for  the discharge  of  process  wastewater
pollutants is provided for this stream.

Nickel-Cobalt  Dye Penetrant Testing  Wastewater.   Three  plants
reported  generating  wastewater from six dye  penetrant  testing
operations.   Flow  information was reported for two  operations.
The  BPT  discharge allowance of 213 1/kkg (50.9 gal/ton) is  the
average production normalized discharge flow from the two  opera-
tions.

Miscellaneous Wastewater

Nickel-Cobalt Miscellaneous Wastewater Sources.
         	 	    Some low volume
         of wastewater were reported in dcps and observed  during
           and sampling visits.   These include  wastewater  from
sources
the  site
maintenance and cleanup.   The Agency has determined that none of
the  plants  reporting these specific water uses discharge  these
wastewaters to surface waters (directly or indirectly).  However,
because  the  Agency believes this type of  low  volume  periodic
discharge  occurs at most plants,  the Agency has combined  these
individual  wastewater  sources  under  the  term  "miscellaneous
wastewater sources" and provided a BPT discharge allowance of 246
1/kkg (58.4 gal/ton).

Degreasing
Nickel-Cobalt Degreasing Spent Solvents.
surveyed  plants  with  solvent degreasing
                                           Only a small number of
                                            operations  indicated
having process wastewater streams associated with the  operation.
Because  most  plants practice solvent degreasing without  waste-
water discharge, the Agency believes zero discharge of wastewater,
is an appropriate discharge limitation.
                               1575

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Wet Air Pollution Control

Nickel-Cobalt  Wet  Air  Pollution  Control  Slowdown.   Wet  air
pollution control devices are used to control air emissions  from
surface treatment operations,  shot blasting,  molten salt treat-
ment and rolling.   Six plants reported achieving over 90 percent
recycle  of  the scrubber water.   Therefore,  the BPT  discharge
allowance  of  810  1/kkg (194 gal/ton) is based  on  90  percent
recycle  of the average production normalized water use  for  six
operations since 90 percent recycle or greater is current typical
industry practice.

Electrocoating

Nickel-Cobalt   Electrocoating   Rinse.    One   plant   reported
discharging  electrocoating  rinse.   The BPT regulatory filow  of
3,370  1/kkg (807 gal/ton) is based on the production  normalized
discharge flow from this one plant.

Regulated Pollutants

The  priority pollutants considered for regulation under BPT  are
listed  in Section VI along with an explanation of why the»y  were
considered.  The priority pollutants considered for regulcition in
this subcategory are cadmium, chromium, copper, lead, nickel, and
zinc.   Chromium and nickel are selected for regulation under BPT
along with fluoride,  total suspended solids,.oil and grease, and
pH.   The priority pollutants cadmium, copper, lead, and :zinc ar.e
not  specifically  regulated under BPT for the reasons  given  in
Section X.   The basis -for regulating total suspended solids, oil
and  grease,  and  pH  under BPT was discussed  earlier  in  this
section.   The basis for regulating total chromium,  nickel,  and
fluoride is discussed below.

Total chromium is regulated since it includes both hexavalent and
trivalent forms of chromium.   Only the trivalent form is removed
by  the lime and settle technology.   Therefore,  the  hexavalent
form  must be reduced by preliminary chromium reduction treatment
in order to meet the limitations on chromium in this subcategory.
Chromium  was found at treatable concentrations in 71 of  90  raw
wastewater  samples,  and 16 of the 18 raw wastewater streams  in
which it was analyzed.

Nickel  has  been selected for regulation under BPT since it  was
found  at  treatable concentrations in 81 of  90  raw  wastewater
samples and because it is the metal being processed.   Nickel was
present  at  treatable concentrations in 16 of the 18 raw  waste-
water streams in which it was analyzed.  The Agency believes that
when  chromium and nickel are controlled with the application  of
lime and settle technology and preliminary treatment when needed,
the control of other priority pollutants which may be present  is
assured.
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Fluoride  was  found at treatable concentrations in 21 of 89  raw
wastewater  samples  and in six of 18 raw wastewater  streams  in
which  it  was analyzed.   Therefore,  fluoride is  selected  for
regulation under BPT.

Treatment Train

The  BPT  model  treatment train for  the  nickel-cobalt  forming
subcategory  consists  of preliminary treatment  when  necessary,
specifically  emulsion breaking and oil  skimming,  and  chromium
reduction.   The  effluent from preliminary treatment is combined
with  other wastewater for common treatment by oil  skimming  and
lime  and settle.   Waste streams potentially needing preliminary
treatment  are  listed in Table IX-3.   Figure  IX-1  presents  a
schematic  of the general BPT treatment train for the  nonferrous
metals forming category.

Effluent Limitations

The pollutant mass discharge limitations (milligrams of pollutant
per  off-kilogram of PNP) were calculated by multiplying the  BPT
regulatory flows summarized in Table IX-15 (1/kkg) by the concen-
tration  achievable by the BPT model treatment system  summarized
in  Table  VII-21 (rag/1) for each pollutant parameter  considered
for  regulation  at  BPT (1/off-kkg x mg/1 x  1  kkg/1,000  kg  =
mg/off-kg).   The  results  of  this computation  for  all  waste
streams  and  regulated pollutants in the  nickel-cobalt  forming
subcategory are summarized in Table IX-16.  This limitation table
lists  all  the pollutants which were considered for  regulation;
those specifically regulated are marked with an asterisk.

Costs and Benefits

In establishing BPT,  EPA must consider the cost of treatment and
control  in  relation to the effluent  reduction  benefits.   BPT
costs  and benefits are tabulated along with BAT costs and  bene-
fits in Section X.  As shown in Table X-5 (page xxxx), the appli-
cation of BPT to the total nickel-cobalt forming subcategory will
remove  approximately 729,230 kg/yr (1,604,300 Ibs/yr) of  pollu-
tants  including  99,570 kg/yr (219,050 Ibs/yr) of toxic  metals.
As shown in Table X-l (page xxxx), the corresponding capital  and
annual  costs (1982 dollars) for this removal are $3.342  million
and $2.077 million per year,  respectively.  As shown in Table X-
15 (page xxxx), the application of BPT to direct dischargers only
will   remove  approximately  21,590  kg/yr  (47,500  Ibs/yr)  of
pollutants  including  10,400  kg/yr  (22,880  Ibs/yr)  of  toxic
metals.   As  shown in Table X-2 (page xxxx),  the  corresponding
capital  and  annual  costs (1982 dollars) for this  removal  are
$392,000 and $186,000 per year,  respectively.   The Agency  con-
cludes  that these pollutant removals justify the costs  incurred
by plants in this subcategory.
                               1577

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PRECIOUS METALS FORMING SUBCATEGORY

Production Operations and Discharge Flows

Production  operations  that generate process wastewater  in  the
precious  metals  forming subcategory include  rolling,  drawing,
metal  powder production,  direct chill  casting,  shot  casting,
stationary casting,  semi-continuous and continuous casting, heat
treatment,   surface  treatment,   alkaline  cleaning,  tumbling,
burnishing,  sawing,  grinding, pressure bonding, and degreasing.
The  wet scrubbers used for air pollution control at some  plants
are  also a source of process wastewater.   Water use  practices,
wastewater  streams  and  wastewater discharge flows  from  these
operations  were discussed in Section V.   This information  pro-
vided  the  basis  for development of  the  BPT  regulatory  flow
allowances  summarized in Table IX-17.   The following paragraphs
discuss  the  basis for the BPT flow allowances  for  each  waste
stream.
Rolling

Rolling  is  performed  at 33 plants in  this  subcategory.
following information is available from these plants:

Number  of  plants and operations using neat  oil  lubricant:
Number  of plants and operations using emulsion  lubricant:
plants, 6 operations.
No  lubricants  were  reported to be  used  at  approximately
plants.
                                                              The
                                                                2
                                                                5

                                                               25
Precious Metals Rolling Spent Neat Oils.
requirement  for  this  waste
                                          No discharge is the BPT
                               stream.   Spent neat  oil  is  not
discharged from the two rolling operations where the use of  neat
oil  lubricants  was  reported.    One  operation  achieves  zero
discharge through recirculation with some loss due to drag-out on
the  product.   No  information regarding how zero  discharge  is
achieved  was reported for the other operation.   Since neat oils
are  pure oil streams,  with no water fraction,  it is better  to
remove the oil directly by contract hauling and not to  discharge
the  stream than to commingle the -oil with water streams and then
remove it later.                                       .

Precious Metals Rolling Spent Emulsions.   Information sufficient
to calculate production normalized flows was available for  three
of  the  six operations where the use of emulsion lubricants  was
reported.   The  BPT  regulatory allowance of  77.1  1/kkg  (18.5
gal/ton)  is based on the average of the three production normal-
ized discharge flows.   This regulatory flow incorporates recycle
with  periodic discharge of spent emulsion since this is  current
practice at the three plants supplying flow data for this  waste-
water stream.
                               1578

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Drawing

Drawing  is performed at 25 precious metals forming plants.
following information is available from these plants:
Number  of  plants and operations using neat  oil
Number  of  plants and operations using  emulsion
plants, 12 operations
Number of plants and operations using soap solutions:
No lubricants are used at approximately 15 plants.
lubricant:
lubricant:
           The
1
8
    2.
Precious  Metals  Drawing Spent Neat Oils.   Neat oils  are  com-
pletely  consumed  in  the one drawing  process  where  neat  oil
lubricants  are used.   As discussed previously/  should a  plant
need  to dispose of these lubricants it is better to remove  them
directly  by  contract hauling and not to discharge  the  stream.
Therefore, this stream should not be discharged.

Precious  Metals Drawing Spent Emulsions.   Drawing emulsions are
completely  recycled  with the only loss due to  evaporation  and
drag-out  in  three operations.   Seven  operations  recycle  the
emulsion with periodic batch discharges.  The spent emulsion from
four  of the seven operations is contract hauled to- treatment and
disposal off-site.   The BPT regulatory flow of 47.5 1/kkg  (11.4
gal/ton)  is  based  on the average of five  non-zero  production
normalized  discharge  flows from operations  where  emulsion  is
recycled with periodic batch discharges.   The production normal-
ized  discharge  flow  from  one operation where  no  recycle  is
practiced was not included in the BPT regulatory flow calculation
since once-through discharge of spent emulsion is not  indicative
of current industry practice.

Precious Metals Drawing Spent Soap Solutions.   No discharge data
were  provided on one operation and one operation was reported to
periodically  discharge spent soap solution.   The BPT  discharge
allowance is the one reported value, 3.12 1/kkg (0.748 gal/ton).

Metal Powder Production

Metal powder production operations are performed at eight plants.
Atomization wastewater is generated at one of these plants.

Precious  Metals Metal Powder Production Atomization  Wastewater.
The BPT discharge allowance, based on the one reported production
normalized discharge flow, is 6,680 1/kkg (1,600 gal/ton).

Casting

Casting is performed at 23 plants in the precious metals  forming
subcategory.   The  following information is available from these
plants:
                               1579

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Number  of plants and operations with direct chill casting  using
contact cooling water:  3 plants, 4 operations
Number of plants and operations with shot casting using   contact
cooling water:  1
Number  of  plants and operations with stationary  casting  using
contact cooling water:  5
Number   of  plants  and  operations  with  semi-continuous   and
continuous casting using contact cooling water:  5.

Precious  Metals Di^ecjb Chill Casting Contact Cooling Water.   In
one reported direct chill casting operation the cooling water  is
completely recycled with no discharge.  The contact cooling water
is  discharged from two operations on a once-through basis.   The
BPT  flow allowance of 10,800 1/kkg (2,590 gal/ton) is  based  on
the average production normalized water use from these two opera-.
tions.   The  production normalized water use from one  operation
with  an  unreported discharge flow was not used in the BPT  flow
calculation  since it is nearly 10 times greater than  the  water
use  for the other two discharging operations,  and therefore not
indicative of current industry practice.
Precious  Metals  Shot Casting Contact Cooling  Water.
The
regulatory flow allowance is the production normalized water
from the one reported operation, 3,670 1/kkg (880 gal/ton).
BPT
use
Precious  Metals Stationary Casting Contact Cooling Water.   Five
plants  reported using contact cooling water to  cool  stationary
castings.   One  plant completely recycles this water,  one prac-
tices  99.8 percent recycle,  and one plant only  discharges  the
cooling  water  periodically.   Water recycle practices were  not
reported by the other two plants.   No BPT discharge allowance is
provided for this waste stream.   The zero discharge allowance is
based on practices currently in use at one plant in this subcate-
gory  and  in  plants from several  other  subcategories  in  the
category which perform the same operation on other metals.

Precious  Metals  Semi-Continuous and Continuous Casting  Contact
Cooling Water.   Two plants completely recycle the cooling  water
wTth no discharge.   Flow data were reported for one of the three
plants which discharge this stream.  The BPT regulatory allowance
is  based on the one reported,  nonrecycled production normalized
water use, 10,300 1/kkg (2,480 gal/ton).

Heat Treatment

Precious  Metals Heat Treatment Contact  Cooling  Water.   Eleven
plants reported using contact cooling water in a total of 20 heat
treatment  operations.   Contact cooling water is used in anneal-
ing,  rolling,  and extrusion heat treatment.  The BPT regulatory
flow is based on the median of 12 reported production  normalized
water uses,  4,170 1/kkg (1,000 gal/ton).  The median is believed
to  be  a better representation of the current typical water  use
for this operation than the average (arithmetic mean) because  of
che large range of reported production normalized water uses (659
1/1-' -•  to 1. i"7 . O'>0 i •"- ':o) .
                               L580

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Surface Treatment

Seventeen   plants  supplied  information  on  surface  treatment
operations.   Wastewater  is generated and discharged from  these
operations as follows:
Number of baths contract hauled or discharged:
Number of baths never discharged:  4
                16
Number  of rinses discharged:
completely recycled:  1.
18 Number of rinses  treated  and
Precious  Metals  Surface Treatment Spent Baths.
                   No
	  	  	 	 	 	        wastewater
discharge data were reported for 12 of the operations.   The  BPT
discharge  allowance is the average of the four reported  produc-
tion normalized discharge flows, 96.3 1/kkg (23.1 gal/ton).

Precious  Metals  Surface Treatment Rinse.   One rinse  operation
uses   two-stage  countercurrent  cascade  rinsing  and   another
operation uses three-stage countercurrent cascade  rinsing.   The
BPT  regulatory  flow of 6,160 1/kkg (1,480 gal/ton) is based  on
the average production normalized water use for seven noncascaded
rinse  operations because flow reduction through cascade  rinsing
is considered to be part of the BAT technology.

Alkaline Cleaning

Nine plants supplied information on alkaline cleaning operations.
Seven plants supplied information on alkaline cleaning prebonding
operations.   Wastewater  is generated and discharged from  these
operations as follows:

Number of alkaline cleaning baths contract hauled or  discharged:
8
Number of alkaline cleaning baths never discharged:  0

Number of alkaline cleaning rinses discharged:  7

Number  of  alkaline cleaning prebonding  operations  discharging
wastewater:  8.

Precious  Metals  Alkaline • Cleaning
	  	  	  	  	  Baths.    Production
normalized  flow information is available for one bath.   The BPT
regulatory  flow  of 60.0 1/kkg (14.4 gal/ton) is  based  on  the
production normalized discharge flow from this bath.

Precious   Metals  Alkaline  Cleaning  Rinse.    Flow  data  were
available  for  four  alkaline  cleaning  rinse  operations.   No
recycle  or other flow reduction techniques are used for  any  of
these operations.  The BPT regulatory flow of 11,200 1/kkg (2,690
gal/ton)  is based on the average production normalized water use
from the four operations.
                               1581

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Precious  Metals Alkaline Cleaning Prebonding  Wastewater.   Flow
information  is available for all of the alkaline  cleaning  pre-
bonding  operations.   The  BPT regulatory flow of  11,600  1/kkg
(2,770  gal/ton)  is  based on the median  production  normalized
water use for the eight operations.  The median is believed to be
a better representation of the current typical water use  for this
operation than the average (arithmetic mean) because of the large
range of reported production normalized water uses (10.2  1/kkg to
93,800 1/kkg).

Tumbling or Burnishing

Precious Metals Tumbling or Burnishing Wastewater.  Flow  informa-
tion was reported for two- tumbling operations and two  burnishing
operations.  No recycle is practiced for any of these operations.
The  BPT flow allowance of 12,100 1/kkg (2,910 gal/ton) is  based
on  the  average  production normalized water use  for  the  four
operations.

Sawing or Grinding

Precious Metals Sawing or Grinding Spent Neat Oils.   Neat oil is
used  as a lubricant in one grinding operation.   The neat oil is
completely  recycled with some loss due to evaporation and  drag-
out.   As  previously  discussed,  since neat oils are  pure  oil
streams,  with no water fraction,  it is better to remove the oil
directly by contract hauling and not to discharge the stream than
to commingle the oil with water streams and then remove it later.
Therefore, the BPT flow allowance is zero.

Precious Metals Sawing or Grinding Spent Emulsions.   An emulsion
lubricant  is  used  in four operations.   In each  of  the  four
operations, the emulsion is recirculated with periodic discharges
contract hauled to treatment and disposal off-site.   However,  a
BPT  regulatory flow has been established for this  stream  since
the  spent emulsion could be treated on-site and the water  frac-
tion discharged (with the oil fraction contract hauled).  The BPT
regulatory  flow  of  93.4 1/kkg (22.4 gal/ton) is based  on  the
median production normalized discharge flow from the four  opera-
tions.   The  median is believed to be a better representation of
the current typical water use for this operation than the average
(arithmetic mean) because of the large range of reported  produc-
tion normalized discharge flows (3.17 1/kkg to 2,775 1/kkg).

Pressure Bonding

Precious  Metals  Pressure Bonding Contact  Cooling  Water.    One
plant  reported  using  contact cooling water  after  a  pressure
bonding operation.  The production normalized discharge flow from
this  operation  is  the BPT regulatory flow,  83.5  1/kkg  (20.0
gal/ton).
                               1582

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Degreasing

Precious Metals Degreasing Spent Solvents.
of  surveyed  plants  with  solvent
process   wastewater  streams
Because  most  plants practice solvent degreasing without
      	    Only a small  number
      degreasing  operations  have
associated  with  the   operation.
                            waste-
water discharge, the Agency believes zero discharge of wastewater
is an appropriate discharge limitation.

Wet Air Pollution Control

Precious  Metals  Wet Air Pollution Control  Slowdown.   Wet  air
pollution control devices are used to control air emissions  from
two  surface  treatment operations and three casting  operations.
The  scrubber water is completely recycled with no  discharge  in
two  operations,  and a periodic discharge is contract hauled  to
treatment and disposal off-site in a third operation.  Since zero
discharge  from  wet air pollution devices is common practice  in
this  subcategory,  no  BPT flow allowance is provided  for  this
stream.

Deleted Waste Streams

Precious Metals Metal Powder Production Milling  Wastewater.   At
proposal,  an  allowance was written for metal powder  production
milling  wastewater.   Upon  re-examination  of  the  information
available,  it  was determined that the operation upon which  the
allowance was based is powder metallurgy part milling, not powder
milling.   The  discharge from this operation is covered by  tum-
bling,  burnishing  wastewater allowance and its reported PNF has
been  included  in the calculation of  the  tumbling,  burnishing
wastewater regulatory flow and discharge allowance.

Regulated Pollutants

The  priority pollutants considered for regulation under BPT  are
listed  in Section VI along with an explanation of why they  have
been  considered.   The pollutants selected for regulation  under
BPT are cadmium,  copper,  lead, silver, cyanide, oil and grease,
total  suspended solids and pH.   The priority  metal  pollutants
chromium,  nickel,  and  zinc,  listed  in  Section  VI  are  not
specifically  regulated  under BPT for the reasons  explained  in
Section  X.   The  basis  for regulating oil  and  grease,  total
suspended  solids and pH was discussed earlier in  this  section.
The  basis for regulating  cadmium,  copper,  lead,  silver,  and
cyanide is discussed below.

Cadmium  is selected for regulation since it was found at  treat-
able concentrations in 23 of 37 raw wastewater samples.   Cadmium
was  present at treatable concentrations in rolling  spent  emul-
sions,  shot  casting contact cooling water,  semi-continuous and
continuous casting contact cooling water,  heat treatment contact
cooling water,  surface treatment spent baths,  surface treatment
rinse,   alkaline   cleaning  spent  baths,   alkaline   cleaning
                               1583

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prebonding wastewater,  tumbling and burnishing  wastewater,  and
pressure bonding contact cooling water.

Copper is selected for regulation since it was found at treatable
concentrations  in 32 of 37 raw wastewater samples.   Copper  was
found  at treatable concentrations in all raw wastewater  streams
in which it was analyzed.  This includes all of the waste streams
where  cadmium  was found at treatable concentrations,  and  also
drawing spent emulsions.

Lead  is selected for regulation since it was found at  treatable
concentrations  in  25 of 37 raw wastewater  samples.   Lead  was
found  at treatable concentration in 11 of the 12 raw  wastewater
streams in which it was analyzed.

Silver is selected for regulation because it was found at  treat-
able  concentrations in 11 of 37 raw wastewater samples,  it is a
toxic metal,  and it is one of the metals formed in this subcate-
gory.   Silver  was found at treatable concentrations in  rolling
spent emulsions, drawing spent emulsions, surface treatment spent
baths,  surface treatment rinse,  alkaline cleaning spent  baths,
and tumbling, burnishing wastewater.

Cyanide  is selected for regulation since it was found at  treat-
able  concentrations  in alkaline cleaning prebonding  wastewater
and semi-continuous and continuous casting contact cooling water.
Preliminary  cyanide  precipitation  is  needed  to  remove  this
pollutant  from wastewater.   Therefore regulation of cyanide  is
appropriate for this subcategory.

Treatment Train

The  BPT  model treatment train for the precious  metals  forming
subcategory  consists  of preliminary treatment  when  necessary,
specifically  chemical emulsion breaking and  oil  skimming,  and
cyanide  precipitation.   The effluent from preliminary treatment
is  combined  with other wastewater for common treatment  by  oil
skimming and lime and settle.   Waste streams potentially needing
preliminary  treatment  are listed in Table  IX-4.   Figure  IX-1
presents  a schematic of the general BPT treatment train for  the
nonferrous metals forming category.

Effluent Limitations

The pollutant mass discharge limitations (milligrams of pollutant
per  metric  ton of PNP) were calculated by multiplying  the  BPT
regulatory flows summarized in Table IX-17 (1/kkg) by the concen-
tration  achievable by the BPT model treatment system  summarized
in  Table VII-21 (mg/1) for each pollutant  parameter  considered
for  regulation  at  BPT  (1/off-kkg x mg/1 x 1  kkg/1,000  kg  =
mg/off-kg).   The  results  of  this computation  for  all  waste
streams  and regulated pollutants in the precious metals  forming
subcategory are summarized in Table IX-18.  This limitation table
lists all the pollutants which were considered for regulation and
t1-• • •  specifically regulated ure marked with an asterisk.


                               1584

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Costs and Benefits

In establishing BPT,  EPA must consider the cost of treatment and
control  in  relation to the effluent  reduction  benefits.   BPT
costs  and benefits are tabulated along with BAT costs and  bene-
fits in Section X.  As shown in Table X-6 (page xxxx), the appli-
cation  of  BPT to the total precious metals forming  subcategory
will remove approximately 12,635 kg/yr (27,800 Ibs/yr) of  pollu-
tants including 110 kg/yr (242 Ibs/yr) of toxic metals.  As shown
in  Table  X-l (page xxxx), the corresponding capital and  annual
costs  (1982  dollars) for this removal are  $1.013  million  and
$0.414  million per year,  respectively.    As shown in Table X-16
(page xxxx),  the application of BPT to direct  dischargers  only
will  remove  approximately 2,875 kg/yr (6,325 Ibs/yr) of  pollu-
tants including 21 kg/yr (46 Ibs/yr) of toxic metals.   As  shown
in  Table  X-2 (page xxxx), the corresponding capital and  annual
costs  (1982 dollars) for this removal are $226,000  and  $98,000
per year,  respectively.   The Agency concludes that these pollu-
tant  removals  justify  the  costs incurred by  plants  in  this
subcategory.

REFRACTORY METALS FORMING SUBCATEGORY

Production Operations and Discharge Flows

Production  operations  that generate process wastewater  in  the
refractory metals forming subcategory include  rolling,  drawing,
extrusion,  forging,  metal powder production, surface treatment,
alkaline cleaning,  molten salt treatment,  tumbling, burnishing,
sawing, grinding, product testing, equipment cleaning, degreasing
and  a few miscellaneous operations.   The wet scrubbers used for
air pollution control at some plants are  also a source of process
wastewater.   Water use practices,  wastewater streams and waste-
water  discharge  flows from these operations were  discussed  in
Section V.   This information provided the basis for  development
of  the BPT regulatory flow allowances summarized in Table IX-19.
The  following  paragraphs  discuss the basis for  the  BPT  flow
allowances for each waste stream.

Rolling

Rolling is performed at approximately 16  plants in the refractory
metals forming subcategory.   The following information is avail-
able from these plants:

Number of plants and operations using neat oil or  graphite-based
lubricants:  2
Number of plants and operations using emulsion lubricants:  1.
No lubricants are used at approximately 13 plants.

Refractory  Metals  Rolling  Spent Neat Oils and  Graphite  Based
Lubricants.   One  operation  uses a neat oil lubricant  and.  the
other operation uses a graphite-based lubricant.   The  lubricant
in  both  processes is completely recycled with some loss due  to


                               1585

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evaporation  and  drag-out.   Should  a plant find  the  need  to
dispose  these  lubricants,  it  would be better  to.  remove  the
lubricants directly by contract hauling and not to discharge  the
stream  rather than to combine the lubricants with water streams,
and remove them later.   Therefore,  rolling spent neat oils  and
graphite-based lubricants should not be discharged.

Refractory Metals Rolling Spent Emulsions.  Spent emulsion in the
one  rolling  operation  which uses an  emulsified  lubricant  is
periodically  batch  dumped and contract  hauled.   As  discussed
previously  for  rolling spent emulsions in the  lead-tin-bismuth
forming  subcategory,  the spent emulsions are often treated  on-
site  and  the water discharged (with the oil  fraction  contract
hauled) by plants in this category and other categories.   There-
fore,  the  production  normalized discharge flow  from  the  one
operation  is  the  BPT  discharge  allowance,   429  1/kkg  (103
gal/ton).

Drawing

Drawing  is  performed  at  approximately  16  refractory  metals
forming plants.   Six plants reported using lubricants in a total
of seven drawing operations.

Refractory  Metals  Drawing Spent Lubricants.   No  lubricant  is
discharged from six of the seven drawing operations reporting the
use  of lubricants.   In four operations,  the lubricant is  com-
pletely  recycled  with some lubricant consumed or  lost  through
evaporation  and  drag-out.   In the other zero discharge  opera-
tions,  the  only losses are due to lubricant being consumed  and
burned  off or through evaporation and drag-out.   One  operation
has  no available water discharge data.   The drawing  lubricants
used include neat oils,  graphite-based lubricants,  and dry soap
lubricants.   Should  a plant find the need to dispose  of  these
lubricants,  it  would be better to remove them directly by  con-
tract  hauling  and  not to discharge the stream rather  than  to
combine the lubricants with water streams and remove them  later.
Therefore, drawing spent lubricants should not be discharged.

Extrusion

Extrusion  is  performed  at approximately seven plants  in  this
subcategory.   The following information is available from  these
plants:

Number of plants and operations using lubricants:  3
Number   of  plants  and  operations  reporting  hydraulic  fluid
leakage:  1.
Four  plants  did not report the use of lubricants  or  hydraulic
fluid leakage from their extrusion operations.

Refractory  Metals  Extrusion Spent  Lubricants.   There  are  no
reported  discharges  of spent extrusion  lubricants.    Should  a
plant need to dispose of these lubricants,  it would be better to
        them directly by contract haulii.-:; rather than to  combine


                               1586

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the  lubricants  with wastewater streams and remove  them
Therefore, this waste stream should not be discharged.

             Metals  Extrusion  Press  Hydraulic  Fluid
                                                           later.
Refractory
Leakage  of extrusion press hydraulic fluid was observed
                                                 Leakage.
                                                  at   one
                    discharge  allowance  is  based   on   the
                                        operation,  1,190
         plant.   The  BPT
production  normalized discharge flow for this
1/kkg (235 gal/ton).

Forging

Forgjno  i,s  performed  at  approximately  10  refractory  metals
forming plants.  The following information is available for these
plants:

Number of plants and operations using lubricants:   3 plants,   4
operations
Number of plants and operations using contact cooling water:  2.
No lubricants or contact cooling water was reported to be used at
over five plants.

Refractory  Metals Forging Spent Lubricants.   No lubricants  are
discharged  from  the  four operations for  which  lubricant  was
reported.   The  only  loss is due to evaporation  and  drag-out.
Should a plant find the need to dispose of these  lubricants,  it
would  be  better to remove the lubricants directly  by  contract
hauling  and  not  to discharge the stream than  to  combine  the
lubricants   with  wastewater  streams  and  remove  them  later.
Therefore, this waste stream should not be discharged.

Refractory Metals Forging Contact Cooling Water.   Flow data were
%
provided for one operation.  None of the contact cooling water in
this operation is recycled.   The BPT discharge allowance is  the
production  normalized  water use from this  one  operation,  323
1/kkg (77.5 gal/ton).

Metal Powder Production

Metal powder production operations are performed at approximately
46 refractory metal forming plants.  The following information is
available from these plants:

Number   of   plants  and  operations  generating  metal   powder
production wastewater:  3 plants, 5 operations
Number of plants and operations generating floorwash  wastewater:
2.
No  process wastewater is generated from metal powder
operations at approximately 40 plants.
                                              production
Refractory  Metals Metal Powder Production Wastewater.    None  of
the  operations practice any recycle of the metal powder  produc-
tion wastewater.  No wastewater is discharged from two operations
since  it evaporates in drying operations.   The  BPT  regulatory
Clow  of 281 1/kkg (67.3 gal/ton) is based on the median  produc-
tion  normalized  water use for five operations which  discharge.
                               1587

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The  median  is  believed to be a better  representation  of  the
current  typical  watet use for this operation than  the  average
(arithmetic mean) because of the large range of reported  produc-
tion normalized water uses (37.1 l./kkg to 34,500 1/kkg).

Refractory  Metals Metal Powder Production Floorwash  Wastewater.
The  floorwash  wastewater  is completely recycled by  one  plant
while  at  the  other plant the wastewater  is  contract  hauled.
Since  neither  plant which generates the waste  stream  reported
discharging  it,  there  shall be no discharge  from  this  waste
stream.
                                                Lubricants.
                         The
Refractory  Metals Metal Powder Pressing 		
one  plant which reported using metal powder pressing  lubricants
achieves  zero  discharge of the lubricants through  100  percent
recycle.  Therefore, the BPT flow allowance is zero.

Surface Treatment

Twelve  plants supplied information on refractory metals  surface
treatment operations.

Refractory Metals Surface Treatment Spent Baths.   Flow data were
supplied for six of the 15 reported surface treatment baths.  The
BPT  regulatory flow of 389 1/kkg (93.3 gal/ton) is based on  the
average  production normalized discharge flow from the six opera-
tions.

Refractory  Metals  Surface Treatment  Rinse.   Fourteen  surface
treatment  rinse operations were  reported.   Two-stage  counter-
current  cascade  rinsing is practiced at two of the  operations.
No  flow  reduction  techniques were reported for  the  other  12
operations.    Discharge   data  were  available  for   the   two
countercurrent  cascade rinses and four non-cascaded rinse opera-
tions.   The BPT flow of 121,000 1/kkg (29,100 gal/ton) is  based
on the average production normalized water use from the four non-
cascaded  rinse  operations.   The countercurrent  cascade  rinse
operations  were  not  included  in the  flow  calculation  since
countercurrent cascade rinsing is a BAT technology,  and does not
represent current typical water use for this operation.

Alkaline Cleaning

Fourteen plants supplied information on alkaline cleaning  opera-
tions.   A  total  of 14 alkaline cleaning baths and 18  alkaline
cleaning rinses were reported.

Refractory Metals Alkaline Cleaning Spent Baths.   Flow data were
available  for three of the 14 reported alkaline cleaning  baths.
The  BPT regulatory flow of 334 1/kkg (80.2 gal/ton) is based  on
the  average production normalized discharge flow from the  three
operations.
Refractory  Metals  Alkaline  Cleanin
av3i~^rble for "> "  rinse operations.
_  Rinse.   Flow  data  were
No flow reduction  practices
                               1588

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(countercurrent cascade rinsing, recycle, etc.) were reported for
any  of  these operations.   The BPT regulatory flow  of  816,000
1/kkg  (196,000  gal/ton)  is  based on  the  average  production
normalized water use from the 11 operations.

Molten Salt Treatment

Refractory  Metals  Molten Salt Rinse.   Five plants  reported  a
total  of six molten salt rinse operations.   No  flow  reduction
practices  were  reported  for five of the  operations.   In  one
operation,  a decreased flow rate is used to significantly reduce
the discharge of molten salt rinse.  Flow data were available for
five  of the six operations.   The BPT regulatory flow  of  6,330
1/kkg   (1,520  gal/ton)  is  based  on  the  average  production
normalized water use from the five operations.

Tumbling or Burnishing Wastewater

Refractory  Metals  Tumbling  or  Burnishing  Wastewater.   Seven
plants  reported  generating  wastewater  from  10  tumbling  and
burnishing operations.  No flow reduction practices were reported
for any of these operations.   Flow data were supplied for  eight
of  the  operations.   The  BPT regulatory flow of  -12,500  1/kkg
(3,000  gal/ton)  is based on the  median  production  normalized
water  use from the eight operations.   The median is believed to
be  a better representation of the current typical water use  for
this  operation  than the average because of the large  range  of
production normalized water uses (953 1/kkg to 666,000 1/kkg).

Sawing or Grinding

Thirteen  plants  reported generating wastewater from  sawing  or
grinding operations.  The following information is available from
these plants:
Number of plants and operations using neat oil lubricant:  3
Number  of plants and operations using emulsion  lubricant:
plants, 16 operations
Number of plants and operations using contact cooling  water:
plants, 8 operations
Number of plants and. operations using a rinse:  2.
8

5
Refractory  Metals Sawing or Grinding Spent Neat Oils.   No  dis-
charge  information was reported for one operation.   Spent  neat
oils  are  contract hauled to treatment and disposal off-site  in
the other two operations.   Since neat oils are pure oil streams,
with no water fraction,  it is better to remove the oil  directly
by  contract  hauling  and not to discharge the  stream  than  to
commingle  the  oil  with  water streams  and  remove  it  later.
Therefore, this waste stream should not be discharged.

Refractory Metals Sawing o£ Grinding Spent Emulsions.   The spent
emulsions from six operations are contract hauled;  emulsions are
completely recycled in one operation;  the only loss of emulsions
from   three  operations  is  through  drag-out  or  consumption.
                               1589

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Discharge data were available for four operations.   The  average
production  normalized discharge flow from the four operations is
the BPT discharge allowance, 297 1/kkg (71.1 gal/ton).

Refractory Metals Sawing or Grinding Contact Cooling Water.  Zero
discharge  is  achieved in three operations through  100  percent
recycle;  in  one  operation 80 percent of the cooling  water  is
recycled; in another operation cooling water is only periodically
discharged; no recycle is practiced in three operations.  The BPT
regulatory  flow of 24,300 1/kkg (5,820 gal/ton) is based on  the
average production normalized water use from the four  operations
where water use data were available.

Refractory Metals Sawing or Grinding Rinse.   No recycle or other
flow  reduction practices are used in either of the two  reported
rinse  operations.   Flow  data were provided for one  operation.
The  BPT  flow  of  135 1/kkg (32.5  gal/ton)  is  based  on  the
production normalized water use for this operation.

Product Testing

Refractory  Metals Dye Penetrant Testing Wastewater.   Wastewater
from  a  dye  penetrant testing operation  was  observed  at  one
sampled  plant.   The  BPT discharge allowance is the  production
normalized  discharge flow for this operation,  77.6 1/kkg  (18.6
gal/ton).

Equipment Cleaning

Refractory  Metals Equipment Cleaning Wastewater.   Three  plants
reported  generating wastewater from cleaning  various  equipment
such as spray driers,  forging presses,  ring rollers, tools, and
wet  abrasive  saw  areas.   A total of  six  equipment  cleaning
operations  were reported.   In one operation,  zero discharge is
achieved  by completely recycling the cleaning  wastewater.   The
BPT regulatory flow of 1,360 1/kkg (326 gal/ton) is based on  the
median  production normalized discharge flow from the six  opera-
tions.  The six production normalized discharge flows included in
the  median calculation include five non-zero discharge flows and
the zero discharge flow from the operation practicing 100 percent
recycle.  The median is believed to be a better representation of
the current typical water use for this operation than the average
because  of  the large range of production  normalized  discharge
flows (0 1/kkg to 2l",140 1/kkg).

Miscellaneous Wastewater

Refractory   Metals  Miscellaneous   Wastewater.    Miscellaneous
wastewater streams identified in this subcategory include  waste-
water  from a post oil coating dip rinse,  a quench of  extrusion
tools,  and  spent  emulsions from grinding the  stainless  steel
rolls  used  in refractory metals rolling  operations.   The  BPT
discharge  allowance is 345 1/kkg (83.0 gal/ton),  10 percent  of
the  one  reported production normalized  discharge  flow.   This
                               1590

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discharge  is a free flowing tool quench which can be 90  percent
flow reduced by recycling it through a holding tank.

Degreasing

Refractory Metals Degreasing Spent Solvents.  Only a small number
of  surveyed  plants  with  solvent  degreasing  operations  have
process   wastewater  streams  associated  with  the   operation.
Because  most  plants practice solvent degreasing without  waste-
water discharge, the Agency believes zero discharge of wastewater
is an appropriate discharge limitation.

Wet Air Pollution Control

Refractory  Metals Wet Air Pollution Control  Scrubber  Slowdown.
In  this subcategory,  wet air pollution control devices are used
to  control air emissions from metal powder  production,  surface
treatment,  surface coating,  and sawing and grinding operations.
The  use of wet air pollution control devices was reported for  a
total of nine operations.   Scrubber water from one operation  is
completely recycled with no discharge.   In two other operations,
the discharge flow of scrubber water is reduced by recycling over
90 percent of the scrubber water.   Water use data were available
for  four operations.   The BPT regulatory flow of 787 1/kkg (189
gal/ton) is based on 90 percent reduction of the average  produc-
tion  normalized water use from three of these  operations.   The
production  normalized  water use for one operation was over  175
times  larger  than the other values and was believed  to  be  so
atypical of current typical water use that it was not included in
the regulatory flow calculation.

Deleted Waste Streams

Following  proposal,  the  Agency  received additional  data  and
conducted  a review of all available data  concerning  wastewater
discharges.   This  review led to a reinterpretation of some data
reported  prior to proposal.   As a result,  the following  waste
streams  included  in the proposed regulation have  been  deleted
from the final regulation:

     o  Extrusion Heat Treatment Contact Cooling Water,
     o  Metal Powder Pressing Spent Lubricant,
     o  Casting Contact Cooling Water, and
     o  Post-Casting Wash Water.

Data  included  under these waste streams at proposal  have  been
reclassified  under  other waste streams in this  subcategory  as
appropriate.

Regulated Pollutants

The  priority pollutants considered for regulation under BPT  are
listed  in Section VI along with an explanation of why they  were
considered.  The pollutants selected for regulation under BPT are
copper,  nickel,  fluoride,  molybdenum,  oil and  grease,  total


                               1591

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suspended solids and pH.  The priority pollutants chromium, lead,
silver,  and zinc,  and the nonconventional pollutants columbium,
tantalum,  tungsten,  and vanadium are not specifically regulated
under BPT for the reasons explained in Section X.   The basis for
regulating oil and grease,  total suspended solids,  and pH under
BPT  was  discussed  earlier  in this  section.   The  basis  for
regulating copper,  nickel, fluoride, and molybdenum is discussed
below.

Copper is selected for regulation since it was found at treatable
concentrations in nine of 25 raw wastewater samples.   Copper was
present  at treatable concentrations in extrusion press hydraulic
fluid leakage,  surface treatment spent baths,  surface treatment
rinse,  alkaline  cleaning spent baths,  tumbling and  burnishing
wastewater, and sawing or grinding contact cooling water.

Nickel is selected for regulation since it was found at treatable
concentrations  in 13 of 25 raw wastewater samples.   Nickel  was
found  at  treatable  concentrations in  all  wastewater  streams
listed in the previous paragraph for copper.  It was also present
at  treatable  concentrations  in  molten  salt  rinse  and   dye
penetrant testing wastewater.

Fluoride  is selected for regulation since it was found at treat-
able  concentrations  in  seven of  21  raw  wastewater  samples.
Fluoride  was  present  at treatable  concentrations  in  surface
treatment  rinse,  alkaline  cleaning spent  baths,  molten  salt
rinse, and wet air pollution control blowdown.

Molybdenum  is  selected for regulation since it was  present  at
treatable concentrations in five of 25 raw wastewater samples and
it  is one of the metals formed in this subcategory.   Molybdenum
is  specifically  regulated  under BPT because  it  will  not  be
adequately  removed by the technology (lime and settle)  required
for  the  removal  of the regulated  priority  metal  pollutants,
copper  and  nickel.   The addition of iron to a lime and  settle
system  (i.e.,  iron coprecipitation) is necessary for  effective
removal of molybdenum.  Regulation of priority metals only is not
sufficient  to ensure the removal of molybdenum  from  refractory
metals forming wastewater.

Treatment Train

The  BPT model.treatment train for the refractory metals  forming
subcategory  consists  of preliminary treatment  when  necessary,
specifically  chemical emulsion breaking and oil  skimming.   The
effluent  from  preliminary  treatment  is  combined  with  other
wastewater  for common oil skimming,  iron  coprecipitation,   and
lime  and  settle treatment.   Waste streams potentially  needing
preliminary  treatment  are listed in Table  IX-5.    Figure  IX-1
presents  a schematic of the general BPT treatment train for   the
nonferrous metals forming category.
                               1592

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Effluent Limitations

The pollutant mass discharge limitations (milligrams of pollutant
per  off-kilogram of PNP) were calculated by multiplying the  BPT
regulatory flows summarized in Table IX-19 (1/kkg) by the concen-
tration  achievable by the BPT model treatment system  summarized
in  Table VII-21 (mg/1) for each pollutant  parameter  considered
for  regulation at BPT (1/kkg x mg/1 x kkg/1,000 kg = mg/off-kg).
The  results  of  this  computation for  all  waste  streams  and
regulated pollutants in the refractory metals forming subcategory
are summarized in Table IX-20.  Although no limitations have been
established  for columbium,  tantalum,  tungsten,  and  vanadium,
Table  IX-20  includes  mass,  discharge  limitations  for   these
pollutants  which are attainable using the BPT model  technology.
These  limitations  are  presented  for the  guidance  of  permit
writers.   Only  daily  maximum  limitations  are  presented  for
columbium,  tantalum, and vanadium, based on the detection limits
of 0.12,  0.46,  and 0.10 mg/1,  respectively.   Lime and  settle
treatment  was  determined  to remove these pollutants  to  below
their level of analytical quantification.  The attainable monthly
average  discharge  is  expected to be  lower  than  the  one-day
maximum  limitation,  but since it would be impossible to monitor
for  compliance with a lower level,  no monthly average has  been
presented.

The limitations table lists all the pollutants which were consid-
ered  for  regulation.   Those specifically regulated are  marked
with an asterisk.

Costs and Benefits

In establishing BPT,  EPA must consider the cost of treatment and
control  in  relation to the effluent  reduction  benefits.   BPT
costs  and benefits are tabulated along with BAT costs and  bene-
fits in Section X.  As shown in Table X-7 (page xxxx), the appli-
cation of BPT to the total refractory metals forming  subcategory
will  remove  approximately  183,300 kg/yr  (403,260  Ibs/yr)  of
pollutants  including 54 kg/yr (119 Ibs/yr) of toxic metals.   As
shown  in Table X-l xxxx),  the corresponding capital and  annual
costs  (1982  dollars) for this removal are  $1.117  million  and
$0.582  million per year,  respectively.   As shown in Table X-17
(page  xxxx),  the application of BPT to direct dischargers  only
will  remove  approximately  24,220  kg/yr  (53,285  Ibs/yr)   of
pollutants.  As shown in Table X-2 (page xxxx), the corresponding
capital  and  annual  costs (1982 dollars) for this  removal  are
$87,000 and $44,000 per year, respectively.  The Agency concludes
that  these  pollutant  removals justify the  costs  incurred  by
plants in this subcategory.

TITANIUM FORMING SUBCATEGORY

Production Operations and Discharge Flows

Production  operations  that generate process wastewater  in  the
titanium forming subcategory include rolling, drawing, extrusion,


                               1593

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forging,   tube  reducing,  heat  treatment,  surface  treatment,
alkaline  cleaning,  molten  salt  treatment,  tumbling,  sawing,
grinding,  product testing,  degreasing and various miscellaneous
operations.   The wet scrubbers used for air pollution control at
some plants are also a source of process wastewater.   Water  use
practices,  wastewater  streams,  and wastewater discharge  flows
from these operations were discussed in Section V.  This informa-
tion  provided  the basis for development of the  BPT  regulatory
flow  allowances summarized in Table IX-21.   The following para-
graphs  discuss  the basis for the BPT flow allowances  for  each
waste stream.

Rolling

Rolling is performed at 16 plants in the titanium forming subcat-
egory.  The following information is available from these plants:

Number  of  plants and operations using neat  oil  lubricant:   2
Number of plants and operations using contact cooling water:  4.
No  lubricants or contact cooling water were reported to be  used
at approximately 10 plants.

Titanium  Rolling Spent Neat Oils.   No neat oils are  discharged
from  either of the operations reporting the use of  this  lubri-
cant.  As previously discussed, should a plant need to dispose of
this stream,  it would be better to remove the neat oils directly
by  contract hauling and not to discharge them than to  commingle
the neat oils with wastewater streams and remove them later using
an  oil-water separation process.   Therefore,  this waste stream
should not be discharged.

Titanium Rolling Contact Cooling Water.   Reliable flow data were
only  available for one of the four rolling operations which  use
contact  cooling water.   No recycle is practiced in this  opera-
tion.   The  BPT flow of 4,880 1/kkg (1,170 gal/ton) is based  on
the production normalized water use for the operation.

Drawing

Drawing is performed at six titanium forming plants.   Two plants
reported using neat oil lubricants in a total of two  operations.
No lubricants were reported to be used at the other four plants.

Titanium  Drawing  Spent Neat Oils.   Spent neat oils  from  both
operations  reporting  the  use of this  lubricant  are  contract
hauled  to  treatment  and disposal off-site.   It is  better  to
handle the neat oils in this manner rather than to commingle them
with wastewater streams and then remove them later using an  oil-
water  separation process.   Therefore,  this waste stream should
not be discharged.

Extrusion

Extrusion is performed at nine plants in this  subcategory.   The
following information is available from these plants:


                               1594

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Number  of  plants and operations using neat  oil  lubricant:   5
Number  of  plants and operations using  emulsion  lubricant:   1
Number of plants and operations with hydraulic fluid leakage:   1
Three  plants  did not report the use of lubricants or  hydraulic
fluid leakage.
Titanium Extrusion Spent Neat Oils.  Neat oils are not discharged
               the five extrusion operations  using  a  neat  oil
           of
from  any
lubricant.   The only loss of neat oil is through evaporation and
drag-out.   Should  a plant from these operations need to dispose
of  this  stream,  it  would be better to remove  the  neat  oils
directly  by  contract hauling rather than to combine  them  with
wastewater streams and remove them later by oil-water separation.
Therefore, this waste stream should not be discharged.

Titanium Extrusion Spent Emulsions.  One plant reported discharg-
ing  spent emulsion lubricants from an extrusion  operation.   No
recycle of the emulsion is practiced in this operation.   The BPT
regulatory  flow  of 71.9 1/kkg (17.2 gal/ton) is  based  on  the
production normalized discharge flow from the operation.
Titanium  Extrusion  Press  Hydraulic  Fluid  Leakage.   The  BPT
                      178 1/kkg (42.8 gal/ton) is  based  on  the
                        discharge flow -from the only plant  which
regulatory  flow  of
production  normalized
reported this stream.
Forging

Forging is performed at 32 titanium forming plants.
ing information is available from these plants:
                                                      The follow-
Number of plants and operations using lubricants:   7 plants,   8
operations
Number of plants and operations using contact cooling water:  4
Number   of  plants  and  operations  with   equipment   cleaning
wastewater:  1 plant, 2 operations
Number of plants and operations with hydraulic fluid leakage:  2.
Over  20  plants  from this subcategory reported  that  no  waste
streams were generated from forging operations.

Titanium  Forging Spent Lubricants.   The lubricants in seven  of
the  eight operations are consumed during forging and the  lubri-
cants from the other operation are contract hauled.   The forging
lubricants are typically neat oils.   As discussed previously, it
is  better  to remove neat oils directly by contract hauling  and
not  to discharge the stream rather than to commingle  them  with
wastewater  streams  and  then  remove them  later  by  oil-water
separation.    Therefore,   this  waste  stream  should  not   be
discharged.

Titanium  Forging  Contact Cooling Water.   Flow  information  is
available  for  three  of the four forging operations  which  use
contact  cooling  water.   In  one operation 95  percent  of  the
cooling water is recycled;  no recycle is practiced for the other
                               1595

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two  operations.   The  BPT regulatory flow of 2,000  1/kkg   (479
gal/ton) is based on th3 average production normalized water  use
for the three operations.

Titanium  Forging Equipment Cleaning Wastewater.   No recycle  is
practiced  for  either  of the two  reported  equipment  cleaning
operations.  The BPT regulatory flow of 40.0 1/kkg (9.60 gal/ton)
is based on the average production normalized discharge flow from
the two operations.

Titanium  Forging Press Hydraulic Fluid Leakage.   Flow data  are
available for one of the forging operations where hydraulic fluid
leakage  was  reported.   The BPT regulatory flow of 1,010  1/kkg
(242  gal/ton)  is based on the production  normalized  discharge
flow from this operation.

Tube Reducing

Titanium Tube Reducing Spent Lubricants.   One of the  lubricants
used  in reducing titanium tubes is a neat oil.   Since neat oils
contain no water,  the Agency believes that it is better to  haul
the  oil directly and not to commingle it with wastewater streams
only to remove it later.  Other titanium tube reducing lubricants
are emulsions.   A tube reducing emulsion was sampled at a nickel
forming plant.   Analysis of the sampled tube reducing  lubricant
showed  treatable  concentrations  of  N-nitrosodiphenylamine,  a
toxic organic pollutant with potentially carcinogenic properties.
If  one nitrosamine compound is present in this wastewater source
then there are likely to be other compounds or other  nitrosamine
compounds could be formed as this compound most likely was in the
presence of precursors,  under the conditions created by the tube
reducing  process.   Therefore,  there  shall be no discharge  of
titanium tube reducing lubricant.
Heat Treatment

Ten  plants  reported
treatment operations.
using contact cooling  water  in  10  heat
Titanium Heat Treatment Contact Cooling Water.    No BPT discharge
allowance  is  provided  for this  stream.   The  zero  discharge
allowance  is  based  on 100 percent reuse  of   this  wastewater,
either  as  heat  treatment  contact cooling water  or  in  other
processes present at the titanium forming plant.   Analysis of  a
similar nickel forming waste stream, "Annealing and Solution Heat
Treatment  Contact Cooling Water," indicated that the  wastewater
did  not  contain  any treatable  concentrations  of  pollutants.
Therefore,  reuse  of the wastewater is  possible.   Furthermore,
reuse  of  nickel annealing and solution heat  treatment  contact
cooling water is demonstrated at three plants.    Because titanium
heat  treatment  contact  cooling water  contains  pollutants  at
concentrations  similar  to  nickel annealing and  solution  heat
treatment  contact cooling water (since the processes  are  simi-
lar), there is no discharge allowance for titanium heat treatment
contact cooling based on the reuse of this wastewater stream.
                               1596

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Surface Treatment      •       :                 " :

Twenty-one  plants  reported  information  on  surface  treatment
operations.  A total of 32 surface treatment baths and 29 surface
treatment rinse operations were reported.

Titanium Surface Treatment Spent Baths.  Flow data were available
for 21 baths which are either discharged or contract hauled.  The
BPT  regulatory flow of 208 1/kkg (49.9 gal/ton) is based on  the
median production normalized discharge flow of the 21 baths.  The
median  is believed to be a better representation of the  current
discharge  from  this operation than the average because  of  the
large  range  of reported production normalized  discharge  flows
(1.71 1/kkg to 1,310 1/kkg).

Titanium Surface Treatment Rinse.  Countercurrent cascade rinsing
                                "the  rinse  operations.   In  one
is  not  practiced  in  any oi
operation 40 percent of the rinse is recycled while rinsewater is
only  periodically  discharged  from five  operations.   The  BPT
regulatory  flow of 29,200 1/kkg (7,000 gal/ton) is based on  the
average  of  16  of  19  reported  production  normalized   rinse
application  rates.   Three  reported  values were  riot  used  to
calculate the average because they are much larger than the other
values.   Therefore,  the  Agency  does  not believe  that  these
outlying  values are representative of current typical water  use
for this operation.

Alkaline Cleaning

Six plants supplied information on alkaline cleaning  operations.
All six plants discharge spent cleaning baths and rinse.

Titanium Alkaline Cleaning Spent Baths.  Flow data were available
for  seven of the eight reported baths.   The BPT regulatory flow
of  240 1/kkg (57.5 gal/ton) is the median production  normalized
discharge flow of the seven reported wastewater discharges.   The
median  is believed to be a better representation of the  current
typical discharge for this operation than the average because  of
the large range of reported production normalized discharge flows
(52.1 1/kkg to 9,810 1/kkg).

Titanium  Alkaline Cleaning Rinse.   Flow data were available for
six of the seven reported rinse operations.   No recycle or other
flow  reduction practices were used in any of  these  operations.
The  BPT regulatory flow of 2,760 1/kkg (663 gal/ton) is based on
the median production normalized water use from four  operations.
Two  operations  with  very high flows were not included  in  the
calculation.   Both of these very high flows came from operations
described  as "Free-Flowing Rinses."  Because this is  the  least
efficient  type  of  rinsing,  in terms of  water  use,  the  two
operations  were  excluded  from  the  determination  of  current
typical  practice  used  for the BPT allowance.   The  median  is
believed  to  be a better representation of the  current  typical
water  use for this operation than the average (arithmetic  mean)
                               1597

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because  of the large range of rinse flows even  after  excluding
the two high values (3-?8 1/kkg to 82,300 1/kkg) .

Molten Salt Treatment

Titanium Molten Salt Rinse.   One plant reported generating rinse
from a molten salt treatment operation.   The BPT regulatory flow
of  955 1/kkg (229 gal/ton) is based on the production normalized
discharge flow from this operation.

Tumbling

Titanium  Tumbling  Wastewater.   One plant  reported  generating
wastewater  from a titanium tumbling operation.   The  wastewater
from this operation is discharged on a once-through  basis.   The

BPT  discharge  flow of 790 1/kkg (189 gal/ton) is based  on  the
production normalized water use for this operation.

Sawing or Grinding

Thirteen  plants  reported generating wastewater from  sawing  or
grinding operations.  The following information is available from
these plants:

Number of plants and operations using neat oil lubricant:  2
Number  of  plants and operations using emulsions  and  synthetic
coolants:  11 plants, 19 operations
Number of plants and operations using contact cooling water:  1.

Titanium  Sawing or Grinding Spent Neat Oils.   In one operation,
the  only loss of neat oils occurs through evaporation and  drag-
out.   Spent  neat  oils from the other  operation  are  contract
hauled  to  treatment  and disposal off-site.   It is  better  to
remove  neat oils directly by contract hauling than to  commingle
the oils with wastewater streams only to remove them later  using
an  oil-water separation process.   Therefore,  this waste stream
should not be discharged.

Titanium  Sawing or Grinding Spent Emulsions and Synthetic  Cool-
ants.    In  this  subcategory,   these  lubricants  are   either
completely  recycled with no discharge or recycled with  periodic
batch  discharges.   The  lubricants in four operations are  com-
pletely recycled with no discharge.  In four other operations the
only  loss  of  lubricant is through  evaporation  and  drag-out.
Lubricant  is periodically dumped from  seven  operations.   Flow
data  were  available for six of the operations  which  discharge
spent  emulsions and synthetic coolants.   Recycle with  periodic
batch  discharges is practiced in four of these operations  while
no recycle is used for the other two operations.   The BPT regula-
tory  flow  of 183 1/kkg (43.8 gal/ton) is based on  the  average
production  normalized discharge flow from these six  operations.
The  four  recycle  operations were included in  the  calculation
since recycle is current typical industry practice.
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Titanium  Sawing or Grinding Contact Cooling Water.    The use  o£
contact  cooling  water  was reported  for  only  one  operation.
Cooling  water  is discharged on a once-through basis  from  this
operation.   The  BPT  regulatory  flow  of  4,760  1/kkg  (1,140
gal/ton) is based on the production normalized water use for this
operation.

Product Testing

Titanium Dye Penetrant Testing Wastewater.   Wastewater is gener-
ated  from six dye penetrant testing operations.   Flow data  are
available  for two of these operations.   The BPT regulatory flow
of  1,120 1/kkg (268 gal/ton) is based on the average  production
normalised discharge flow from these two operations.

Miscellaneous Wastewater Sources

TJ tanium Miscellaneous Wastewater Sources.   Miscellaneous waste-
water  sources identified in this subcategory include  wastewater
from cleaning tools,  hydrotesting wastewater,  and spillage from
an abrasive saw area.  Discharge data were only available for the
tool  cleaning and hydrotesting operations.   The BPT  regulatory
flow  of  32.4 1/kkg (7.77 gal/ton) is based  on  the-  production
normalized  discharge  flow  from the  tool  cleaning  operation.
Hydrotesting  wastewater is not included in the basis because the
Agency  believes  that  hydrotesting  wastewater  should  not  be
discharged,  but  should  be  reused for  hydrotesting  or  other
forming operations.

Degreasing

Titanium  Degreasing  Spent Solvents.   Only a  small  number  of
surveyed  plants with solvent degreasing operations have  process
wastewater  streams associated with the operation.   Because most
plants practice solvent degreasing without wastewater  discharge,
the  Agency believes zero discharge of wastewater is an appropri-
ate discharge limitation.

Wet Air Pollution Control

Titanium  Wet Air Pollution Control Slowdown.   Titanium  forming
plants  reported  using  wet air  pollution  control  devices  to
control  air emissions from forging and surface treatment  opera-
tions.   Ninety  percent or greater recycle of the scrubber water
is  practiced  by  five of the 14 reported  operations  and  only
periodic  batch discharges were reported for  another  operation.
Scrubber  water  is discharged on a once-through basis from  five
operations.   No flow data are available for the remaining  three
operations.  The BPT regulatory flow of 2,140 1/kkg (514 gal/ton)
is  based on the median production normalized water use from  the
11  operations  for  which water use data  were  available.   The
median  is believed to be a better representation of the  current
typical  water use than the average (arithmetic mean) because-  of
the  large range of production normalized water uses from the  11
operations (88.1 1/kkg to 554,000 1/kkg).


                               1599

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Deleted Waste Streams

Titanium Cold Rolling Spent Lubricants.    Following proposal, the
Agency  received  additional data and conducted a review  of  all
available data concerning wastewater discharges in this  subcate-
gory.   This  review  led  to  a reinterpretation  of  some  data
reported prior to proposal.   As a result, the Cold Rolling Spent
Lubricant  waste stream included in the proposed  regulation  for
this subcategory has been deleted from the final regulation.  All
data  included  under Cold Rolling Spent Lubricants at  proposal,
have been reclassified under other waste streams in this subcate-
gory for the final regulation.

Regulated Pollutants

The  priority pollutants considered for regulation under BPT  are
listed  in Section VI along with an explanation of why they  have
been  considered.   The pollutants selected for regulation  under
BPT are lead,  zinc,  cyanide, ammonia,  fluoride, oil and grease,
total  suspended solids,  and pH.   The priority metals chromium,
copper,  and nickel,  and the nonconventional pollutant  titanium
are   not  specifically  regulated  under  BPT  for  the  reasons
explained in Section X.  The basis for regulating oil and grease,
total suspended solids and pH under BPT was discussed earlier  in
this  section.   The basis for regulating  lead,  zinc,  cyanide,
ammonia, and fluoride is discussed below.

Lead  is selected for regulation since it was found at  treatable
concentrations  in  18 of 21 raw wastewater  samples.   Lead  was
present at treatable concentrations in all raw wastewater streams
in  which  it was analyzed.   These streams are  rolling  contact
cooling water,  surface treatment spent baths,  surface treatment
rinse,  molten  salt rinse,  tumbling wastewater,  dye  penetrant
testing wastewater, wet air pollution control blowdown and sawing
or grinding spent emulsions and synthetic coolants.

Zinc  is selected for regulation since it was found at  treatable
concentrations  in  10 of 21 raw wastewater  samples.   Zinc  was
present  at  treatable concentrations in seven of the  eight  raw
wastewater streams in which it was analyzed.

Cyanide  is selected for regulation since it  was found at  treat-
able  concentrations in rolling contact  cooling  water,  tumbling
wastewater,  dye  penetrant  testing wastewater,  and  sawing  or
grinding  spent  emulsions and synthetic  coolants.   Preliminary
cyanide  precipitation  is needed to remove this  pollutant  from
wastewater.   Therefore, regulation of cyanide is appropriate for
the titanium forming subcategory.

Ammonia  is selected for regulation since it  was found at  treat-
able  concentrations  in  surface treatment  rinse  and  tumbling
wastewater.   Preliminary  ammonia steam stripping is  needed  to
remove ammonia from these wastewaters.   Therefore, regulation of
ammonia is appropriate for the titanium forming subcategory.


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Fluoride  is selected for regulation since it was found at treat-
able concentrations in 17 of 22 raw wastewater samples and  seven
of the eight raw wastewater streams in which it was analyzed.

Treatment Train

The  BPT model treatment train for the titanium forming  subcate-
gory  consists of preliminary treatment when necessary,  specifi-
cally  chemical  emulsion  breaking  and  oil  skimming,  cyanide
precipitation,  and ammonia steam stripping.   The effluent  from
preliminary  treatment  is  combined with  other  wastewater  for
common  treatment  by oil skimming and lime  and  settle.   Waste
streams  potentially needing preliminary treatment are listed  in

Table  IX-6.   Figure  IX-1 presents a schematic of  the  general
treatment train for the nonferrous metals forming category.

Effluent Limitations

The pollutant mass discharge limitations (milligrams of pollutant
per  off-kilogram of PNP) were calculated by multiplying the  BPT
regulatory flows summarized in Table IX-21 (1/kkg) -by the concen-
tration  achievable by the BPT model treatment system  summarized
in  Table  VII-21 (mg/1) for each pollutant parameter  considered
for regulation at BPT (1/kkg x mg/1 x kkg/1,000 kg =  mg/off-kg).
The  results of this computation for all waste streams and  regu-
lated  pollutants in the titanium forming subcategory are  summa-
rized  in  Table  IX-22.    Although  no  limitations  have  been
established  for  titanium,  Table IX-22 includes  titanium  mass
discharge  limitations attainable using the BPT model technology.
These  limitations are presented as guidance for permit  writers.
This limitation table lists all the pollutants which were consid-
ered  for regulation.   Those specifically regulated  are  marked
with an asterisk.

Costs and Benefits

In establishing BPT,  EPA must consider the cost of treatment and
control  in  relation to the effluent  reduction  benefits.   BPT
costs  and benefits are tabulated along with BAT costs and  bene-
fits in Section X.  As shown in Table X-8 (page xxxx), the appli-
cation  of  BPT  to the total titanium forming  subcategory  will
remove  approximately  350,650 kg/yr (771,430 Ibs/yr)  of  pollu-
tants,  including  300 kg/yr (660 Ibs/yr) of  toxic  metals.   As
shown  in Table X-l,  the corresponding capital and annual  costs
(1982  dollars)  for this removal are $2.879 million  and  $2.571
million  per year,  respectively.   As shown in Table X-18  (page
xxxx),  the  application  of BPT to direct dischargers only  will
remove approximately 105,460 kg/yr (232,010 Ibs/yr) of pollutants
including  90 kg/yr (200 Ibs/yr) of toxic metals.   As  shown  in
Table X-2 (page xxxx), the corresponding capital and annual costs
(1982  dollars)  for this removal are $2.238 million  and  .$2.261
million per year,  respectively.  The Agency concludes that these
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pollutant  removals justify the costs incurred by plants in  this
subcategory.


URANIUM FORMING SUBCATEGORY

Production Operations and Discharge Flows

Production  operations  that generate process wastewater  in  the
uranium  forming subcategory  include  extrusion,  forging,  heat
treatment,  surface treatment,  sawing,  grinding, area cleaning,
drum washing,  on-site laundries, and degreasing.  The wet scrub-
bers  used  for air pollution control at some plants are  also  a
source  of process wastewater.   Water use practices,  wastewater
streams,  and  wastewater discharge flows from  these  operations
were discussed in Section V.  This information provided the basis
for  development of the BPT regulatory flow allowances summarized
in Table IX-23.   The following paragraphs discuss the basis  for
the BPT flow allowances for each waste stream.

Extrusion

Extrusion is performed at one uranium forming plant.  The follow-
ing  information  was  reported on extrusion operations  by  this
plant:

Number of operations:  1
Number of operations using lubricants:  1
Number of operations using contact cooling water:  1.

Uranium Extrusion Spent Lubricants.  No lubricants are discharged
from  the  one uranium extrusion operation where  their  use  was
reported.   Extrusion lubricants are typically neat oils.  Should
a  uranium  forming  plant need to dispose of a  spent  neat  oil
stream,  it  would  be  better to remove the stream  directly  by
contract hauling rather than to commingle the oil with wastewater
streams  only  to remove it later using an  oil-water  separation
process.  Therefore, this waste stream should not be discharged.

Uranium Extrusion Tool Contact Cooling Water.  One plant reported
using  contact  cooling  water to  quench  extrusion  tools.   No
recycle  is  practiced for this  operation.   The  BPT  discharge
allowance  is the production normalized water use from the opera-
tion, 344 1/kkg (82.5 gal/ton).

Forging

The  following information was reported on forging operations  in
this subcategory:

Number of plants:   1
Number of operations:  1
Number of operations using lubricants:  1.
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Uranium Forging Spent Lubricants.    No lubricants are  discharged
fromthe  only  reported forging operation.   The only  loss  of
lubricant from this operation is due to evaporation and drag-out.
Forging  lubricants  are  typically  neat  oils.   As  previously
discussed, should a plant need to dispose of the oil, it would be
better to remove the oil directly by contract hauling rather than
to  commingle it with other wastewaters only to remove  it  later
using  an oil-water separation process.   Therefore,  this  waste
stream should not be discharged.

Heat Treatment

Two  plants  reported using contact cooling water in a  total  of
five heat treatment operations.

Uranium  Heat Treatment Contact Cooling Water.   In -three  opera-
tions/  the cooling water is periodically batch discharged.   The
cooling  water  is  discharged on a once-through basis  from  two
operations.  The BPT regulatory flow of 1,900 1/kkg (455 gal/ton)
is  based  on the average production normalized  water  use  from
these two operations.

Surface Treatment

All  three uranium forming plants provided information on surface
treatment  operations.   Three  surface treatment baths  and  two
surface treatment rinse operations were reported.

Uranium Surface Treatment Spent Baths.   Flow data were available
for one of the three surface treatment bath operations.   The BPT
regulatory  flow  of 27.2 1/kkg (6.52 gal/ton) is  based  on  the
production normalized discharge flow from this bath.

Uranium  Surface Treatment Rinse.    Flow data were available  for
each  of  the two reported rinse  operations.   Although  neither
countercurrent cascade rinsing nor recycle is practiced in either
rinse operation, water use for both operations is low, indicating
conservative  water  use.   The BPT regulatory flow of 337  1/kkg
(80.9  gal/ton)  is based on the  average  production  normalized
discharge flow from the two operations.

Sawing or Grinding

Uranium  Sawing or Grinding Spent Emulsions.   Lubricating  emul-
sions  are  used in three operations.   In all three  operations,
spent emulsions are periodically discharged.  Discharge flow data
were  available for two of the operations.   The  BPT  regulatory
flow of 5.68 1/kkg (1.36 gal/ton)  is based on the average produc-
tion normalized discharge flow from the two operations.

Uranium  Sawing  or Grinding Contact Cooling  Water.   One  plant
reported  using contact cooling water to quench parts following a
shear cutting operation.  No information on recycle or other flow
reduction  practices was reported for this  operation.   The  BPT
regulatory  flow  of  1,650 1/kkg (395 gal/ton) is based  on  the


                               1603

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production
tion.
normalized discharge flow from the  quenching  opera-
Uranium  Sawing  or Grinding Rinse.   One plant reported using  a
stagnant rinse after a sawing operation.   The stagnant rinse  is
periodically discharged.   The BPT regulatory flow is the produc-
tion  normalized  discharge flow from the  stagnant  rinse,  4.65
1/kkg (1.12 gal/ton).

Area Cleaning

Uranium Area Cleaning Wastewater.  One plant reported discharging
wastewater  from  cleanup operations in three different areas  of
the plant.   The BPT regulatory flow of 42.9 1/kkg (10.3 gal/ton)
is based on the average production normalized discharge flow from
the three cleanup operations.
Degreasing

Uranium  Degreasing
                Solvents.    Only a  small
	  	  	  	                   number  of
plants with solvent degreasing operations have  process
                                          Because  most
surveyed
wastewater streams associated with the operation.
plants  practice solvent degreasing without wastewater discharge,
the Agency believes zero discharge of wastewater is an  appropri-
ate discharge limitation.

Wet Air Pollution Control

Uranium Wet Air Pollution Control Slowdown.   Two plants reported
usingwet air pollution control scrubber devices to control  air
emissions  from surface treatment operations.   No wastewater  is
discharged  from  one  scrubber operation.   Wastewater  is  only
periodically  discharged  from  the  other  operation.   The  BPT
regulatory  flow  of 3.49 1/kkg (0.836 gal/ton) is based  on  the
production normalized discharge flow from this operation.

Drum Wash

Uranium Drum Washwater.   One plant reported washing solid  waste
drums before they were contract hauled to off-site disposal.  The
BPT  regulatory flow of 44.3 1/kkg (10.6 gal/ton) is based on the
production normalized discharge flow from this operation.

Laundry

Uranium Laundry Washwater.   Wastewater from the on-site launder-
ing of employee uniforms is generated at one plant.   The  Agency
established  the normalizing parameter for this building block as
the  number  of employees,  not a unit of  production.  . The  BPT
regulatory flow of 52.4 I/employee-day (12.6 gal/employee-day) is
based on the water use for the one reported operation.
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Regulated Pollutants

The  priority pollutants considered for regulation under BPT  are
listed  in Section VI along with an explanation of why they  have
been  considered.   The pollutants selected for regulation  under
BPT  are  cadmium,  total  chromium,  copper,  nickel,  fluoride,
molybdenum,  oil and grease, total suspended solids, and pH.  The
priority  pollutants  lead  and  zinc,  and  the  nonconventional
pollutants  uranium and radium-226 are not specifically regulated
for the reasons explained in Section X.  The basis for regulating
oil  and grease,  total suspended solids,  and pH under  BPT  was
discussed  earlier  in this section.   The basis  for  regulating
cadmium,  chromium,  copper,  nickel, fluoride, and molybdenum is
discussed below.

Cadmium  is selected for regulation since it was found at  treat-
able  concentrations  in seven of 14 raw wastewater  samples  and
four  of  the eight raw wastewater streams in which it  was  ana-
lyzed.  Treatable concentrations of cadmium were found in surface
treatment  spent baths,  surface treatment rinse,  area  cleaning
wastewater and sawing, grinding spent emulsions.

Total chromium is selected for regulation since it was present at
treatable  concentrations  in seven of 14 raw wastewater  samples
and  five  of the eight raw wastewater streams in  which  it  was
analyzed.   Treatable concentrations of total chromium were found
in heat treatment contact cooling water,  surface treatment spent
baths,  surface  treatment  rinse,  area cleaning wastewater  and
sawing or grinding spent emulsions.  Total chromium includes both
the  trivalent and hexavalent forms of chromium.   Only the  tri-
valent form is effectively removed by lime and settle technology.
Hexavalent chromium,  which may be present in wastewaters such as
surface treatment spent baths and surface treatment  rinse,  must
be   reduced  to  the  trivalent  form  by  preliminary  chromium
reduction  treatment  in order to meet the  limitation "on  total
chromium  in this subcategory.   Therefore,  regulation of  total
chromium is appropriate for the uranium forming subcategory.

Copper is selected for regulation since it was found at treatable
concentrations  in 10 of 14 raw wastewater samples and six of the
eight  raw wastewater streams in which it was  analyzed.   Copper
was found at treatable concentrations in all of the waste streams
listed  in the previous paragraph for chromium,  and it was  also
present at treatable concentrations in drum washwater.

Lead  is selected for regulation since it was found at  treatable
concentrations  in 13 of 14 raw wastewater samples and  seven  of
the eight raw wastewater streams in which it was analyzed.   Lead
was found at treatable concentrations in all of the waste streams
listed  in the previous paragraph for chromium,  and it was  also
present at treatable concentrations in drum washwater and surface
treatment wet air pollution control blowdown.

Nickel is selected for regulation since it was found at treatable
concentrations  in eight of 14 raw wastewater samples and four of
                               1605

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the  eight  raw  wastewater streams  in  which  it  was  analyzed.
Treatable concentrations of nickel were present in heat treatment
contact  cooling water,  surface treatment spent  baths,  surface
treatment rinse, and area cleaning wastewater.

Fluoride  is  selected  for regulation since it  was  present  at
treatable  concentrations in one of  14 raw wastewater samples and
one  of  eight raw wastewater streams in which it  was  analyzed.
Fluoride is specifically regulated under BPT because it will  not
be  adequately  removed  by  the  technology  (lime  and  settle)
required  for the removal of the regulated priority metals pollu-
tants, copper and nickel.

Molybdenum  is  selected for regulation since it was  present  at
treatable  concentrations in three of 14 raw  wastewater  samples
and  two  of  the eight raw wastewater streams in  which  it  was.
analyzed.  Molybdenum is specifically regulated under BPT because
it  will  not be adequately removed  by the technology  (lime  and
settle)  required for the removal of the regulated priority metal
pollutants,  copper and nickel.   The addition of iron to a  lime
and  settle system (i.e.,  iron coprecipitation) is necessary for
efficient removal of molybdenum.   Regulation of priority  metals
only  is not sufficient to ensure the removal of molybdenum  from
uranium forming wastewater.

Treatment Train

The BPT model treatment train for the uranium forming subcategory
consists  of preliminary treatment when  necessary,  specifically
chromium  reduction,  and  chemical  emulsion  breaking  and  oil
skimming.   The  effluent from preliminary treatment is  combined
with other wastewater for common treatment by oil skimming,  iron
coprecipitation,  and lime and settle.  Waste streams potentially
needing  preliminary treatment are listed in Table IX-7.    Figure
IX-1 presents a schematic of the general BPT treatment train  for
the nonferrous metals forming category.

Effluent Limitations

The pollutant mass discharge limitations (milligrams of pollutant
per  off-kilogram of PNP) were calculated by multiplying the  BPT
regulatory flows summarized in Table IX-23 (1/kkg) by the concen-
tration  achievable by the BPT model treatment system  summarized
in  Table  VII-21 (mg/1) for each pollutant parameter  considered
for regulation'at BPT (1/kkg x mg/1 x kkg/1,000 kg =  mg/off-kg).
The  results of this computation for all waste streams and  regu-
lated  pollutants  in the uranium forming subcategory are  summa-
rized  in  Table  IX-24.    Although  no  limitations  have  been
established  for  uranium,   Table  IX-24  includes  uranium  mass
discharge limitations attainable using the BPT model  technology.
These  limitations  are  presented  for the  guidance  of  permit
writers.   The  limitations table lists all the pollutants  which
were considered for regulation.   Those specifically regulated are
marked with an asterisk.
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Costs and Benefits

In establishing BPTf  EPA must consider the cost of treatment and
control and the pollutant reduction benefits to evaluate economic
achievability. As shown in Table X-9 (page xxxx), the application
of  BPT  to  the total uranium forming  subcategory  will  remove
approximately  23,100 kg/yr (50,820 Ibs/yr) of pollutants includ-
ing 46 kg/yr (100 Ibs/yr) of toxic pollutants.   The  application
of  BPT  to  direct dischargers will remove the  same  amount  of
pollutants  since all uranium forming plants are direct discharg-
ers.   Since there are only two plants in this subcategory, total
subcategory  and direct discharger capital and annual costs  will
not be reported in this document in order to protect  confidenti-
ality  claims.   The Agency concludes that the pollutant removals
justify the costs incurred by plants in this subcategory.

ZINC FORMING SUBCATEGORY

Production Operations and Discharge Flows

Production  operations  that generate process wastewater  in  the
zinc forming subcategory include rolling,  drawing,  direct chill
casting,  stationary casting,  annealing heat treatment,  surface
treatment,  alkaline cleaning,  sawing, grinding, degreasing, and
electroplating.   Water use practices,  wastewater  streams,  and
wastewater  discharge flows from these operations were  discussed
in  Section V.   This information provided the basis for develop-
ment  of the BPT regulatory flow allowances summarized  in  Table
IX-25.   The  following paragraphs discuss the basis for the  BPT
flow allowances for each, waste stream.
Rolling

Rolling is performed at four zinc forming plants.
information is available from these plants:
The following
Number  of  plants and operations using neat  oil  lubricant:
Number  of  plants and operations using  emulsion  lubricant:
Number  of plants and operations using contact cooling water:
plant, 2 operations.
            1
            3
            1
Zinc  Rolling Spent Neat Oils.   The one rolling  operation  that
uses  a  neat oil lubricant does not discharge any of the  lubri-
cant.   Drag-out  on  the product surface accounts for  the  only
loss.   Should  the plant ever need to dispose the neat  oil,  it
would  be better to remove the oil directly by  contract  hauling
and  not to discharge the stream.   Therefore,  this waste stream
should not be discharged.

Zinc Rolling Spent Emulsions.  The spent emulsion from one of the
three  operations  is applied to land;  the spent  emulsion  from
another operation is contract hauled; and the spent emulsion from
the third operation is treated on-site and the water fraction  is
completely  reused.   As  discussed previously for rolling  spent
emulsions  in  the lead-tin-bismuth  forming  subcategory,  spent
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emulsions  are  often created on-site and  the  water  discharged
(with  the  oil  fract:on contract  hauled).  Therefore,  EPA  is
providing a discharge allowance.   The BPT discharge allowance is
1.39  1/kkg  (0.334  gal/ton),   the  only  reported   production
normalized flow.

Zinc Rolling Contact Cooling Water.  Flow data were available for
two  of  the  three rolling operations where the use  of  contact
cooling water was reported.   Contact cooling water is discharged
on a once-through basis from both operations.  The BPT regulatory
flow  of 536 1/kkg (129 gal/ton) is based on the average  produc-
tion normalized water use from the two operations.

Drawing

Drawing is performed at seven plants in this  subcategory.   Pour
plants reported the use of emulsion lubricants in a total of four
drawing operations.

Zinc Drawing Spent Emulsions.  The spent emulsion from two of the
four  operations  is contract hauled and the spent emulsion  from
two operations is treated on-site and the water fraction is  dis-
charged.   Flow  data  were available for one of the four  opera-
tions.   The BPT regulatory flow of 5.80 1/kkg (1.39 gal/ton)  is
based  on  the  production normalized discharge  flow  from  this
operation.

Casting

Casting  is performed at six zinc forming plants.   The following
information is available from these plants:

Number  of plants and operations with direct chill casting  using
contact cooling water:  2
Number  of  plants and operations with stationary  casting  using
contact cooling water:  1
Number of plants and operations with continuous casting:  2
Number dry:  2.

Zinc  Direct Chill Casting Contact Cooling  Water.   The  contact
cooling  water from one operation is completely recycled with  no
discharge;  the contact cooling water from the other operation is
discharged  with no recycle.   The BPT discharge allowance is 505
1/kkg (121 gal/ton),  the production normalized water use for the
one reported non-zero discharge operation.

Zinc  Stationary  Casting Contact  Cooling  Water.   The  contact
cooling  water  in  the one operation is  completely  evaporated.
Therefore, the BPT discharge allowance is zero.

Heat Treatment

The  following information was reported on heat treatment  opera-
tions in this subcategory:
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Number of plants:  1
Number of operations:  1
Number of operations using contact cooling water:
                    1.
Zinc Annealing Heat Treatment Contact Cooling Water.  The contact
cooling  water in the one operation is batch dumped  daily.   The
BPT discharge allowance is 763 1/kkg (183 gal/ton),  the  produc-
tion normalized discharge flow from the one operation.

Surface Treatment

Two  plants provided information on zinc surface treatment opera-
tions.   Four surface treatment baths and three surface treatment
rinse operations were reported.

Zinc  Surface Treatment Spent Baths.   Discharge flow  data  were
available for three of the four baths.   The BPT discharge allow-
ance of 88.7 1/kkg (21.3 gal/ton) is based on the average produc-
tion normalized discharge flow from the three operations.

Zinc  Surface  Treatment Rinse.   Neither countercurrent  cascade
rinsing  or  recycle was reported for any of  the  three  surface
treatment  rinse  operations.   The BPT regulatory flow of  3,580
1/kkg is based on the average production normalized water use for
the three operations.
Alkaline Cleaning

Two  plants supplied information on alkaline cleaning.   At
plant, an alkaline cleaning bath is followed by a rinse.
                              each
Zinc Alkaline Cleaning Spent Baths.   The BPT regulatory flow  of
3.55  1/kkg(0.850 gal/ton) is based on the  average  production
normalized  discharge  flow from the two alkaline  cleaning  bath
operations.

Zinc  Alkaline Cleaning Rinse.   Two stage countercurrent cascade
rinsing  is  utilized  in  one operation  and  spray  rinsing  is
practiced in the other operation.   Both of these rinsing methods
reduce  water use compared to traditional rinsing  methods.   The
BPT  discharge flow of 1,690 1/kkg (405 gal/ton) is based on  the
average production normalized discharge flow from the two  opera-
tions.
Sawing or Grinding
                                             One
                   plant  provided
An emulsion is used as a lubricant
Zinc  Sawing  or Grinding Spent Emulsions.
information on grinding zinc.
in  the grinding operation.    The emulsion is completely recircu-
lated and periodically batch dumped.   The BPT discharge allowance
is 23.8 1/kkg (5.71 gal/ton),  the production normalized discharge
flow from the operation.
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Degreasing

Zinc Degreasing Spent Solvent.   Only a small number of  surveyed
plants with solvent degreasing operations have process wastewater
streams  associated  with  the operation.   Because  most  plants
practice  solvent degreasing without  wastewater  discharge,  the
Agency  believes  zero discharge of wastewater is an  appropriate
discharge limitation.

Electrocoating

Zinc  Electrocoating  Rinse.    One  plant  reported  discharging
wastewater  from  an electrocoating  rinse  operation.   The  BPT
discharge  allowance of 2,290 1/kkg (550 gal/ton) is based on the
production normalized water use for the rinse operation.

Regulated Pollutants

The  priority pollutants considered for regulation under BPT  are
listed  in Section VI along with an explanation of why they  were
considered.  The pollutants selected for regulation under BPT are
total chromium,  copper,  zinc,  cyanide,  oil and grease,  total
suspended solids,  and pH.  The priority pollutant nickel, listed
in  Section  VI as selected for  further  consideration,  is  not
specifically  regulated  under BPT for the reasons  explained  in
Section  X.  The  basis  for regulating  oil  and  grease,  total
suspended  solids,  and pH was discussed earlier in this section.
The  basis  for regulating  total  chromium,  copper,  zinc,  and
cyanide is discussed below.

Total  chromium  is  selected for regulation since it  was  found
above  treatability in a surface treatment rinse sample  and  the
Agency believes it is also present at treatable concentrations in
surface treatment spent baths.  Surface treatment baths and rinse
may contain the hexavalent form of chromium which must be reduced
by  the  trivalent form by preliminary chromium reduction  before
mium is appropriate for this subcategory.

Copper is selected for regulation since the Agency believes  that
treatable  concentrations of copper may be present in raw  waste-
water  streams  such as electrocoating rinse.   In  one  electro-
coating operation reported in this subcategory,  copper is plated
onto  zinc.    Therefore,  the  electrocoating  rinse  from  this
operation is likely to contain treatable copper concentrations.

Zinc  is selected for regulation since it was found at  treatable
concentrations  in  both raw wastewater streams in which  it  was
analyzed  and  it is the metal being formed in this  subcategory.
In  addition,  the  Agency  believes that  other  raw  wastewater
streams may contain treatable zinc concentrations.

Cyanide  is selected for regulation since it was found above  its
treatable concentration in an alkaline cleaning rinse sample  and
is  a  process  chemical  used  in  the  electrocoating  process.
Preliminary  cyanide precipitation treatment is needed to  remove


                               1610

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cyanide from wastewater.  Therefore, regulation of cyanide in the
zinc forming subcategory jLs appropriate.

Treatment Train

The  BPT  model treatment train for the zinc forming  subcategory
consists  of preliminary treatment when  necessary,  specifically
chromium reduction,  chemical emulsion breaking and oil skimming,
and cyanide precipitation.   The effluent from preliminary treat-
ment  is combined with other wastewater for common  treatment  by
oil  skimming,  and lime and settle.   Waste streams  potentially
needing  preliminary treatment are listed in Table IX-8.   Figure
IX-1 presents a schematic of the general BPT treatment train  for
the nonferrous metals forming category.

Effluent Limitations

The pollutant mass discharge limitations (milligrams of pollutant
per  off-kilogram of PNP) were calculated by multiplying the  BPT
regulatory flows summarized in Table IX-25 (1/kkg) by the concen-
tration  achievable by the BPT model treatment system  summarized
in  Table  VII-21 (mg/1) for each pollutant parameter  considered
for regulation at BPT (1/kkg x mg/1 x kkg/1,000 kg -  mg/off-kg).
The  results of this computation for all waste streams and  regu-
lated  pollutants in the zinc forming subcategory are  summarized
in Table IX-26.   This limitations table lists all the pollutants
which  were  considered  for regulation  and  those  specifically
regulated are marked with an asterisk.

Costs and Benefits

In  establishing  BPT,  EPA considered the cost of treatment  and
control and the pollutant reduction benefits to evaluate economic
achievability.   As shown in Table X-10 (page xxxx), the applica-
tion  of  BPT to the total zinc forming subcategory  will  remove
approximately  308,260  kg/yr  (678,170  Ibs/yr)  of   pollutants
including 262,210 kg/yr (576,860 Ibs/yr) of toxic pollutants.  As
shown in Table X-20 (page xxxx), the application of BPT to direct
dischargers only will remove approximately 307,400 kg/yr (676,280
Ibs/yr) of pollutants including 262,150 kg/yr (576,730 Ibs/yr) of
toxic pollutants.  Since there is only one direct discharge plant
in  this subcategory,  total subcategory capital and-annual costs
and  direct  discharger  capital and annual  costs  will  not  be
reported  in  this document in order to  protect  confidentiality
claims.  The Agency concludes that the pollutant removals justify
the costs incurred by plants in this subcategory.

ZIRCONIUM-HAFNIUM FORMING SUBCATEGORY

Production  operations  that generate process wastewater  in  the
zirconium-hafnium  forming subcategory include rolling,  drawing,
extrusion,   swaging,  tube  reducing,  heat  treatment,  surface
treatment,  alkaline  cleaning,  molten salt  treatment,  sawing,
grinding,  product testing,  and degreasing.   The wet  scrubbers
used  for air pollution control at some plants are also a  source
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of process wastewater.   Water use practices, wastewater streams,
and  wastewater  discharge flows from these operations were  dis-
cussed  in Section V.   This information provided the  basis  for
development  of the BPT regulatory flow allowances summarized  in
Table IX-27.   The following paragraphs discuss the basis for the
BPT flow allowances for each waste stream.

Production Operations and Discharge Flows

Rolling

Rolling  is  performed at seven plants in  the  zirconium-hafnium
forming subcategory.  One plant reported using a lubricant in one
rolling operation.
Zirconium-Hafnium  Rolling
jent  Neat  Oils.
No neat
 	             oils  are
Should the plant ever  find
                     remove
dischargedfrom the one operation.
the  need to dispose the neat oil,  it would be better to
the oil directly by contract hauling rather than to commingle the
oil  with wastewater streams and remove it later using  oil-water
separation treatment.  Therefore, this waste stream should not be
discharged.

Drawing

Drawing  is performed at four plants in this subcategory.   These
plants  reported  using  lubricant in a total  of  three  drawing
operations.

Zirconium-Hafnium  Drawing Spent Lubricants.   The only  loss  of
lubricantin one operation is through evaporation and  drag-out;
spent  lubricants from another operation are contract hauled;  no
flow information is available for the other  operation.   Drawing
lubricants are typically neat oils.  It is better to remove these
lubricants  directly by contract hauling rather than to commingle
the lubricants withvwastewater streams only to remove them later.
Therefore, this waste stream should not be discharged.

Extrusion

Extrusion is performed at five zirconium-hafnium forming  plants.
The following information is available from these plants:

Number of plaats and operations using lubricants:   4 plants,   5
operations
Number of plants and operations with hydraulic fluid leakage:  1.
Zirconium-Hafnium Extrusion Spent Lubricants.
                  No lubricants are
                Should a plant need
discharged from any of the five operations.
to dispose of these lubricants, it would be better to remove them
directly by contract hauling rather than commingle the lubricants
with wastewater streams and remove them later.   Therefore,  this
waste-stream should not be discharged.
                                612

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Zirconium-Hafnium  Extrusion Press Hydraulic Fluid Leakage.   One
plant  reported the discharge of leakage from extrusion  presses.
Hydraulic fluid leaks result from the moving connection points in
high pressure extrusion presses.   The BPT discharge allowance of
237  1/kkg (56.9 gal/ton) is based on the  production  normalized
discharge flow of leakage from the one operation.

Swaging

Zirconium-Hafnium  Swaging Spent Neat Oils.   One plant  reported
using neat oil lubricants in a swaging operation.   The only loss
of neat oils from this operation is through dragout.   Should the
plant ever need to dispose of spent neat oils, it would be better
to  remove  the oil directly by contract hauling rather  than  to
combine  the neat oil with wastewater streams and then remove  it
later  using  oil-water separation  treatment.   Therefore,  this
waste stream should not be discharged.

Tube Reducing

Zirconium-Hafnium Tube Reducing Spent Lubricants.  There shall be
no discharge allowance for the discharge of pollutants from  tube
reducing spent lubricants, if once each month for six consecutive
months  the facility owner or operator demonstrate the absence of
N-nitrosodi-n-propylamine,    N-nitrosodimethylamine,    and   N-
nitrosdiphenylamine by sampling and analyzing spent tube reducing
lubricants.   If the facility complies with this requirement  for
six  months then the frequency of sampling may be reduced to once
each quarter.   A facility shall be considered in compliance with
this  requirement if the concentrations of the three  nitrosamine
compounds  does not exceed the analytical  quantification  levels
set  forth  in  40  CFR  Part 136 which are  0.020  mg/1  for  N-
nitrosodiphenylamine,  0.020 mg/1 for  N-nitrosodi-n-propylamine,
and 0.050 mg/1 for N-nitrosodimethylamine.

Heat Treatment

Zirconium-Hafnium Heat Treatment Contact Cooling Water.   Contact
coolingwater is used in six heat  treatment  operations.   Flow
information was available for four of these operations.   The BPT
regulatory  flow  of  343 1/kkg (82.3 gal/ton) is  based  on  the
median  production normalized water use for the four  operations.
The  median  is  believed to be a better  representation  of  the
current  typical  water use for this operation than  the  average
(arithmetic  mean) because of the large range of reported produc-
tion normalized water uses (135 1/kkg to 6,000 1/kkg).

Surface Treatment

Eight plants supplied information on surface treatment operations
in the zirconium-hafnium forming subcategory.

Zirconium-Hafnium Surface Treatment Spent Baths.   Flow data- were
available  for nine of the 14 reported surface  treatment  baths.
The  BPT regulatory flow of 340 1/kkg (81.5 gal/ton) is based  on


                               1613

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the  median  production  normalized discharge flow  of  the  nine
operations.  The median is believed to be a better representation
of  the  current typical discharge from this operation  than  the
average  (arithmetic mean) because of the large range of  produc-
tion normalized discharge flows  (102 1/kkg to 64,300 1/kkg).
Zirconium-Hafnium  Surface  Treatment  Rinse.
                                                 Flow  data
                                                 treatment
                                                             were
                                                            rinse
available  for  10  of the 12 reported  surface
operations.   Countercurrent  cascade rinsing and recycle are not
practiced in any of these operations.  The BPT regulatory flow of
8,880  1/kkg  (2,130 gal/ton) is based on the  median  production
normalized  water  use  for the 10  operations.   The  median  is
believed  to  be a better representation of the  current  typical
water  use for this operation than the average (arithmetic  mean)
because  of the large range of production normalized  water  uses
(297 1/kkg to 971,000 1/kkg).
                                                    A total of 13
                                                   Flow data were
Alkaline Cleaning

Zirconium-Hafnium  Alkaline Cleaning Spent Baths.
alkaline cleaning bath operations were reported.
available for 12 of these operations.  The BPT regulatory flow of
1,600  1/kkg  (384 gal/ton) is based on  the  average  production
normalized discharge flow of the 12 operations.

Zirconium-Hafnium  Alkaline  Cleaning  Rinse.    Flow  data  were
available  for  10 of 11 reported alkaline cleaning rinse  opera-
tions.   Countercurrent  cascade  rinsing  and  recycle  are  not
practiced in any of these operations.  The BPT regulatory flow of
31,400  1/kkg (7,530 gal/ton) is based on the average  production
normalized water use for the 10 operations.
Molten Salt Treatment

Zirconium-Hafnium  Molten  Salt  Rinse.    Two  plants   reported
discharging   molten   salt  rinse.    Neither  plant   practices
Countercurrent cascade rinsing or recycle of the  rinse,  however
the water use for one plant was very low (only 20.86 1/kkg).  The
BPT  regulatory  flow of 7,560 1/kkg (1,810 gal/ton) is based  on
the   average  production  normalized  water  use  for  the   two
operations.

Sawing or Grinding

Zirconium-Hafnium Sawing or Grinding Spent Neat Oils.  The use of
a  neat oil lubricant was reported for only one  operation.   The
only  loss of lubricant from this operation is through  drag-out.
Should  spent neat oil from this operation ever need to  be  dis-
posed, it would be better to contract haul the lubricant directly
and  not to discharge the stream.   Therefore,  this waste stream
should not be discharged.

Zirconium-Hafnium Sawing or Grinding Spent Emulsions.  The use of
emulsion lubricants was reported for seven operations.   No  flow
      were  available  for three operations;  the  only  loss  of
                               1614

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emulsion  from  three  other operations is from  evaporation  and
drag-out;  flow  data were available for one operation  in  which
spent emulsion is periodically discharged to an evaporation pond.
Since  spent  emulsions are often treated on-site and  the  water
fraction  discharged  (with the oil fraction reused  or  contract
hauled),  EPA is allowing a discharge for this waste stream.  The
BPT  regulatory flow of 281 1/kkg (67.2 gal/ton) is based on  the
production  normalized discharge flow for the one operation which
discharges spent emulsion to an evaporation pond.

Zirconium-Hafnium Sawing or Grinding Contact Cooling Water.  Flow
data  were available for one of the two operations where the  use
of contact cooling water was reported.   The BPT regulatory  flow
of 321 1/kkg (77.0 gal/ton) is based on the production normalized
discharge flow from this operation.

Zirconium-Hafnium   Sawing  or  Grinding  Rinse.    Products  are
sometimes  rinsed  following  grit blasting  and  belt  polishing
operations.  Pour rinse operations were reported in this subejCte-
gory.   No recycle is practiced in any of these operations.   The
BPT regulatory flow of 1,800 1/kkg (431 gal/ton) is based on  the
median  production normalized water use for the four  operations.
The  median  is  believed to be a better  representation  of  the
current  typical  water use for this operation than  the  average
(arithmetic  mean)  because  of  the large  range  of  production
normalized water uses (123 1/kkg to 19,600 1/kkg).

Product Testing

Zirconium-Hafnium Inspection and Testing Wastewater.   Wastewater
is  discharged  from  four product  testing  operations  in  this
subcategory:  a hydrotesting operation, a non-destructive testing
operation,  a dye penetrant testing operation,  and an ultrasonic
tube testing operation.    Flow data were available for the hydro-
testing operation and non-destructive testing operation.  The BPT
regulatory  flow  of  15.4 1/kkg (3.70 gal/ton) is based  on  the
production  normalized  discharge flow from  the  non-destructive
testing  operation.   The  hydrotesting operation  flow  was  not
included  in  the regulatory flow calculation because the  Agency
believes that the water used for hydrotesting can be recycled  or
reused in other water-demanding operations at the forming plant.

Degreasing

Zirconium-Hafnium  Degreasing Spent Solvents.   Three  degreasing
operations were reported in this subcategory.   In one operation,
the  solvent  is  completely recycled with  no  discharge;   spent
solvent from two operations is contract hauled.   Therefore,  the
BPT discharge allowance is zero.

Zirconium-Hafnium   Degreasing   Rinse.    One  plant   dischages
wastewater from a degreasing rinse operation.   This is the  only
plant in the subcategory discharging wastewater from a degreasing
operation.   Samples  of  this  wastewater  were  analyzed  after
proposal  and  high concentrations of volatile  organic  solvents


                               1615

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were  detected.   Some  plants degrease formed zirconium  without
generating  any  wastewater by using solvents which need  not  be
followed  by a water rinse,  while other plants  degrease  formed
zirconium   without  solvents,   by  using  alkaline   (detergent)
cleaning followed by a water rinse.   Because the Agency believes
this  plant could'achieve zero discharge by converting the  water
rinse  into  a  second  solvent cleaning  step  or  could  use  a
detergent  cleaning  instead of solvents,  the BPT allowance  for
this solvent degreasing rinse stream is based on zero discharge.

Wet Air Pollution Control

Zirconium-Hafnium  Wet Air Pollution Control Slowdown.   Water is
used  in wet air pollution control devices on surface  treatment,
rolling,  forging,  and extrusion operations.   A total of  eight
operations  where wet air pollution control devices are used were
identified.   However, wastewater is reported to be discharged to
surface water from only one of the eight operations.   Therefore,
since  the  majority of plants with this  wastewater  stream  are
achieving  no  discharge  from this stream,  there  shall  be  no
allowance for the discharge of wastewater pollutants.

Regulated Pollutants

The  priority pollutants considered for regulation under BPT  are
listed  in Section VI along with an explanation of why they  were
considered.  The pollutants selected for regulation under BPT are
total chromium,  nickel, cyanide, fluoride, oil and grease, total
suspended solids, and pH.   The priority pollutants copper, lead,
and  zinc,  and  the  nonconventional  pollutants  zirconium  and
hafnium, are not specifically regulated under BPT for the reasons
explained in Section X.  The basis for regulating oil and grease,
total  suspended  solids,  and pH was discussed earlier  in  this
section.   The  basis  for  regulating  total  chromium,  nickel,
cyanide, ammonia, and fluoride is discussed below.

Total  chromium is selected for regulation since it was found  at
treatable  concentrations in 10 of 19 raw wastewater samples  and
five  of  nine raw wastewater streams in which it  was  analyzed.
Treatable  total  chromium  concentrations  were  found  in  tube
reducing spent lubricant,  surface treatment spent baths, surface
treatment  rinse,  alkaline cleaning spent baths,  and degreasing
spent  solvents.   Waste streams such as surface treatment  spent
baths and surface treatment rinse may contain the hexavalent form
of  chromium. '  As  previously  discussed,  preliminary  chromium
reduction  is  needed  to  reduce  hexavalent  chromium  to   the
trivalent  state since the hexavalent form is not removed by lime
and settle technology.   Therefore,  regulation of total chromium
is appropriate for this subcategory.

Nickel is selected for regulation since it was found at treatable
concentrations  in six of 19 raw wastewater samples and three  of
the nine raw wastewater streams in which it was analyzed.  Nickel
was  found  at treatable concentrations in  tube  reducing  spent
                               1616

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lubricant,  surface  treatment spent baths,  and degreasing spent
solvents.                       •                     .

Cyanide  is selected for regulation since it was found at  treat-
able concentrations in surface treatment spent  baths.   Prelimi-
nary  cyanide  precipitation is needed to remove  this  pollutant
from wastewater.  Therefore, regulation of cyanide is appropriate
for tnis subcategory.

Ammonia  is  selected  for  regulation because it  was  found  at
treatable  concentrations  in surface treatment  baths  and  tube
reducing  spent lubricants.   Preliminary ammonia steam stripping
may be needed to remove ammonia from these  wastewaters.   There-
fore,  regulation  of  ammonia is appropriate for the  zirconium-
hafnium forming subcategory.

Fluoride is selected for regulation since it was found at  treat-
able  concentrations  in  five  of  18  raw  wastewater  samples.
Fluoride  was found at treatable concentrations in surface treat-
ment baths and rinses.

Treatment Train

The  BPT model treatment train for the zirconium-hafnium  forming
subcategory  consists  of preliminary treatment  when  necessary,
specifically chromium reduction,  chemical emulsion breaking  and
oil  skimming,  and  cyanide precipitation.   The  effluent  from
preliminary  treatment  is  combined with  other  wastewater  for
common  treatment  by oil skimming and lime  and  settle.   Waste
streams  potentially needing preliminary treatment are listed  in
Table IX-9.   Figure IX-1 presents a schematic of the general BPT
treatment train for the nonferrous metals forming category.

Effluent Limitations

The pollutant mass discharge limitations (milligrams of pollutant
per  off-kilogram of PNP) were calculated by multiplying the  BPT
regulatory flows summarized in Table IX-27 (1/kkg) by the concen-
tration  achievable by the BPT model treatment system  summarized
in  Table  VII-21 (mg/1) for each pollutant parameter  considered
for regulation at BPT (1/kkg x mg/1 x kkg/1,000 kg =  mg/off-kg).
The  results of this computation for all waste streams and  regu-
lated pollutants in the zirconium-hafnium forming subcategory are
summarized  in  Table IX-28.   Although no limitations have  been
established  for  zirconium and  hafnium,  Table  IX-28  includes
zirconium and hafnium mass discharge limitations attainable using
the  BPT model technology.   These limitations are presented  for
the guidance of permit writers.   The limitations table lists all
the  pollutants  which  were considered  for  regulation.   Those
specifically regulated are marked with an asterisk.

Costs and Benefits

In establishing BPT,  EPA must consider the cost of treatment and
control  in  relation to the effluent  reduction  benefits.   BPT
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costs  and benefits are tabulated along with BAT costs and  bene-
fits  in  Section  X.   As shown in Table X-ll  (page xxxx),  the
application of BPT to the total zirconium-hafnium forming subcat-
egory  will remove approximately 17,340 kg/yr (38,150 Ibs/yr)  of
pollutants  including 640 kg/yr (1,410 Ibs/yr) of  toxic  metals.
As  shown in Table X-l (page xxxx), the corresponding capital and
annual  costs (1982 dollars) for this removal are $0.367  million
and $0.330 million per year,  respectively.  As shown in Table X-
21 (page xxxx), the application of BPT to direct dischargers only
will  remove  approximately  16,315  kg/yr  (35,890  Ibs/yr)   of
pollutants  including  640 kg/yr (1,410 Ibs/yr) of toxic  metals.
As shown in Table X-2 (page xxxx), the corresponding capital  and
annual  costs (1982 dollars) for this removal are $0.359  million
and $0.327 million per year,  respectively.  The Agency concludes
that  these  pollutant  removals justify the  costs  incurred  by
plants in this subcategory.

METAL POWDERS SUBCATEGORY

Production Operations and Discharge Flows

Production  operations  that generate process wastewater  in  the
metal   powders  subcategory  include  metal  powder  production,
tumbling,  burnishing,  cleaning, sawing, grinding, sizing, steam
treatment,  oil-resin impregnation, degreasing, hot pressing, and
mixing.   Water use practices,  wastewater streams and wastewater
discharge  flows from these operations were discussed in  Section
V.   This  information provided the basis for development of  the
BPT  regulatory flow allowances summarized in Table  IX-29.   The
following  paragraphs discuss the basis for the BPT  flow  allow-
ances for each waste stream.

Metal Powder Production

Metal powder production operations were reported by approximately
70  plants  in this subcategory.   The following  information  is
available from these plants:

Number  of plants and operations with wet atomization wastewater:
5 plants, 6 operations
Number  of plants and operations with wet air  pollution  control
devices:  2.

Metal  Powder Production Wet Atomization Wastewater.    No recycle
was reported for any of the six operations.   From an examination
of  the  available data,   it is not apparent that  there  is  any
significant  difference  in  water use and  discharge  among  the
different  metals in this subcategory.   Therefore,  the BPT dis-
charge  allowance is the average production normalized  discharge
flow from the six operations, 5,040 1/kkg (1,210 gal/ton).

Tumbling, Burnishing or Cleaning

Metal  Powders  Tumbling,   Burnishing  or_  Cleaning  Wastewater.
Twer^'-r.ine p^^s reported information on 40 tumbling,   burnish-
                               1618

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ing,  and other physical-chemical cleaning operations  associated
with  powder  metallurgy parts production.   Water use data  were
available  for 25 operations.   The BPT regulatory flow of  4,400
1/kkg (1,050 gal/ton) is based on the average production  normal-
ized water use for the 25 operations.

Sawing or Grinding

Metal  Powders  Sawing or Grinding Spent Neat Oils.    A neat  oil
lubricant  is used in one operation.   Spent neat oils from  this
operation are contract hauled to treatment and disposal off-site.
It  is  better  to handle neat oils in this  manner  rather  than
combine  them with wastewater streams only to remove  them  later
using  oil-water separation treatment.   Therefore,   the BPT dis-
charge allowance is zero.

Metal  Powders  Sawing or  Grinding  Spent  Emulsions.   Emulsion
lubricants  are  used  in seven  operations.   No  emulsions  are
discharged  from one operation;  emulsions are periodically  dis-
charged from five operations; emulsions are discharged on a once-
through  basis  from one operation.   The  production  normalized
discharge flow from the once-through operation is over five times
higher than the discharge values from the other operations.  This
value was not included in the regulatory flow calculation because
it  does not represent the current typical discharge practice for
this  subcategory.   The BPT regulatory flow of 18.1 1/kkg  (4.33
gal/ton) is based on the average production normalized  discharge
flow of the five periodic discharge operations.

Metal Powders Sawing or_ Grinding Contact Cooling Water.   Contact
cooling water is used in four operations.   Plow data were avail-
able  for  one .of these operations.   The cooling water  is  dis-
charged on a once-through basis from this operation.  The current
water  use  at  the one plant reporting flow  data  is  excessive
compared to current water use for this operation in other subcat-
egories.  The BPT regulatory flow of 1,620 1/kkg (389 gal/ton) is
based  on 99 percent recycle of the water use for this one opera-
tion.   This is comparable to the allowance for this operation in
other subcategories.

Sizing

Metal  Powders Sizing Spent Neat Oils.   Neat oil lubricants  are
used  in  two sizing operations.   The neat oils  are  completely
recycled with no discharge in either operation.   Should the neat
oil from either operation ever need to be disposed,   it would  be
better to directly remove the oil by contract hauling rather than
to  commingle the oil with wastewater streams and then remove  it
later.  Therefore, the BPT discharge allowance is zero.

Metal  Powders Sizing Spent Emulsions.   An emulsion lubricant is
used  in one sizing operation.   Since spent emulsions are  often
treated  on-site and the water fraction discharged by  plants  in
this  category and other categories,  EPA is allowing a discharge
for this waste stream.  The BPT discharge allowance of 14.6 1/kkg


                               1619

-------
 (3.50  gal/ton)  is based on the production normalized  water  use
 for this operation.

 Steam Treatment

 Metal Powders Steam Treatment Wet Air Pollution Control Blowdown.
 One  plant operates a wet scrubber to control air pollution  from
 its steam treatment process.  No recycle of the scrubber water is
 practiced.   The  BPT  discharge  allowance  of  792  1/kkg  (190
 gal/ton)  is based on the production normalized water use for the
 one operation.

 Oil-Resin Impregnation

 Metal  Powders  Oil-Resin Impregnation Spent  Neat  Oils.   Seven
 plants  reported using neat oils in oil-resin  impregnation  pro-
 cesses.   Neat  oils are completely recycled with no discharge in
 two  operations;  spent neat oils from three operations are  con-
 tract hauled; no data are available for the other two operations.
 It  is  better to remove neat oils directly by  contract  hauling
 rather  than to commingle them with wastewater streams  and  then
 remove  them later using oil-water separation treatment.   There-
 fore, this waste stream should not be discharged.

 Degreasing

Metal Powders Degreasing Spent Solvents.   Only a small number of
 surveyed  plants with solvent degreasing operations have  process
 wastewater streams associated with the operation.   Because  most
plants  practice solvent degreasing without wastewater discharge,
 the Agency believes zero discharge of wastewater is an  appropri-
ate discharge limitation.

Hot Pressing

Metal  Powders  Hot Pressing Contact Cooling  Water.   One  plant
 reported using contact cooling water in a hot pressing operation.
 None  of  the cooling water used in this operation  is  recycled.
The  BPT regulatory flow of 8,800 1/kkg (2,110 gal/ton)  is  based
on the production normalized water use for the one operation.

Mixing

Metal  Powders.  Mixing Wet Air Pollution Control  Blowdown.   One
plant reported using a wet scrubber to control air pollution from
a  mixing  operation.   Ninety percent of the scrubber  water  is
 recycled.  The BPT regulatory flow of 7,900 1/kkg (1,890 gal/ton)
 is  based  on the production normalized discharge flow  from  the
scrubber.

Deleted Waste Streams

Metal Powder Production Milling Wastewater.   Following proposal,
 the Agency received additional data and conducted a review of all
avai1*v»le data concerning wastswater discharges in this  subcate-


                               1620

-------
gory.   This  review  led  to  a reinterpretation  of  some  data
reported  prior  to proposal.   As a  result,  the  Metal  Powder
Production  Milling  wastewater stream included in  the  proposed
regulation  for this subcategory has been deleted from the  final
regulation.   This  waste  stream  was improperly  classified  at
proposal.   Since  the plant believed to have this wastewater  at
proposal  actually  mills  fabricated  parts,   not  powder,  its
reported   production  normalized  flow  was  included   in   the
calculation  of the tumbling,  burnishing or cleaning  wastewater
discharge allowance.

Metal  Pp.wder  Production  Wet Air  Pollution  Control  Slowdown.
Prior to proposal,  two plants reported the use of wet air pollu-
tion  control  devices associated with metal powders  production.
One plant reported complete recycle of scrubber water;  the other
reported  that  85  percent of the scrubber  water  is  recycled.
Following proposal,  the Agency received additional data concern-
ing  wastewater  discharges  in  this  subcategory.   These  data
included  the  fact that the discharging scrubber  is  no  longer
operated.   Therefore, the Metal Powder Production Wet Air Pollu-
tion  Control  Slowdown  waste stream included  in  the  proposed
regulation  for this subcategory has been deleted from the  final
regulation.

Regulated Pollutants

The  priority pollutants considered for regulation under BPT  are
listed  in Section VI along with an explanation of why they  were
considered.  The pollutants selected for regulation under BPT are
copper, lead, cyanide, oil and grease, total suspended solids and
pH.   The priority pollutants chromium, nickel, and zinc, and the
nonconventional pollutants iron and aluminum are not specifically
regulated under BPT for the reasons explained in Section X.   The
basis for regulating oil and grease,  total suspended solids, and
pH  was  discussed  earlier  in  this  section.   The  basis  for
regulating copper, lead, and cyanide is discussed below.

Copper is regulated since it is one of the metals being processed
in  this subcategory and it was found at treatable concentrations
in  10  of 18 raw wastewater samples and three of  the  four  raw
wastewater streams in which it was analyzed.   Copper was present
at  treatable  concentrations  in  metal  powder  production  wet
atomization wastewater,  tumbling,  burnishing or cleaning waste-
water, and sawing or grinding spent emulsions.

Lead  is selected for regulation since it was found at  treatable
concentrations  in eight of 18 samples and three of the four  raw
wastewater  streams in which it was analyzed.   Lead was found at
treatable concentrations in the same raw waste streams listed  in
the previous paragraph for copper.

Cyanide  is  selected  for  regulation since it  was  present  in
treatable  concentrations in eight of 17 raw  wastewater  samples
and  three  of  the four raw wastewater streams in which  it  was
analyzed.   Treatable  concentrations  of cyanide were  found  in


                               1621

-------
tumbling,  burnishing or cleaning wastewater,  sawing or grinding
spent  emulsions,  and steam treatment wet air pollution  control
blowdown.   Preliminary cyanide precipitation is needed to remove
cyanide from these wastewater streams.   Therefore, regulation of
cyanide is appropriate for this subcategory.

Treatment Train

The  BPT model treatment train for the metal powders  subcategory
consists  of preliminary treatment when  necessary,  specifically
chemical emulsion breaking and oil skimming and cyanide  precipi-
tation.  The effluent from preliminary treatment is combined with
other  wastewater  for common treatment by oil skimming and  lime
and  settle.    Waste  streams  potentially  needing  preliminary
treatment  are  listed in Table IX-10.   Figure IX-1  presents  a
schematic  of the general BPT treatment train for the  nonferrous
metals forming category.

Effluent Limitations

The pollutant mass discharge limitations (milligrams of pollutant
per  off-kilogram of PNP) were calculated by multiplying the  BPT
regulatory flows summarized in Table IX-29 (1/kkg) by the concen-
tration  achievable by the BPT model treatment system  summarized
in  Table VII-21 (mg/1) for each pollutant  parameter  considered
for  regulation at BPT (1/kkg x mg/1 x kkg/1,000 kg = mg/off-kg).
The  results of this computation for all waste streams and  regu-
lated pollutants in the metal powders subcategory are  summarized
in  Table IX-30.   Although no limitations have been  established
for  iron  and  aluminum,  Table IX-30  includes  mass  discharge
limitations  for these pollutants attainable using the BPT  model
technology.   These limitations are presented for the guidance of
permit  writers.   The limitations table lists all the pollutants
which  were  considered  for  regulation.    Those   specifically
regulated are marked with an asterisk.

Costs and Benefits

In  establishing BPT,  EPA considered the cost of  treatment  and
control and the pollutant reduction benefits to evaluate economic
achievability.   As shown in Table X-12 (page xxxx), the applica-
tion  of  BPT to the total metal powders subcategory will  remove
approximately 57,570 !:g/yr (126,650 Ibs/yr) of pollutants includ-
ing 1,085 kg/yr (2,390 Ibs/yr) of toxic pollutants.   As shown in
Table  X-22  (page  xxxx),  the  application  of  BPT  to  direct
dischargers  only  will remove approximately 4,105  kg/yr  (9,030
Ibs/yr)  of pollutants including 128 kg/yr (282 Ibs/yr) of  toxic
pollutants.   Since there are only three direct discharge  plants
in  this subcategory,  total subcategory capital and annual costs
will  not  be  reported  in this document  in  order  to  protect
confidentiality claims.   The Agency concludes that the pollutant
removals   justify   the  costs  incurred  by  plants   in   this
subcategory.
                               1622

-------
APPLICATION OF REGULATION IN PERMITS

The  purpose  of these limitations (and standards) is to  form  a
uniform basis for regulating wastewater effluent from the nonfer-
rous metals forming category.   For direct dischargers,  this  is
accomplished through NPDES permits.   Since the nonferrous metals
forming  category  is  regulated on an  individual  waste  stream
"building-block"  approach,  three  examples  of  applying  these
limitations  to determine the allowable discharge from nonferrous
metals forming facilities are given below.

Example 1

Plant  X  forms a refractory metal strip by a  rolling  operation
which uses an emulsion as a lubricant.  The plant produces 20 kkg
(44,000 Ibs) of final product strip per day.   In the process,  a
stock  billet is heated and put through a reversing rolling  mill
for five passes,  then annealed (dry annealing),  brought back to
the rolling mill for three more passes,  annealed  again,  rolled
for  four more passes,  and annealed for a final time to  produce
the  product.   Table  IX-31 illustrates the calculation  of  the
allowable  BPT discharge for nickel,  one of the pollutants regu-
lated in this subcategory.  The allowable discharge for the other
regulated pollutants would be calculated in the same way.

This  example illustrates the calculation of an allowable  pollu-
tant  mass discharge using "off-kilograms."  The term  "off-kilo-
gram"  means  the  mass of metal or metal alloy  removed  from  a
forming operation at the end of a process cycle for transfer to a
different machine or process.   A reversing mill allows the metal
to  pass between the rollers several times without having  to  be
removed from the mill.   Therefore,  on a multiple pass roll, the
mass  of  metal rolled is considered to have been processed  only
once;  the off-mass equals the mass.   In this example, since the
metal  is removed from the reversing mill for annealing and  then
returned,  the off-mass of rolling equals the mass of metal times
the  number of times it is returned to the  process.   Therefore,
for  this  plant,  the off-kilograms to produce 20 kkg  of  final
product is 60 off-kkg.   This is the daily production used in the
calculations presented in Table IX-31.

Example 2

Plant  Y forms lead bullets by an extrusion and  swaging  process
and casts lead shot.  The plant operates 250 days per year with a
total  annual production of 250,000 kg (551,000 Ibs) of shot  and
1,000,000  kg  (2,205,000 Ibs) of bullets.   Shot is produced  by
casting.   Bullets  are  produced  by casting  lead  into  ingots
(stationary casting), extrusion followed by a spray quench at the
press,  and swaging.  Approximately 5 percent of the lead is lost
to scrap following extrusion.   The bullets are washed and rinsed
before being assembled into cartridges.   Table IX-32 illustrates
the calculation of the allowable BPT discharge of total suspended
solids (TSS).
                               1623

-------
The daily shot casting production is 250,000 kg/yr divided by 250
days/yr  or 1,000 kg/day.   The number of kg of shot produced  is
equal  to  the  number of  off-kg  formed.   This  production  is
multiplied  by the shot casting limitation (mg/off-kg) to get the
daily  discharge limit for shot casting at Plant  Y.   The  daily
amount  of  lead cast and extruded is 1,050,000 kg/yr divided  by
250  days/yr or 4,200 kg/day.   This production is multiplied  by
the limitations (mg/off-kg) for extrusion press or solution  heat
treatment  contact  cooling water and extrusion  press  hydraulic
fluid leakage to get the first part of the daily discharge limits
for  bullet  making.   The daily bullet production  is  1,000,000
kg/yr divided by 250 days/yr or 4,000 kg/day.  This production is
multiplied  by  the  limitations (mg/off-kg)  for  swaging  spent
emulsions,  alkaline cleaning spent baths,  and alkaline cleaning
rinse  to  get the second part of the daily discharge limits  for
bullet  making.   The sum of the daily limits for the  individual
operations becomes the plant limit.
                     ^

Example 3

Plant Z forms nickel and titanium alloys.   This plant forges 125
kkg  (275,000 Ibs) of nickel and 25 kkg (55,000 Ibs) of  titanium
per year (250 days).  Eighty percent of the nickel and 10 percent
of the titanium are pickled, then rinsed with a spray.  The plant
also contact cools forgings with water following forging and  has
a  wet  air pollution control scrubber to control the fumes  from
the pickling bath.   This example demonstrates the application of
the limitations for nickel which is a regulated pollutant in  the
nickel  forming subcategory and for cyanide a regulated pollutant
in the titanium forming subcategory to the combined discharge  of
nickel  forming  process wastewater and titanium forming  process
wastewater.   Table IX-33 illustrates the calculation of the  BPT
discharge allowance for nickel.  Although nickel was not specifi-
cally  regulated  in  the titanium  forming  subcategory,  it  is
present  in  treatable concentrations in titanium forming  waste-
water.   The Agency chose not to specifically regulate nickel  in
this  subcategory  because it should be adequately controlled  by
the other regulated pollutants.   Since nickel is present in  the
titanium  forming wastewater,  Plant Z will need an allowance for
nickel  from  this  source to comply with  the  nickel  discharge
allowance.   Therefore,  the  mass allowance for nickel from  the
titanium  forming wastewater is added to the mass allowance  from
nickel-cobalt  forming.   The mass limitations for nickel can  be
obtained  from Tables IX-16 and IX-22 which provide  the  limita-
tions  for  regulated pollutants and other pollutants  considered
for but not specifically regulated.

The  calculation of the mass allowance for the pollutant  cyanide
is  illustrated  in Table IX-34.   Cyanide is  regulated  in  the
titanium  forming  subcategory,  but  not  in  the  nickel-cobalt
forming  subcategory.   Cyanide  was  not  found  in  significant
quantities  in any nickel-cobalt process wastewater,  and was not
considered  for  regulation  in  the  nickel-cobalt  subcategory.
Since  the nickel-forming process wastewater from Plant  Z  would
not  be expected to contribute any cyanide to the mass loading in
                               1624

-------
the effluent,  it is not appropriate to add a mass allowance  for
cyanide  from the nickel forming wastewater to the mass allowance
for cyanide from the titanium forming wastewater.
                               1625

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-------
                           Table IX-12

              LEAD-TIN-BISMUTH FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Lead-Tin-Bismuth Forming
Rolling Spent Emulsions
Pollutant or           Maximum for     Maximum for
pollutant property     any one day     monthly average

mg/off-kg (Ib/million off-lbs) of lead-tin-bismuth
rolled with emulsions

*Antimony                     .067                .030
*Lead                         .010                .005
*Oil and Grease               .468                .281
*TSS                          .960                .457
   *pH    Within the range of 7.5 to 10.0 at all times
BPT
Lead-Tin-Bismuth Forming
Rolling Spent Soap Solutions

Pollutant or~~Maximum forMaximum for
pollutant property     any one day     monthly average

mg/off-kg (Ib/million off-lbs) of lead-tin-bismuth
rolled with soap solutions

*Antimony                     .124                .055
*Lead                         .018                .009
*Oil and Grease               .860                .516
*TSS                         1.770                .839
   *pH    Within the range of 7.5 to 10.0 at all times
BPT
Lead-Tin-Bismuth Forming
Drawing Spent Neat Oils

     There shall be no discharge of process wastewater
     pollutants.
                                1641

-------
                     Table IX-12 (Continued)

              LEAD-TIN-BISMUTH FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Lead-Tin-Bismuth Forming
Drawing Spent Emulsions
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of lead-tin-bismuth
drawn with emulsions
*Antimony
*Lead
*0il and Grease
*TSS
       .076
       .011
       .526
      1.080
           .034
           .005
           .316
           .513
          Within the range of 7.5 to 10.0 at all times
BPT
Lead-Tin-Bismuth Forming
Drawing Spent Soap Solutions
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of lead-tin-bismuth
drawn with soap solutions
*Antimony
*Lead
*Oil and Grease
*TSS
       .021
       .003
       .149
       .306
           .010
           .001
           .090
           .146
          Within the range of 7.5 to 10.0 at all times
                               1642

-------
                     Table IX-12 (Continued)

              LEAD-TIN-BISMUTH FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS

BPT
Lead-Tin-Bismuth Forming
Extrusion Press or Solution Heat Treatment CCW

Pollutant orMaximum forMaximum for
pollutant property     any one day     monthly average

mg/off-kg (Ib/million off-lbs) of lead-tin-bismuth
heat treated

*Antimony                    4.130               1.850
*Lead                         .605                .288
*Oil and Grease             28.800              17.300
*TSS                        59.100              28.100
   *pH    Within the range of 7.5 to 10.0 at all times
BPT
Lead-Tin-Bismuth Forming
Extrusion Press Hydraulic Fluid Leakage

Pollutant orMaximum forMaximum for
pollutant property     any one day     monthly average

mg/off-kg (Ib/million off-lbs) of lead-tin-bismuth
extruded

*Antimony                     .158                .070
*Lead                         .023                .011
*Oil and Grease              1.100                .660
*TSS                         2.260               1.070
   *pH    Within the range of 7.5 to 10.0 at all times
                               1643

-------
                     Table IX-12 (Continued)

              LEAD-TIN-BISMUTH FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Lead-Tin-Bismuth Forming
Swaging Spent Emulsions
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of lead-tin-bismuth
swaged with emulsions

*Antimony                    .0051               .0023
*Lead                        .0008               .0004
*Oil and Grease              .0354               .0213
*TSS                         .0726               .0345
   *pH    Within the range of 7.5 to 10.0 at all times
BPT
Lead-Tin-Bismuth Forming
Continuous Strip Casting Contact Cooling Water
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of lead-tin-bismuth
cast by the continuous strip method
*Antimony
*Lead
*Oil and Grease
*TSS
      .0029
      .0004
      .0200
      .0410
          .0013
          .0002
          .0120
          .0195
          Within the range of 7.5 to 10.0 at all times
                               1644

-------
                     Table IX-12 (Continued)

              LEAD-TIN-BISMUTH FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS

BPT
Lead-Tin-Bismuth Forming
Semi-Continuous Ingot Casting Contact Cooling Water

Pollutant orMaximum forMaximum for
pollutant property     any one day     monthly average

mg/off-kg (Ib/million off-lbs) of lead-tin-bismuth
ingot cast by the semi-continuous method

*Antimony                     .084                .038
*Lead                         .012                .006
*0il and Grease               .588                .353
*TSS                         1.210                .574
   *pH    Within the range of 7.5 to 10.0 at all times
BPT
Lead-Tin-Bismuth Forming
Shot Casting Contact Cooling Water .

Pollutant orMaximum forMaximum for
pollutant property     any one day     monthly average

mg/off-kg(Ib/million off-lbs) of lead-tin-bismuth
shot cast

*Antimony                     .107                .048
*Lead                         .016                .007
*Oil and Grease               .746                .448
*TSS                         1.530                .728
   *pH    Within the range of 7.5 to 10.0 at all times
                               1645

-------
                     Table IX-12 (Continued)

              LEAD-TIN-BISMUTH FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Lead-Tin-Bismuth Forming
Shot-Forming Wet Air Pollution Control Slowdown
Pollutant or
pollutant property
             Maximum for
             any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of lead^-tin-bismuth
shot formed
*Antimony
*Lead
*Oil and Grease
*TSS
                   1.690
                    .247
                  11.800
                  24.100
           .753
           .118
          7.060
         11.500
    'pH
Within the range of 7.5 to 10.0 at all times
BPT
Lead-Tin-Bismuth Forming
Alkaline Cleaning Spent Baths
Pollutant or
pollutant property
             Maximum for
             any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of lead-tin-^bismuth
alkaline cleaned
*Antimony
*Lead
*Oil and Grease
*TSS
                    .345
                    .050
                   2.400
                   4.920
           .154
           .024
          1.440
          2.340
          Within the range of 7.5 to 10.0 at all times
                               1646

-------
                     Table IX-12 (Continued)

              LEAD-TIN-BISMUTH FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Lead-Tin-Bismuth Forming
Alkaline Cleaning Rinse
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of lead-tin-bismuth
alkaline cleaned
*Antimony                    6.780               3.020
*Lead                         .991                .472
*0il and Grease             47.200              28.300
*TSS                        96.800              46.000
*pH    Within the range of 7.5 to 10.0 at all times
BPT
Lead-Tin-Bismuth Forming
Degreasing Spent Solvents

     There shall be no discharge of process wastewater
     pollutants.
                               1647

-------
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-------
                           Table ix-14

                  MAGNESIUM FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Magnesium Forming
Rolling Spent Emulsions
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of magnesium
rolled with emulsions
*Chromium
*Zinc
*Ammonia
*Fluoride
 Magnesium
*Oil and Grease
*TSS
       .033
       .109
      9.950
      4.440
       .007
      1.490
      3.060
            .013
            .046
          4.370
          1.970

            .895
          1.460
          Within the range of 7.5 to 10.0 at all times
BPT
Magnesium Forming
Forging Spent Lubricants.

     There could be no discharge of process wastewater
     pollutants.
BPT
Magnesium Forming
Forging Contact Cooling Water
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of forged magnesium
cooled with water
*Chromium
*Zinc
*Ammonia
*Fluoride
 Magnesium
*Oil and Grease
*TSS
      1.270
      4.220
    385.000
    172.000
       .289
     57.800
    119.000
           .520
          1.760
        170.000
         76.300

         34.700
         56.400
          Within the range of 7.5 to 10.0 at all times
                               1649

-------
                     Table.IX-14 (Continued)

                  MAGNESIUM FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Magnesium Forming
Forging Equipment Cleaning Wastewater
Pollutant or
pollutant property
             Maximum for
             any one day
Maximum for
monthly average
mg/off-kg(Ib/million off-lbs)of magnesium
forged
*Chromium
*Zinc
*Ammonia
*Fluoride
 Magnesium
*Oil and Grease
*TSS
                   .0176
                   .0583
                  5.3200
                  2.3800
                   .0040
                   .7980
                  1.6400
           ,0072
           ,0244
           ,3400
           ,0600

           ,4790
           ,7780
   "pH
Within the range of 7.5 to 10.0 at all times
BPT
Magnesium Forming
Direct Chill Casting Contact Cooling Water
Pollutant or
pollutant property
             Maximum for
             any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of magnesium
cast with direct chill methods
*Chromium
*Zinc
*Ammonia
*Fluoride
 Magnesium
*Oil and Grease
*TSS
                   1.740
                   5.770
                 527..000
                 235.000
                    .395
                  79.000
                 162.000
           .711
          2.410
        232.000
        104.000

         47.400
         77.000
   *pH
Within the range of 7.5 to 10.0 at all times
                               1650

-------
                     Table IX-14 (Continued)

                  MAGNESIUM FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Magnesium Forming
Surface Treatment Spent Baths
Pollutant or
pollutant property
             Maximum for
             any one day
Maximum for
monthly average
mg/off-kg(Ib/million off-lbs) of magnesium
surface treated
*Chromium
*Zinc
*Ammonia
*Fluoride
 Magnesium
*Oil and Grease
*TSS
                    .205
                    .681
                  62.100
                  27.700
                    .047
                   9.320
                  19.100
           .084
           .284
         27.300
         12.300

          5.590
          9.090
          Within the range of 7.5 to 10.0 at all times
BPT
Magnesium Forming
Surface Treatment Rinse
Pollutant or
pollutant property
             Maximum for
             any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of magnesium
surface treated
*Chromium
*Zinc
*Ammonia
*Fluoride
 Magnesium
*Oil and Grease
*TSS
                   8.320
                  27.600
               2,520.000
               1,130.000
                   1.890
                 378.000
                 775.000
          3.400
         11.500
      1,110.000
        499.000

        227.000
        369.000
   *pH
Within the range of 7.5 to 10.0 at all times
                              1651

-------
                     Table IX-14 (Continued)

                  MAGNESIUM FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Magnesium Forming
Sawing or Grinding Spent Emulsions
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of magnesium
sawed or ground
*Chromium
*Zinc
*Ammonia
*Fluoride
 Magnesium
*Oil and Grease
*TSS
       .009
       .029
      2.600
      1.160
       .002
       .390
       .800
           .004
           .012
          1.140
           .515

           .234
           .380
          Within the range of 7.5 to 10.0 at all times
BPT
Magnesium Forming
Degreasing Spent Solvents

     There shall be no discharge of process wastewater
     pollutants.
BPT
Magnesium Forming
Wet Air Pollution Control Slowdown
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of magnesium
formed
*Chromium
*Zinc
*Ammonia
*Fluoride
 Magnesium
*Oil and Grease
*TSS
       .273
       .904
     82.500
     36.900
       .062
     12.400
     25.400
           .112
           .378
         36.300
         16.400

          7.430
         12.100
          Within the range of 7.5 to 10.0 at all times
                               1652

-------
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-------
                           Table IX-16

                NICKEL-COBALT FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Nickel-Cobalt Forming
Rolling Spent Neat Oils

     There shall be no discharge of process wastewater
     pollutants.

BPT
Nickel-Cobalt Forming
Rolling Spent Emulsions
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of nickel-cobalt
rolled with emulsions
 Cadmium
*Chromium
 Copper
 Lead
*Nickel
 Zinc
*Fluoride
*Oil and Grease
*TSS
       .058
       .075
       .323
       .071
       .327
       .248
     10.100
      3.400
      6.970
           .026
           .031
           .170
           .034
           .216
           .104
          4.490
          2.040
          3.320
          Within the range of 7.5 to 10.0 at all times
BPT
Nickel-Cobalt Forming
Rolling Contact Cooling Water
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg(Ib/million off-lbs)of nickel-cobalt
rolled with water

 Cadmium                     1.280                .566
*Chromium                    1.660                .679
 Copper                      7.170               3.770
 Lead                        1.590                .754
*Nickel                      7.240               4.790
 Zinc                        5.510               2.300
*Fluoride                  225.000              99.500
*Oil and Grease             75.400              45.300
*TSS      /                155.000              73.500
   *pH   /Within the range of 7.5 to 10.0 at all times
                               1656

-------
                      xaoie xx-ie fcontinued)

                NICKEL-COBALT FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Nickel-Cobalt Forming
Tube Reducing Spent Lubricants

     There shall be no discharge of process wastewater
     pollutants.

BPT
Nickel-Cobalt Forming
Drawing Spent Neat Oils

     There shall be no discharge of process wastewater
     pollutants.
BPT
Nickel-Cobalt Forming
Drawing Spent Emulsions
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs
drawn with emulsions
Cadmium
*Chromium
Copper
Lead
*Nickel
Zinc
*Fluoride
*0il and Grease
*TSS
*pH Within the range of
) of nickel-cobalt
.033
.042
.181
.040
.183
.139
5.680
1.910
3.910
7.5 to 10.0 at all

.014
.017
.095
.019
.121
.058
2.520
1.150
1.860
times
BPT
Nickel-Cobalt Forming
Extrusion Spent Lubricants

     There shall be no discharge of process wastewater
     pollutants.
                              1657

-------
                      Table IX-16  (Continued)

                NICKEL-COBALT FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Nickel-Cobalt Forming
Extrusion Press or Solution Heat Treatment Contact
Cooling Water
Pollutant or
pollutant property
             Maximum for
             any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of nickel-cobalt
heat treated
 Cadmium
*Chromium
 Copper
 Lead
*Nickel
 Zinc
*Fluoride
*0il and Grease
*TSS
                     .028
                     .037
                     .158
                     .035
                     .160
                     .122
                   4.950
                   1.670
                   3.410
            .013
            .015
            .083
            .017
            .106
            .051
          2.200
            .999
          1.620
   *pH
Within the range of 7.5 to 10.0 at all times
BPT
Nickel-Cobalt Forming
Extrusion Press Hydraulic Fluid Leakage
Pollutant or
pollutant property
             Maximum for
             any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of nickel-cobalt
extruded
 Cadmium
*Chromium
 Copper
 Lead
*Nickel
 Zinc
*Fluoride
*Oil and Grease
*TSS
                    .079
                    .102
                    .441
                    .098
                    .446
                    .339
                  13.800
                   4.640
                   9.510
           .035
           .042
           .232
           .046
           .295
           .142
          6.130
          2.790
          4.530
   "pH
Within the range of 7.5 to 10.0 at all times
                               1658

-------
                      Table IX-16 (Continued)

                NICKEL-COBALT FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS

BPT
Nickel-Cobalt Forming
Forging Spent Lubricants

     There shall be no discharge of process wastewater
     pollutants.

BPT
Nickel-Cobalt Forming
Forging Contact Cooling Water
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of forged nickel-cobalt
cooled with water
 Cadmium
*Chromium
 Coppe r
 Lead
*Nickel
 Zinc
*Fluoride
*Oil and Grease
*TSS
       .161
       .209
       .901
       .199
       .910
       .692
     28.200
      9.480
     19.500
           .071
           .085
           .474
           .095
           .602
           .289
         12.500
          5.690
          9.250
          Within the range of 7.5 to 10.0 at all times
BPT Nickel-Cobalt Forming
Forging Equipment Cleaning Wastewater
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of nickel-cobalt
forged
 Cadmium
*Chromium
 Copper
 Lead
*Nickel
 Zinc
*Fluoride
*Oil and Grease
*TSS
       ,0136
       ,0176
       ,0760
       ,0168
       ,0768
       ,0584
       ,3800
       ,8000
       .6400
           0060
           ,0072
           ,0400
           0080
           ,0508
           ,0244
           ,0600
           ,4800
           ,7800
          Within the range of 7.5 to 10.0 at all times
                               1659

-------
                      Table  IX-16  (Continued)

                NICKEL-COBALT FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Nickel-Cobalt Forming
Forging Press Hydraulic Fluid Leakage
Pollutant or
pollutant property
Maximum for
any one day
          Maximum for
          monthly average
mg/off-kg (Ib/million off-lbs) of nickel-cobalt
forged
 Cadmium
*Chromium
 Copper
 Lead
*Nickel
 Zinc
*Fluoride
*0il and Grease
*TSS
        .064
        .082
        .356
        .079
        .359
        .273
     11.100
      3.740
      7.670
                     .028
                     .034
                     .187
                     .037
                     .238
                     .114
                    4.940
                    2.250
                    3.650
          Within the range of 7.5 to 10.0 at all times
BPT
Nickel-Cobalt Forming
Metal Powder Production Atomization Wastewater
Pollutant or
pollutant property
Maximum for
any one day
          Maximum for
          monthly average
mg/off-kg(Ib/million off-lbs) of nickel-cobalt
metal powder atomized
 Cadmium
*Chromium
 Copper
 Lead
*Nickel
 Zinc
*Fluoride
*0il and Grease
*TSS
       .891
      1.150
      4.980
       ,100
        030
      3.830
    156.000
     52.400
    108.000
1,
5,
  .393
  .472
 2.620
  .524
 3.330
 1.600
69.200
31.500
51.100
          Within the range of 7.5 to 10.0 at all times
                              1660

-------
                      Table IX-16  (Continued)

                NICKEL-COBALT FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS

BPT
Nickel-Cobalt Forming
Stationary Casting Contact Cooling Water
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of nickel-cobalt
cast with stationary casting methods
 Cadmium
*Chromium
 Copper
 Lead
*Nickel
 Zinc
*Fluoride
*Oil and Grease
*TSS
      4.120
      5.330
     23.000
      5.080
     23.300
     17.700
    720.000
    242.000
    496.000
          1.820
          2.18C
         12.100
          2.420
         15.400
          7.380
        320.000
        145.000
        236.000
          Within the range of 7.5 to 10.0 at all times
BPT
Nickel-Cobalt Forming
Vacuum Melting Steam Condensate

     There shall be no discharge of process wastewater
     pollutants.

BPT
Nickel-Cobalt Forming
Annealing and Solution Heat Treatment Contact Cooling Water

     There shall be no discharge of process wastewater
     pollutants.
                               1661

-------
                      Table IX-16  (Continued)

                NICKEL-COBALT FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Nickel-Cobalt Forming
Surface Treatment Spent Baths
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg (ib/miilion off-lbs) of nickel-cobalt
surface treated
 Cadmium
*Chromium
 Copper
 Lead
*Nickel
 Zinc
*Fluoride
*Oil and Grease
*TSS
       .318
       .412
      1.780
       .393
      1.800
      1.370
     55.700
     18;700
     38.400
           .140
           .169
           .935
           .187
          1.190
           .571
         24.700
         11.200
         18.300
          Within the range of 7.5 to 10.0 at all times
BPT
Nickel-Cobalt Forming
Surface Treatment Rinse
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg(Ib/million off-lbs) of nickel-cobalt
surface treated
 Cadmium
*Chromium
 Copper
 Lead
*Nickel
 Zinc
*Fluoride
*Oil and Grease
*TSS
      8.030
     10.400
     44.900
      9.910
     45.300
     34.500
  1,410.000
    472.000
    968.000
          3.540
          4.250
         23.600
          4.720
         30.000
         14.400
        623.000
        283.000
        460,000
          Within the range of 7.5 to 10.0 at all times
                               1662

-------
                      Table IX-16 (Continued)

                NICKEL-COBALT FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS  •
BPT
Nickel-Cobalt Forming
Ammonia Rinse
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
•monthly average
mg/off-kg(Ib/million off-lbs) of nickel-cobalt
treated with ammonia solution
 Cadmium
*Chromium
 Copper
 Lead
*Nickel
 Zinc
*Fluoride
*0il and Grease
*TSS
       .005
       .007
       .028
       .006
       .028
       .022
       .881
       .296
       .607
            .002
            .003
            .015
            .003
            .019
            .009
            .391
            .17.8
            .289
          Within the range of 7.5 to 10.0 at all times
BPT
Nickel-Cobalt Forming
Alkaline Cleaning Spent Baths
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of nickel-cobalt
alkaline cleaned
 Cadmium
*Chromium
'Copper
 Lead
*Nickel
 Zinc
*Fluoride
*Oil and Grease
*TSS
       .012
       .015
       .064
       .014
       .065
       .050
      2.020
       .678
      1.390
            .005
            .006
            .034
            .007
            .043
            .021
            .895
            .407
            .661
          Within the range of 7.5 to 10.0 at all times
                               1663

-------
                      Table IX-16  (Continued)

                NICKEL-COBALT FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Nickel-Cobalt Forming
Alkaline Cleaning Rinse
Pollutant or
pollutant property
             Maximum for
             any one day
          Maximum for
          monthly average
mg/off-kg (Ib/million off-lbs) of nickel-cobalt
alkaline cleaned
 Cadmium
*Chromium
 Copper
 Lead
*Nickel
 Zinc
*Fluoride
*Oil and Grease
*TSS
                    .792
                   1.030
                   4.430
                    .979
                    ,480
                    ,400
                 139.000
                  46.600
                  95.600
4,
3,
  .350
  .420
 2.330
  .466
 2.960
 1.420
61.500
28.000
45.500
          Within the range of 7.5 to 10.0 at all times
BPT
Nickel-Cobalt Forming
Molten Salt Rinse
Pollutant or
pollutant property
             Maximum for
             any one day
          Maximum for
          monthly average
mg/off-kg (Ib/million off-lbs) of nickel-cobalt
treated with molten salt
 Cadmium
*Chromium
 Copper
 Lead
*Nickel
 Zinc
*Fluoride
*Oil and Grease
*TSS
                   2.870
                   3.720
                  16.100
                   3.550
                  16.200
                  12.300
                 502.000
                 169.000
                 346.000
                    1.270
                    1.520
                    8.440
                    1.690
                   10.700
                    5.150
                  223.000
                  101.000
                  165.000
   *pH
Within the range of 7.5 to 10.0 at all times
                               1664

-------
                      Table IX-16 (Continued)

                NICKEL-COBALT FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Nickel-Cobalt Forming
Sawing or Grinding Spent Emulsions
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg {Ib/million off-lbs) of nickel-cobalt
sawed or ground with emulsions
 Cadmium
*Chromium
 Copper
 Lead
*Nickel
 Zinc
*Fluoride
*Oil and Grease
*TSS
       .013
       .017
       .075
       .017
       .076
       .058
      2.350
       .788
      1.620
           .006
           .007
           .039
           .008
           .050
           .024
          1.040
           .473
           .769
          Within the range of 7.5 to 10.0 at all times
BPT
Nickel-Cobalt Forming
Sawing or Grinding Rinse
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg {Ib/million off-lbs) of sawed or ground
nickel-cobalt rinsed
 Cadmium
*Chromium
 Copper
 Lead
*Nickel
 Zinc
*Fluoride
*Oil and Grease
*TSS
       .616
       .797
      3.440
       .760
      3.480
      2.640
    108.000
     36.200
     74.200
           .272
           .326
          1.810
           .362
          2.300
          1.110
         47.800
         21.700
         35.300
          Within the range of 7.5 to 10.0 at all times
                               1665

-------
                      Table IX-16 (Continued)

                NICKEL-COBALT FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Nickel-Cobalt Forming
Steam Cleaning Condensate
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of nickel-cobalt
steam cleaned
 Cadmium
*Chromium
 Copper
 Lead
*Nickel
 Zinc
*Fluoride
*Oil and Grease
*TSS
       .010
       .013
       .057
       .013
       .058
       .044
      1.790
       .602
      1.240
           .005
           .005
           .030
           .006
           .038
           .018
           .795
           .361
           .587
          Within the range of 7.5 to 10.0 at all times
BPT
Nickel-Cobalt Forming
Hydrostatic Tube Testing and Ultrasonic Testing
Wastewater           ,;  . •; :. .

     There shall be no discharge of process wastewater
     pollutants.
                               1666

-------
                      Table IX-16 (Continued)

                NICKEL-COBALT FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Nickel-Cobalt Forming
Dye Penetrant Testing Wastewater
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of nickel-cobalt
tested with dye penetrant methods
 Cadmium
*Chromium
 Copper
 Lead
*Nickel
 Zinc
*Fluoride
*Oil and Grease
*TSS
       .072
       .094
       .405
       .090
       .409
       .311
     12.700
      4.260
      8.740
           .032
           .038
           .213
           .043
           .271
           .130
          5.630
          2.560
          4.160
          Within the range of 7.5 to 10.0 at all times
BPT
Nickel-Cobalt Forming
Miscellaneous Wastewater Sources
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of nickel-cobalt
formed
 Cadmium
*Chromium
 Copper
 Lead
*Nickel
 Zinc
*Fluoride
*Oil and Grease
*TSS
       .084
       .108
       .468
       .104
       .473
       .359
     14.700
      4.920
     10.100
           .037
           .044
           .246
           .049
           .313
           .150
          6.500
          2.950
          4.800
          Within the range of 7.5 to 10.0 at all times
                               1667

-------
                      Table IX-16 (Continued)

                NICKEL-COBALT FORMING SUBCATEGORY
                 -   BPT EFFLUENT LIMITATIONS

BPT
Nickel-Cobalt Forming
Degreasing Spent Solvents

     There shall be no discharge of process wastewater
     pollutants.
BPT
Nickel-Cobalt Forming
Wet Air Pollution Control Slowdown
Pollutant or
pollutant property
Maximum for
any one day
          Maximum for
          monthly average
mg/off-kg (Ib/million off-lbs) of nickel-cobalt
formed
 Cadmium
*Chromium
 Copper
 Lead
*Nickel
 Zinc
*Pluoride
*Oil and Grease
*TSS
        ,276
        ,357
        ,540
        ,340
        ,560
        ,180
     48.200
     16.200
     33.200
1,
1,
  .122
  .146
  .810
  .162
 1.030
  .494
21.400
 9.720
15.800
          Within the range of 7.5 to 10.0 at all times
                              1668

-------
                      Table IX-16 (Continued)

                NICKEL-COBALT FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Nickel-Cobalt Forming
Electrocoating Rinse
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of nickel-cobalt
electrocoated
 Cadmium
*Chromium
 Copper
 Lead
*Nickel
 Zinc
*Fluoride
*0il and Grease
*TSS
      1.150
      1.480
      6.410
      1.420
      6.470
      4.920
    201.000
     67.400
    138.000
           .506
           .607
          3.370
           .674
          4.280
          2.060
         89.000
         40.500
         65.700
          Within the range of 7.5 to 10.0 at all times
                               -1669

-------




















































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-------
                           Table IX-18

               PRECIOUS METALS FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Precious Metals Forming
Rolling Spent Neat Oils

     There shall be no discharge of process wastewater
     pollutants.
BPT
Precious Metals Forming
Rolling Spent Emulsions
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of precious metals
rolled with emulsions
*Cadmium
Chromium
*Copper
*Cyanide
*Lead
Nickel
*Silver
Zinc
*Oil and Grease
*TSS
*pH Within the
.026
.034
.147
.022
.032
.148
.032
.113
1.540
3.160
range of 7.5 to 10.0 at all
.012
.014
.077
.009
.015
.098
.013
.0,47
.925
1.510
times
BPT
Precious Metals Forming
Drawing Spent Neat Oils

     There shall be no discharge of process wastewater
     pollutants.
                               1672

-------
                           table IX-18

               PRECIOUS METALS FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Precious Metals Forming
Drawing Spent Emulsions
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg(Ib/million off-lbs)of precious metals
drawn with emulsions
*Cadmium
 Chromium
*Copper
*Cyanide
*Lead
 Nickel
*Silver
 Zinc
*0il and Grease
*TSS
       .016
       .021
       .090
       .014
       .020
       .091
       .020
       .069
       .950
      1.950
           .007
           .009
           .048
           .006
           .010
           .060
           .008
           .029
           .570
           .926
          Within the range of 7.5 to 10.0 at all times
BPT
Precious Metals Forming
Drawing Spent Soap Solutions
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of precious metals
drawn with soap solutions
*Cadmium
 Chromium
*Copper
*Cyanide
*Lead
 Nickel
*Silver
 Zinc
*Oil and Grease
*TSS
      .0011
      .0014
      .0059
      .0009
      .0013
      .0060
      .0013
      .0046
      .0624
      .1280
          .0005
          .0006
          .0031
          .0004
          .0006
          .0040
          .0005
          .0019
          .0375
          .0609
          Within the range of 7.5 to 10.0 at all times
                               1673

-------
                     Table IX-18 (Continued)

               PRECIOUS METALS FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS

BPT
Precious Metals Forming
Metal Powder Production Atomization Wastewater
Pollutant or
pollutant property
             Maximum for
             any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of precious metals
powder wet atomized
*Cadmium
 Chromium
*Copper
*Cyanide
*Lead
 Nickel
*Silver
 Zinc
*0il and Grease
*TSS
                   2.270
                   2.940
                  12.700
                   1.940
                   2.810
                  12.800
                   2.740
                   9.750
                 134.000
                 274.000
          1,
          1,
   ,000
   ,200
  6.680
   .802
  1.340
  8.490
  1.140
  4.080
 80.200
130.000
   *pH
Within the range of 7.5 to 10.0 at all times
BPT
Precious Metals Forming
Direct Chill Casting Contact Cooling Water
Pollutant or
pollutant property
             Maximum for
             any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of precious metals
cast by the direct chill method
*Cadmium
 Chromium
*Copper
*Cyanide
*Lead
 Nickel
*Silyer
 Zinc
*0il and Grease
*TSS
                   3.670
                   4.750
                  20.500
                   3.130
                   4.540
                  20.800
                   4.430
                  15.800
                 216.000
                 443.000
          1.620
          1.950
         10.800
          1.300
          2.160
         13.700
          1.840
          6.590
        130.000
        211.000
          Within the range of 7.5 to 10.0 at all times
                               1674

-------
                     Table IX-18 (Continued)

               PRECIOUS METALS FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Precious Metals Forming
Shot Casting Contact Cooling Water
Pollutant or
pollutant property
Maximum for
any one day
            Maximum for
            monthly average
mg/off-kg(Ib/million off-lbs) of precious metals
shot cast
*Cadmium
 Chromium
*Copper
*Cyanide
*Lead
 Nickel
*Silver
 Zinc
*0il and Grease
*TSS
      1,
      1,
  1.250
  1.620
  6.980
   ,070
   ,540
  7.050
  1.510
  5.360
 73.400
151.000
  .551
  .661
 3.670
  .441
  .734
 4.660
  .624
 2.240
44.100
71.600
          Within the range of 7.5 to 10.0 at all times
BPT
Precious Metals Forming
Stationary Casting Contact Cooling Water

     There shall be no discharge of process wastewater
     pollutants.
                               1675

-------
                     Table IX-18 (Continued)

               PRECIOUS METALS FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS

BPT
Precious Metals Forming
Semi-Continuous and Continuous Casting Contact
Cooling Water
Pollutant or
pollutant property
Maximum for
any one day
            Maximum for
            monthly average
mg/off-kg (Ib/million off-lbs) of precious metals cast
by the semi-continuous or continuous method
*Cadmium
 Chromium
*Copper
*Cyanide
*Lead
 Nickel
*Silver
 Zinc
*Oil and Grease
*TSS
      3.500
      4.530
     19.600
      2.990
      4.330
     19.800
      4.230
     15.100
    206.000
    423.000
                      1.550
                      1.860
                     10.300
                      1.240
                      2.060
                     13.100
                      1.750
                      6.290
                    124.000
                    201.000
          Within the range of 7.5 to 10.0 at all times
BPT
Precious Metals Forming
Heat Treatment Contact Cooling Water
Pollutant or
pollutant property
Maximum for
any one day
            Maximum for
            monthly average
mg/off-kg (Ib/million off-lbs) of extruded precious
metals heat treated
*Cadmium
 Chromium
*Copper
*Cyanide
*Lead
 Nickel
*Silver
 Zinc
*Oil and Grease
*TSS
      1,
      1,
      7,
      1,
      1,
   ,420
   ,840
   ,930
   ,210
   ,750
  8.010
  1.710
  6.090
 83.400
171.000
  .626
  .751
 4.170
  .501
  .834
 5.300
  .709
 2.550
50.100
81.300
         Within the range of 7.5 to 10.0 at all times
                               1676

-------
                     Table IX-18 (Continued)

               PRECIOUS METALS FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Precious Metals Forming
Surface Treatment Spent Baths
Pollutant or
pollutant property
              Maximum for
              any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of extruded precious
metals heat treated
*Cadmium
 Chromium
*Copper
*Cyanide
*Lead
 Nickel
*Silver
 Zinc
*Oil and Grease
*TSS
                     .033
                     .042
                     .183
                     .028
                     .041
                     .185
                     .040
                     .141
                     ..930
                     1.950
           .015
           .017
           .096
           .012
           .019
           .123
           .016
           .059
          1.160
          1.880
         Within the range of 7.5 to 10.0 at all times
BPT
Precious Metals Forming
Surface Treatment Rinse
Pollutant or
pollutant property
              Maximum for
              any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of precious metals
surface treated
*Cadmium
 Chromium
*Copper
*Cyanide
*Lead
 Nickel
*Silver
 Zinc
*Oil and Grease
*TSS
                    2.100
                    2.710
                   11.700
                    1.790
                    2.590
                   11.800
                    2.530
                    9.000
                  123.000
                  253.000
           .924
          1.110
          6.160
           .739
          1.230
           ,830
           ,050
           ,760
         73.900
        120.000
7.
1,
3,
  *pH
Within the range of 7.5 to 10.0 at all times
                                1677

-------
                     Table IX-18 (Continued)

               PRECIOUS METALS FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Precious Metals Forming
Alkaline Cleaning Spent Baths
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of precious metals
alkaline cleaned
*Cadmium
 Chromium
*Copper
*Cyanide
*Lead
 Nickel
*Silver
 Zinc
*Oil and Grease
*TSS
        ,020
        ,026
        ,114
        ,017
        ,025
        ,115
        ,025
        ,088
        ,200
        ,460
           .009
           .011
           .060
           .007
           .012
           .076
           .010
           .037
           .720
          1.170
         Within the range of 7.5 to 10.0 at all times
BPT
Precious Metals Forming
Alkaline Cleaning Rinse
Pollutant or
pollutant' property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of precious metals
alkaline cleaned
*Cadmium
 Chromium
*Copper
*Cyanide
*Lead
 Nickel
*Silver
 Zinc
*Oil and Grease
*TSS
      3.810
      4.930
     21.300
      3.250
      4.710
     21.500
      4.590
     16.400
    224.000
    459.000
          1.680
          2.020
         11.200
          1.350
          2.240
         14.200
          1.910
          6.830
        135.000
        219.000
         Within the range of 7.5 to 10.0 at all times
                              1678

-------
                     Table IX-18 (Continued)

               PRECIOUS METALS FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Precious Metals Forming
Alkaline Cleaning Prebonding Wastewater
Pollutant or
pollutant property
              Maximum for
              any one day
Maximum for
monthly average
mg/off-kg (lb/million off-lbs) of precious metals and
base metal cleaned prior to bonding

*Cadmium                     3.950               1.740
 Chromium                    5.110               2.090
*Copper                     22.100              11.600
*Cyanide                     3.370
*Lead                        4.870
 Nickel                     22.300
*Silver                      4.760
 Zinc                       17.000
*Oil and Grease            232.000
*TSS                       476.000
  *pH    Within the range of 7.5 to 10.0 at all times
                                        1.390
                                        2.320
                                       14.800
                                          970
                                          080
                                      139.000
                                      226.000
          1,
          7.
BPT
Precious Metals Forming
Tumbling or Burnishing Wastewater
Pollutant or
pollutant property
              Maximum for
              any one day
Maximum for
monthly average
mg/off-kg (lb/million off-lbs) of precious metals
tumbled or burnished
*Cadmium
 Chromi-um
*Copper
*Cyanide
*Lead
 Nickel
*Silver
 Zinc
*Oil and Grease
*TSS
                    4.120
                    5.330
                   23.000
                    3.510
                    5.080
                   23.300
                    4.960
                   17.700
                  242.000
                  496.000
          1.820
          2.180
         12.100
          1.450
          2.420
         15.400
          2.060
          7.380
        145.000
        236.000
  *pH
Within the range of 7.5 to 10.0 at all times
                               1679

-------
                     Table IX-18 (Continued)

               PRECIOUS METALS FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS

BPT
Precious Metals Forming
Sawing or Grinding Spent Neat Oils

     There shall be no discharge of process wastewater
     pollutants.
BPT
Precious Metals Forming
Sawing or Grinding Spent Emulsions
Pollutant or
pollutant property
              Maximum for
              any one day
Maximum for
monthly average
mg/off-kg(Ib/million off-lbs)of precious metals
sawed or ground with emulsions
*Cadmium
 Chromium
*Copper
*Cyanide
*Lead
 Nickel
*Silver
 Zinc
*Oil and Grease
*TSS
                      ,032
                      ,041
                      ,178
                      ,027
                      ,039
                      ,180
                      ,038
                      ,137
                      ,870
                      ,830
           .014
           .017
           .093
           .011
           .019
           .119
           .016
           .057
          1.120
          1.820
  *pH
Within the range of 7.5 to 10.0 at all times
                               1680

-------
                     Table IX-18 (Continued)

               PRECIOUS METALS FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Precious Metals Forming
Pressure Bonding Contact Cooling Water
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of precious metals and
base metal pressure bonded
*Cadmium
 Chromium
*Copper
*Cyanide
*Lead
 Nickel
*Silver
 Zinc
*Oil and Grease
*TSS
        ,028
        ,037
        ,159
        024
        ,035
        ,161
        ,034
        ,122
        ,670
        ,430
           .013
           .015
           .084
           .010
           .017
           .106
           .014
           .051
          1.000
          1.630
         Within the range of 7.5 to 10.0 at all times
BPT
Precious Metals Forming
Degreasing Spent Solvents

     There shall be no discharge of process wastewater
     pollutants.
BPT
Precious Metals Forming
Wet Air Pollution Control Slowdown

     There shall be no discharge of process wastewater
     pollutants.
                               1681

-------
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                            1683

-------
                           Table IX-20

             REFRACTORY METALS FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Refractory Metals Forming
Rolling Spent Neat Oils and Graphite-Based Lubricants

     There shall be no discharge of process wastewater
     pollutants.
BPT
Refractory Metals Forming
Rolling Spent Emulsions
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg(Ib/million off-lbs) of refractory metals
rolled with emulsions
Chromium
*Copper
Lead
*Nickel
Silver
Zinc
Columbium
*Fluoride
*Molybdenum
Tantalum
Vanadium
Tungsten
*Oil and Grease
*TSS
*pH Within
.189
.815
.180
.824
.176
.627
.052
25.500
2.840
.193
.043
2.990
8.580
17.600
the range of 7.5 to
.077
.429
.086
.545
.073
.262
	
11.300
1.470
	
	
1.190
5.150
8.370
10.0 at all times
BPT
Refractory Metals Forming
Drawing Spent Lubricants

     There shall be no discharge of process wastewater
     pollutants.
                               1684

-------
                     Table IX-20 (Continued)

             REFRACTORY METALS FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Refractory Metals Forming
Extrusion Spent Lubricants

     There shall be no discharge of process wastewater
     pollutants.
BPT
Refractory Metals Forming
Extrusion Press Hydraulic Fluid Leakage
Pollutant or
pollutant property
Maximum for
any prie day
Maximum for
mpnthly average
mg/off-kg (Ib/million off-lbs) of refractory metals
extruded
Chromium
* Copper
Lead
*Nickel
Silver
Zinc
Columbium
*Fluoride
*Molybdenum
Tantalum
Vanadium
Tungsten
*Oil and Grease
*TSS
*pH Within
.524
2.260
.500
2.290
.488
1.740
.143
70.800
7.870
.536
.119
8.280
23.800
48.800
the range of 7.5 to
.214
1.190
.238
1.510
.203
.726
	
31.400
4.070
	
	
3.310
14.300
23.200
10.0 at all times
BPT
Refractory Metals Forming
Forging Spent Lubricants

     There shall be no discharge of process wastewater
     pollutants.
                               1685

-------
                     Table IX-20 (Continued)

             REFRACTORY METALS FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Refractory Metals Forming
Forging Contact Cooling Water
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of forged refractory
metals cooled with water
 Chromium
*Copper
 Lead
*Nickel
 Silver
 Zinc
 Columbium
*Fluoride
*Molybdenum
 Tantalum
 Vanadium
 Tungsten
*Oil and Grease
*TSS
       .142
       .614
       .136
       .620
       .133
       .472
       .039
     19.200
      2.140
       .146
       .032
      2.250
      6.460
     13.300
           .058
           .323
           .065
           .410
           .055
           .197

          8.530
          1.110
           .898
          3.880
          6.300
          Within the range of 7.5 to 10.0 at all times
                               1686

-------
                     Table IX-20 (Continued)

             REFRACTORY METALS FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Refractory Metals Forming
Metal Powder Production Wastewater
Pollutant or
pollutant property
             Maximum for
             any one day
Maximum for
monthly average
mg/off-kg(Ib/million off-lbs) of refractory metals
powder produced
 Chromium
*Copper
 Lead
*Nickel
 Silver
 Zinc
 Columbium
*Fluoride
*Molybdenum
 Tantalum
 Vanadium
 Tungsten
*Oil"and Grease
*TSS
                    .124
                    .534
                    .118
                    .540
                    .115
                    .410
                    .034
                  16.700
                   1.860
                    .127
                    .028
                   1.960
                   5.620
                  11.500
           .051
           .281
           .056
           .357
           .048
           .172

          7.420
           .961
           .781
          3.370
          5.480
   "pH
Within the range of 7.5 to 10.0 at all times
BPT
Refractory Metals Forming
Metal Powder Production Floor Wash Water

     There shall be no discharge of process wastewater
     pollutants.
BPT
Refractory Metals Forming
Metal Powder Pressing Spent Lubricants

     There shall be no discharge of process wastewater
     pollutants.
                               1687

-------
                     Table IX-20 (Continued)

             REFRACTORY METALS FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Refractory Metals Forming
Surface Treatment Spent Baths
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg(Ib/million off-lbs) of refractory metals
surface treated
Chromium
*Copper
Lead
*Nickel
Silver
Zinc
Columbium
*Fluoride
*Molybdenum
Tantalum
Vanadium
Tungsten
*Oil and Grease
*TSS
*pH Within
.171
.739
.164
.747
.160
.568
.047
23.200
2.570
.175
.039
2.710
7.780
16.000
the range of 7.5 to 10.0
.070
.389
.078
.494
.066
.237
	
10.300
1.330
	
_• —
1.080
4.670
7.590
at all times
                               1688

-------
                     Table IX-20 (Continued)

             REFRACTORY METALS FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Refractory Metals Forming
Surface Treatment Rinse
Pollutant or
pollutant property
  Maximum for
  any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of refractory metals
surface treated
 Chromium
*Copper
 Lead
*Nickel
 Silver
 Zinc
 Columbium
*Fluoride
*Molybdenum
 Tantalum
 Vanadium
 Tungsten
*Oil and Grease
*TSS
   *pH    Within the
       53.300
      230.000
       50.800
      233.000
       49.600
      177.OOP
       14.5QO
    7,200.000
      800.000
       54.500
       12.100
      842.000
    2,420.000
    4,960.000
range of 7.5 to 10,
         21.800
        121.000
         24.200
        154.000
         20.600
         73.800

      3,200.000
        414.000
        337.000
      1,450.000
      2,360.000
   at all times
                               1689

-------
                     Table IX-20 (Continued)

             REFRACTORY METALS FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Refractory Metals Forming
Alkaline Cleaning Spent Baths
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of refractory metals
alkaline cleaned
 Chromium
*Copper
 Lead
*Nickel
 Silver
 Zinc
 Columbium
*Fluoride
*Molybdenum
 Tantalum
 Vanadium
 Tungsten
*Oil and Grease
*TSS
       .147
       .635
       .140
       .641
       .137
       .488
       .040
     19.900
      2.210
       .151
       .033
      2.330
      6.680
     13.700
           .060
           .334
           .067
           .424
           .057
           .204

          8.820
          1.140
           .929
          4.010
          6.520
          Within the range of 7.5 to 10.0 at all times
                              1690

-------
                     Table IX-20 (Continued)

             REFRACTORY METALS FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Refractory Metals Forming
Alkaline Cleaning Rinse
                       Maximum for
                       any one day
Pollutant or
pollutant property
        Maximum for
        monthly average
mg/off-kg (Ib/million off-lbs) of refractory metals
alkaline cleaned
 Chromium
*Copper
 Lead
*Nickel          	
 Silver
 Zinc
 Columbium
*Fluoride
*Molybdenum
 Tantalum
 Vanadium
 Tungsten
*Oil and Grease
*TSS
   *pH    Within the
                           359.
                         1,550.
                           343.
                         1,570.
                           335.
                         1,190.
                            97.
                        48,600.
                         5,400.
                           367.
                            81.
                         5,680.
                        16,300.
                        33,500.
                     range of 7
000
000
000
000
000
000
900
000
000
000
600
000
000
000
.5 to
          147.000
          816.000
          163.000
        1,040.000
          139.000
          498.000

       21,600.000
        2,790.000
        2,270.000
        9,790.000
       15,900.000
10.0 at all times
                               1691

-------
r
                                          Table IX-20 (Continued)

                                  REFRACTORY METALS FORMING SUBCATEGORY
                                         BPT EFFLUENT LIMITATIONS
                     BPT
                     Refractory Metals Forming
                     Molten Salt Rinse
                     Pollutant or
                     pollutant property
Maximum for
any one day
Maximum for
monthly average
                     mg/off-kg (Ib/million off-lbs) of refractory metals
                     treated with molten salt
                      Chromium
                     *Copper
                      Lead
                     *Nickel
                      Silver
                      Zinc
                      Columbium
                     *Fluoride
                     *Molybdenum
                      Tantalum
                      Vanadium
                      Tungsten
                     *Oil and Grease
                     *TSS
                        *pH ,   Within the range
      2.790
     12.000
      2.660
     12.200
      2.600
      9.240
       .760
    377.000
     41.900
      2.850
       .633
     44.100
    127.000
    260.000
    of 7.5 to 10.0
          1.140
          6.330
          1.270
          8.040
          1.080
          3.860

        167.000
         21.700
         17.600
         76.000
        124.000
   at all times
                                                    1692

-------
                     Table IX-20 (Continued)

             REFRACTORY METALS FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Refractory Metals Forming
Tumbling or Burnishing Wasfcewater
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of refractory metals
tumbled or burnished
Chromium
* Copper
Lead
*Nickel
Silver
Zinc
Columbium
*Fluoride
*Molybdenum
Tantalum
Vanadium
Tungsten
*Oil and Grease
*TSS
*pH Within the
5.500
23.800
5.250
24.000
5.130
18.300
1.500
744.000
82.600
5.630
1.250
87.000
250.000
513.000
range of 7.5 to
2.250
12.500
2.500
15.900
2.130
7.630
	
330.000
42.800
	
	
34.800
150.000
244.000
10.0 at all times
BPT
Refractory Metals Forming
Sawing or Grinding Spent Neat Oils

     There shall be no discharge of process wastewater
     pollutants.
                               1693

-------
                     Table IX-20 (Continued)

             REFRACTORY METALS FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Refractory Metals Forming
Sawing or Grinding Spent Emulsions
Pollutant or
pollutant property
Maximum for
any one day
          Maximum for
          monthly average
mg/off-kg (Ib/million off-lbs) of refractory metals
sawed or ground with emulsions
 Chromium
*Copper
 Lead
*Nickel
 Silver
 Zinc
 Columbium
*Fluoride
*Molybdenum
 Tantalum
 Vanadium
 Tungsten
*Oil and Grease
*TSS
       .131
       .565
       .125
       .570
       .122
       .434
       .036
     17.700
      1.970
       .134
       .030
       ,070
2,
5,
        940
     12.200
                     .054
                     .297
                     .059
                     .377
                     .051
                     .181

                    7.840
                    1.020
 .826
3.570
5.790
   *pH    Within the range of 7.5 to 10.0 at all times
                               1694

-------
                     Table IX-20 (Continued)
             REFRACTORY METALS FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS

B~PT
Refractory Metals Forming
Sawing or Grinding Contact Cooling Water
Pollutant or
pollutant property
Maximum for
any one day
         Maximum for
         monthly average
mg/off-kg (Ib/million off-lbs) of refractory metals
sawed or ground with contact cooling water
 Chromium
*Copper
 Lead
*Nickel
 Silver
 Zinc
 Columbium
*Fluoride
*Molybdenum
 Tantalum
 Vanadium
 Tungsten
*Oil and Grease
*TSS
     10
     45
     10
     46
      9
     35
      2
  1,450
    161
     11
      2
    169
    486
    997
.700
.200
.200
.700
.970
.500
.920
.000
.000
.000
.430
.000
.000
.000
          Within the range of 7.5 to 10.0
       4.380
      24.300
       4.860
      30.900
       4.130
      14.800

     642.000
      83.100
      67.600
     292.000
     474.000
at all times
                               1695

-------
                     Table IX-20  (Continued)

             REFRACTORY METALS FORMING  SUBCATEGORY
                    BPT EFFLUENT  LIMITATIONS
BPT
Refractory Metals Forming
Sawing or Grinding Rinse
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg  (Ib/million off-lbs) of sawed or ground
refractory metals rinsed
 Chromium
*Copper
 Lead
'*Nickel
 Silver
 Zinc
 Columbium
*Fluoride
*Molybdenum
 Tantalum
 Vanadium
 Tungsten
*0il and Grease
*TSS
       .059
       .257
       .057
       .259
       .055
       .197
       .016
      8.030
       .893
       .061
       .014
       .940
      2.700
      5.540
           .024
           .135
           .027
           .172
           .023
           .082

          3.570
           .462
           .376
          1.620
          2.630
          Within the range of 7.5 to 10.0 at all times
                               1696

-------
                     Table IX-20 (Continued)

             REFRACTORY METALS FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Refractory Metals Forming
Dye Penetrant Testing Wastewater
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of refractory metals,
tested with dye penetrant methods
 Chromium
*Copper
 Lead
*Nickel
 Silver
 Zinc
 Columbium
*Fluoride
*Molybdenum
 Tantalum
 Vanadium
 Tungsten
*Oil and Grease
*TSS
       .034
       .148
       .033
       .149
       .032
       .113
       .009
      4.620
       .513
       .035
       .008
       .540
      1.550
      3.180
           .014
           .078
           .016
           .099
           .013
           .047

          2.050
           .266
           .216
           .931
          1.520
          Within the range of 7.5 to 10.0 at all times
                              1697

-------
                     Table IX-20 (Continued)

             REFRACTORY METALS FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Refractory Metals Forming
Equipment Cleaning Wastewater
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of refractory metals
formed
 Chromium                     .599                .245
*Copper                      2.590               1.360
 Lead                         .571                .272
*Nickel                      2.610               1.730
 Silver                       .558                .231
 Zinc                        1.990                .830
 Columbium                    .163                 	
*Fluoride                   80.900              35.900
*Molybdenum                  8.990               4.650
 Tantalum                     .612                 	
 Vanadium                     .136                 	
 Tungsten                    9.470               3.780
*Oil and Grease             27.200              16.300
*TSS                        55.800              26.500
   *pH    Within the range of 7.5 to 10.0 at all times
                              1698

-------
                     Table IX-20 (Continued)

             REFRACTORY METALS FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Refractory Metals Forming
Miscellaneous Wastewater Sources
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of refractory metals
formed
 Chromium
*Copper
 Lead
*Nickel
 Silver
 Zinc
 Columbium
*Fluoride
*Molybdenum
 Tantalum
 Vanadium
 Tungsten
*Oil and Grease
*TSS
       .152
       .656
       .145
       .663
       .142
       .504
       .041
     20.500
      2.280
       .155
       .035
      2.400
      6.900
     14.200
           .345
           .069
           .438
           .059
           .211

          9.110
          1.180
           .959
          4.140
          6.730
          Within the range of 7.5 to 10.0 at all times
                               1699

-------
                     Table IX-20 (Continued)

             REFRACTORY METALS FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Refractory Metals Forming
Degreasing Spent Solvents

     There shall be no discharge of process wastewater
     pollutants.
BPT
Refractory Metals Forming
Wet Air Pollution Control Slowdown
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg(Ib/million off-lbs)of refractory metals
formed
Chromium
*Copper
Lead
*Nickel
Silver
Zinc
Columbium
*Fluoride
*Molybdenum
Tantalum
Vanadium
Tungsten
*Oil and Grease
*TSS
*pH Within the
.346
1.500
.331
1.510
.323
1.150
.095
46.800
5.200
.354
.079
5.480
15.800
32.300
range of 7.5 to
.142
.787
.158
1.000
.134
.480
	
20.800
2.690
	
2.190
9.450
15,400
10.0 at all times
                               1700

-------
ng
oduction Norma
Parameter
Mass of titanium rolled
contact cooling water
rud
                                                                4-<  «
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-------
                           Table IX-22

                  TITANIUM FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Titanium Forming
Rolling Spent Neat Oils

     There shall be no discharge of process wastewater
     pollutants.
BPT
Titanium Forming
Rolling Contact Cooling Water
Pollutant or
pollutant property
Maximum for
any one day
          Maximum for
          monthly average
mg/off-kg(Ib/million off-lbs)of titanium
rolled with contact cooling water
 Chromium
 Copper
*Cyanide
*Lead
 Nickel
*Zinc
*Ammonia
*Fluoride
 Titanium
*Oil and Grease
*TSS
      2.150
      9.270
        ,420
        ,050
        ,370
        ,130
    651.000
    291.000
      4.590
     97.600
    200.000
1,
2,
9,
7,
   .879
  4.880
   .586
   .976
  6.200
  2.980
286.000
129.000
  2.000
 58.600
 95.200
          Within the range of 7.5 to 10.0 at all times
BPT
Titanium Forming
Drawing Spent Neat Oils

     There shall be no discharge of process wastewater
     pollutants.

BPT
Titanium Forming
Extrusion Spent Neat Oils

     There shall be no discharge of process wastewater
     pollutants.
                               1703

-------
                     Table IX-22 (Continued)
                  TITANIUM FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Titanium Forming
Extrusion Spent Emulsions
Pollutant or
pollutant property
             Maximum for
             any one day
Maximum for
monthly average
mg/off-kg (lb/million off-lbs) of titanium
extruded with emulsions
 Chromium
 Copper
*Cyanide
*Lead
 Nickel
*Zinc
*Ammonia
*Fluoride
 Titanium
*Oil and Grease
*TSS
                    .032
                    .137
                    .021
                    .030
                    .138
                    .105
                   9.590
                   4.280
                    .068
                   1.440
                   2.950
           .013
           .072
           .009
           .014
           .091
           .044
          4.220
          1.900
           .030
           .863
          1.400
   *pH
Within the range of 7.5 to 10.0 at all times
BPT
Titanium Forming
Extrusion Press Hydraulic Fluid Leakage
Pollutant or
pollutant property
             Maximum for
             any one day
Maximum for
monthly average
mg/off-kg (lb/million off-lbs) of titanium
extruded
 Chromium
 Copper
*Cyanide
*Lead
 Nickel
*Zinc
*Ammonia
*Fluoride
 Titanium
*Oil and Grease
*TSS
                    .078
                    .338
                    .052
                    .075
                    .342
                    .260
                  23.700
                  10.600
                    .168
                   3.560
                   7.300
           .032
           .178
           .021
           .036
           .226
           .109
         10.500
          4.700
           .073
          2.140
          3.470
          Within the range of 7.5 to 10.0 at all times
                               1704

-------
                     Table IX-22 (Continued)

                  TITANIUM FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Titanium Forming
Forging Spent Lubricants

     There shall be no discharge of process wastewater
     pollutants.
BPT
Titanium Forming
Forging Contact Cooling Water
Pollutant or
pollutant property
             Maximum for
             any one day
          Maximum for
          monthly average
mg/off-kg (Ib/million off-lbs) of forged titanium
cooled with water
 Chromium
 Copper
*Cyanide
*Lead
 Nickel
*Zinc
*Ammonia
*Fluoride
 Titanium
*Oil and Grease
*TSS
                     ,880
                     ,800
                     ,580
                     ,840
                     ,840
                     ,920
                 267.000
                 119.000
                   1.880
                  40.000
                  82.000
3,
2.
   .360
  2.000
   .240
   .400
  2.540
  1.220
117.000
 52.800
   .R20
 24.000
 39.000
    "PH
Within the range of 7.5.. to 10.0 at all times
                               1705

-------
                     Table IX-22 (Continued)
                  TITANIUM FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS

BPT
Titanium Forming
Forging Equipment Cleaning Wastewater
Pollutant or
pollutant property
             Maximum for
             any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of titanium
forged
 Chromium
 Copper
*Cyanide
*Lead
 Nickel
*Zinc
*Ammonia
*Fluoride
 Titanium
*Oil and Grease
*TSS
                     .018
                     .076
                     .012
                     .017
                     .077
                     .058
                   5.330
                   2.380
                     .038
                     .800
                   1.640
           .007
           .040
           .005
           .008
           .051
           .024
          2.350
          1.060
           .016
           .480
           .780
   "pH
Within the range of 7.5 to 10.0 at all times
BPT
Titanium Forming
Forging Press Hydraulic Fluid Leakage
Pollutant or
pollutant property
             Maximum for
             any one day
Maximum for
monthly average
mg/off-kg(Ib/million off-lbs)of titanium
forged
 Chromium
 Copper
*Cyanide
*Lead
 Nickel
*Zinc
*Ammonia
*Fluoride
 Titanium
*0il and Grease
*TSS
                    .445
                   1.920
                    .293
                    .424
                   1.940
                   1.480
                 135.000
                  60.100
                    .950
                  20.200
                  41.400
           .182
          1.010
           .121
           .202
          1.280
           .616
         59.200
         26.700
           .414
         12.100
         19.700
   *pH
Within the range of 7.5 to 10.0 at all times
                                1706

-------
                     Table IX-22 (Continued)

                  TITANIUM FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Titanium Forming
Tube Reducing Spent Lubricants

     There shall be no discharge of process wastewater
     pollutants.
BPT
Titanium Forming
Heat Treatment Contact Cooling Water

     There shall be no discharge of process wastewater
     pollutants.
BPT
Titanium Forming
Surface Treatment Spent Baths
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of titanium
surface treated
 Chromium
 Copper
*Cyanide
*Lead
 Nickel
*Zinc
*Ammonia
*Fluoride
 Titanium
*Oil and Grease
*TSS
       .092
       .395
       .060
       .087
       .400
       .304
     27.700
     12.400
       .196
      4.160
      8.530
           .038
           .208
           .025
           .042
           .264
           .127
         12.200
          5.490
           .085
          2.500
          4.060
          Within the range of 7.5 to 10.0 at all times
                               1707

-------
                     Table IX-22 (Continued)

                  TITANIUM FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Titanium  Forming
Surface Treatment Rinse
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of titanium
surface treated
 Chromium
 Copper
*Cyanide
*Lead
 Nickel
*Zinc
*Ammonia
*Fluoride
 Titanium
*Oil and Grease
*TSS
     12.900
     55.500
      8.470
     12.300
     56.100
     42.700
  3,890.000
  1,740.000
     27.500
    584.000
  1,200.000
          5.260
         29.200
          3.510
          5.840
         37.100
         17.800
      1,710.000
        771.000
         12.000
        351.000
        570.000
          Within the range of 7.5 to 10.0 at all times
BPT
Titanium Forming
Alkaline Cleaning Spent Baths
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of titanium
alkaline cleaned
 Chromium
 Copper
*Cyanide
*Lead
 Nickel
*Zinc
*Ammonia
*Fluoride
 Titanium
*0il and Grease
*TSS
       .106
       .456
       .070
       .101
       .461
       .351
     32.000
     14.300
       .226
      4.800
      9.840
           .043
           .240
           .029
           .048
           .305
           .147
         14.100
          6.340
           .098
          2.880
          4.680
          Within the range of 7.5 to 10.0 at all times
                              1708

-------
                     Table IX-22 (Continued)

                  TITANIUM FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Titanium Forming
Alkaline Cleaning Rinse
Pollutant or
pollutant property
Maximum for
any one day
                                       Maximum for
                                       monthly average
mg/off-kg {Ib/million off-lbs) of titanium
alkaline cleaned
 Chromium
 Copper
*Cyanide
*Lead
 Nickel
*Zinc
*Ammonia
*Fluoride
 Titanium
*Oil and Grease
*TSS
      1,
      5,
                               ,220
                               ,250
                               .801
                             1.160
                             5.300
                             4.030
                           368.000
                           164.000
                             2.600
                            55.200
                           113.000
   .497
  2.760
   .331
   .552
    5.10
   ,690
162.000
 72.900
  1.130
 33.100
 53.800
                          3,
                          1,
          Within the range of 7.5 to 10.0.at all times
BPT
Titanium Forming
Molten Salt Rinse

Pollutant or
pollutant property
                       Maximum for
                       any one day
                Maximum for
                monthly average
mg/off-kg (Ib/million off-lbs) of titanium
treated with molten salt
 Chromium
 Copper
*Cyanide
*Lead
 Nickel
*Zinc
*Ammonia
*Fluoride
 Titanium
*Oil and Grease
*TSS
       .420
      1.820
       .277
       .401
      1.840
      1.400
    128.000
     56.800
       .898
     19.100
     39.200
                                                  .172
                                                  .955
                                                  .115
                                                  .191
                                                 1.210
                                                  .583
                                                56.000
                                                25.200
                                                  .392
                                                11.500
                                                18.600
          Within the range of 7.5 to 10.0 at all times
                               1709

-------
                     Table IX-22 (Continued)

                  TITANIUM FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATION'S
BPT
Titanium Forming
Tumbling Wastewater
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of titanium tumbled
 Chromium
 Copper
*Cyanide
*Lead
 Nickel
*Zinc
*Ammonia
*Fluoride
 Titanium
*Oil and Grease
*TSS
       .348
      1.500
       .229
       .332
      1.520
      1.160
    106.000
     47.000
       .743
     15.800
     32.400
           .142
           .790
           .095
           .158
          1.010
           .482
         46.300
         20.900
           .324
          9.480
         15.400
          Within the range of 7.5 to 10.0 at all times
BPT
Titanium Forming
Sawing or Grinding Spent Neat Oils

     There shall be no discharge of process wastewater
     pollutants.
                               1710

-------
                     Table IX-22 (Continued)

                  TITANIUM FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Titanium Forming
Sawing or Grinding Spent Emulsions
Pollutant or
pollutant property
             Maximum for
             any one day
            Maximum for
            monthly average
ing/off-kg (Ib/million off-Ibs) of titanium
sawed or ground with em:.; Is ions
 Chromium
 Copper
*Cyanide
*Lead
 Nickel
*Zinc
*Ammonia
*Fluoride
 Titanium
*Oil and Grease
*TSS
                    .081
                    .348
                    .053
                    .077
                    .352
                    .267
                  24.400
                  10.900
                    .172
                   3.660
                   7.510
                       .033
                       .183
                       .022
                       .037
                       .233
                       .112
                     10.700
                      4.830
                       .075
                      2.200
                      3.570
   fcpH
Within the range of 7.5 to 10.0 at all times
BPT
Titanium Forming
Sawing or Grinding Contact Cooling Water
Pollutant or
pollutant property
             Maximum for
             any one day
            Maximum for
            monthly average
mg/off-kg (Ib/million off-lbs) of titanium
sawed or ground with contact cooling water
 Chromium
 Copper
*Cyanide
*Lead
 Nickel
*Zinc
*Ammonia
*Fluoride
 Titanium
*0il and Grease
*TSS
    100
    050
   .380
   ,000
   ,140
   ,950
   ,000
   ,000
  4.480
 95.200
195.000
                   2.
                   9.
                   1,
                   2,
                   9,
                   6,
                 635,
                 283,
   .857
  4.760
   .571
   .952
  6.050
  2.910
279.000
126.000
  1.950
 57.100
 92.800
          Within the range of 7.5 to 10.0 at all times
                               1711

-------
                     Table IX-22 (Continued)

                  TITANIUM FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Titanium Forming
Dye Penetrant Testing Wastewater
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of titanium
tested with dye penetrant methods
 Chromium
 Copper
*Cyanide
*Lead
 Nickel
*Zinc
*Ammonia
*Fluoride
 Titanium
*Oil and Grease
*TSS
       .493
      2.130
       .325
       .471
      2.150
      1.640
    149.000
     66.700
      1.050
     22.400
     45.900
           .202
          1.120
           .135
           .224
          1.420
           .683
         65.700
         29.600
           .459
         13.500
         21.900
          Within the range of 7.5 to 10.0 at all times
BPT
Titanium Forming
Hydrotesting Wastewater

     There shall be no discharge of process wastewater
     pollutants.
                               1712

-------
                     Table IX-22 (Continued)

                  TITANIUM FORMING SUBCATEGORY
                    BPT EFFLUENT LIMITATIONS
BPT
Titanium Forming
Miscellaneous Wastewater Soi
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of titanium formed
 Chromium
 Copper
*Cyanide
*Lead
 Nickel
*Zinc
*Ammonia
*Fluoride
 Titanium
*Oil and Grease
*TSS
       .014
       .062
       .009
       .014
       .062
       .047
      4.320
      1.930
       ,031
       .648
      1.330
           .OC5
           .032
           .004
           .006
           .041
           .020
          1.900
           .856
           .013
           .389
           .632
          Within the range of 7.5 to 10.0 at all times
BPT
Titanium- Forming
Degreasing Spent Solvents

     There shall be no discharge of process wastewater
     pollutants.
                                1713

-------
                     Table IX-22 (Continued)

                  TITANIUM FORMING SUBCATEGQRY
                    BPT EFFLUENT LIMITATIONS
BPT
Titanium Forming
Wet Air Pollution Control Slowdown
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/off-kg (Ib/million off-lbs) of titanium
formed
 Chromium
 Copper
*Cyanide
*Lead
 Nickel
*Zinc
*Ammonia
*Fluoride
 Titanium
*Oil and Grease
*TSS
       .942
      4.070
       .621
       .899
      4.110
      3.130
    285.000
    128.000
      2.010
     42.800
     87.800
           .385
          2.140
           .257
           .428
          2.720
          1.310
        126.000
         56.500
           .878
         25.700.
         41.800
          Within the range of 7.5 to 10.0 at all times
                               1714

-------
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