United States Office of Water December 1989
Environmental Protection (WH-552) EPA 800/B-89/001
Agency (EN-336)
Aluminum, Copper, And
Nonferrous Metals Forming
And Metal Powders
Pretreatment Standards
A Guidance Manual
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GUIDANCE MANUAL FOR ALUMINUM, COPPER, AND
NONFERROUS METALS FORMING AND METAL POWDERS
PRETREATMENT STANDARDS
Prepared by:
Industrial Technology Division
Office of Water Regulations and Standards
and
Permits Division
Office of Water Enforcement and Permits
December 1989
U.S. Environmental Protection Agency
401 M Street, S.W.
Washington, D.C. 20460
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TABLE OF CONTENTS
Page
1. INTRODUCTION .. 1-1
1.1 DESCRIPTIONS OF THE METALS FORMING CATEGORIES 1-2
1.1.1 Aluminum Forming Category 1-3
1.1.2 Copper Forming Category 1-4
1.1.3 Nonferrous Metals Forming and Metal Powders
Category 1-4
1.2 HISTORY OF THE ALUMINUM FORMING, COPPER FORMING, AND
NONFERROUS METALS FORMING AND METAL POWDERS CATEGORICAL
PRETREATMENT STANDARDS 1-6
2. CATEGORICAL PRETREATMENT STANDARDS FOR THE ALUMINUM, COPPER,
AND NONFERROUS METALS FORMING AND METAL POWDERS CATEGORIES
(40 CFR PARTS 467, 468, AND 471) 2-1
2.1 AFFECTED CATEGORIES 2-1
2.1.1 Aluminum Forming... 2-1
2.1.2 Copper Forming 2-2
2.1.3 Non£errous Metals Forming and Metal Powders 2-2
2.2 SUBCATEGORIES 2-3
2.2.1 Aluminum Forming..... 2-3
2.2.2 Copper Forming 2-7
2.2.3 Nonferrous Metals Forming and Metal Powders 2-8
2.3 PROCESS OPERATIONS 2-11
2.3.1 Forming Operations 2-11
2.3.2 Ancillary Operations 2-16
2.4 EXCEPTIONS FROM REGULATION COVERAGE.. 2-23
2.4.1 Aluminum Forming 2-23
2.4.2 Copper Forming 2-24
2.4.3 Nonferrous Metals Forming and Metal Powders 2-24
2.5 PRETREATMENT STANDARDS FOR THE ALUMINUM FORMING, COPPER
FORMING, AND NONFERROUS METALS FORMING AND METAL
POWDERS CATEGORY 2-25
2.6 COMPLIANCE DATES 2-26
2.7 ALTERNATIVES TO MONITORING REQUIREMENTS 2-27
3. TREATMENT TECHNOLOGIES 3-1
3.1 ALUMINUM FORMING CATEGORY 3-1
3.2 COPPER FORMING CATEGORY 3-4
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TABLE OF CONTENTS (Continued)
Page
3.3 NONFERROUS METALS FORMING AND METAL POWDERS CATEGORY 3-4
3.4 END-OF-PIPE TREATMENT TECHNOLOGIES 3-9
3.5 IN-PLANT CONTROL TECHNOLOGIES 3-14
4. REQUIREMENTS OF THE GENERAL PRETREATMENT REGULATIONS 4-1
4.1 INTRODUCTION 4-1
4.2 REQUESTS FOR CATEGORICAL DETERMINATIONS 4-2
4.3 MONITORING AND REPORTING REQUIREMENTS OF THE GENERAL
PRETREATMENT REGULATIONS 4-2
4.3.1 Baseline Monitoring Reports 4-2
4.3.2 Compliance Schedule Progress Reports 4-7
4.3.3 Report on Compliance 4-7
4.3.4 Periodic Reports on Continued Compliance 4-8
4.3.5 Notice of Potential Problems, Including Slug
Loading 4-8
4.3.6 Monitoring and Analysis to Demonstrate Continued
Compliance 4-8
4.3.7 Notification of Changed Discharge 4-9
4.3.8 Signatory Requirements for Industrial User
Reports 4-9
4.3.9 Recordkeeping Requirements 4-10
4.4 THE COMBINED WASTESTREAM FORMULA 4-10
4.5 REMOVAL CREDITS 4-15
4.6 FUNDAMENTALLY DIFFERENT FACTORS (FDF) VARIANCE 4-16
4.7 LOCAL LIMITS 4-17
5. APPLICATION OF PRODUCTION-BASED CATEGORICAL PRETREATMENT
STANDARDS.. 5-1
5.1 INTRODUCTION 5-1
5.2 USE OF EQUIVALENT MASS LIMITS 5-1
5.3 USE OF EQUIVALENT CONCENTRATION ^LIMITS 5-2
5.4 OBTAINING PRODUCTION AND FLOW RATE INFORMATION 5-3
5.5 DETERMINING AN APPROPRIATE PRODUCTION RATE 5-5
5.6 DETERMINING AN APPROPRIATE FLOW RATE 5-6
5.7 CATEGORIZATION OF ALUMINUM, COPPER AND NONFERROUS
FORMING FACILITIES 5-7
5.8 APPLICATION OF PRETREATMENT STANDARDS TO METAL FORMING
FACILITIES 5-8
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APPENDICES
APPENDIX A REFERENCES
APPENDIX B GLOSSARY OF TERMS
APPENDIX C PRETREATMENT STANDARDS FOR EXISTING AND NEW SOURCES
C-l PRETREATMENT STANDARDS FOR EXISTING SOURCES (PSES)
ALUMINUM FORMING CATEGORY
C-2 PRETREATMENT STANDARDS FOR NEW SOURCES (PSNS)
ALUMINUM FORMING CATEGORY
C-3 ' PRETREATMENT STANDARDS FOR EXISTING SOURCES (PSES)
COPPER FORMING CATEGORY
C-4 PRETREATMENT STANDARDS FOR NEW SOURCES (PSNS)
COPPER FORMING CATEGORY
C-5 PRETREATMENT STANDARDS FOR EXISTING SOURCES (PSES)
NONFERROUS METALS FORMING CATEGORY
SUBPART A - LEAD-TIN-BISMUTH FORMING SUBCATEGORY
C-6 PRETREATMENT STANDARDS FOR NEW SOURCES (PSNS)
NONFERROUS METALS FORMING CATEGORY
SUBPART A - LEAD-TIN-BISMUTH FORMING SUBCATEGORY
C-7 PRETREATMENT STANDARDS FOR EXISTING SOURCES (PSES)
NONFERROUS METALS FORMING CATEGORY
SUBPART B - MAGNESIUM FORMING SUBCATEGORY
C-8 PRETREATMENT STANDARDS FOR NEW SOURCES (PSNS)
NONFERROUS METALS FORMING CATEGORY
SUBPART B - MAGNESIUM FORMING SUBCATEGORY
C-9 PRETREATMENT STANDARDS FOR EXISTING SOURCES (PSES)
NONFERROUS METALS FORMING CATEGORY
SUBPART C - NICKEL-COBALT FORMING SUBCATEGORY
C-10 PRETREATMENT STANDARDS FOR NEW SOURCES (PSNS)
NONFERROUS METALS FORMING CATEGORY
SUBPART C - NICKEL-COBALT FORMING SUBCATEGORY
C-ll PRETREATMENT STANDARDS FOR EXISTING SOURCES (PSES)
NONFERROUS METALS FORMING CATEGORY
SUBPART D - PRECIOUS METALS FORMING SUBCATEGORY
C-12 PRETREATMENT STANDARDS FOR NEW SOURCES (PSNS)
NONFERROUS METALS FORMING CATEGORY
SUBPART D - PRECIOUS METALS FORMING SUBCATEGORY
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APPENDICES (Continued)
Page
C-13 PRETREATMENT STANDARDS FOR EXISTING SOURCES (PSES)
NONFERROUS METALS FORMING CATEGORY
SUBPART E - REFRACTORY METALS FORMING SUBCATEGORY
C-17
C-14 PRETREATMENT STANDARDS FOR NEW SOURCES (PSNS)
NONFERROUS METALS FORMING CATEGORY
SUBPART E - REFRACTORY METALS FORMING SUBCATEGORY
C-18
C-15 PRETREATMENT STANDARDS FOR EXISTING SOURCES (PSES)
NONFERROUS METALS FORMING CATEGORY
SUBPART F - TITANIUM FORMING SUBCATEGORY
C-19
C-16 PRETREATMENT STANDARDS FOR NEW SOURCES (PSNS)
NONFERROUS METALS FORMING CATEGORY
SUBPART F - TITANIUM FORMING SUBCATEGORY
C-20
C-17 PRETREATMENT STANDARDS FOR EXISTING SOURCES (PSES)
NONFERROUS METALS FORMING CATEGORY
SUBPART G - URANIUM FORMING SUBCATEGORY [RESERVED]
PRETREATMENT STANDARDS FOR NEW SOURCES (PSNS)
NONFERROUS METALS FORMING CATEGORY
SUBPART G - URANIUM FORMING SUBCATEGORY C-21
C-18 PRETREATMENT STANDARDS FOR EXISTING SOURCES (PSES)
NONFERROUS METALS FORMING CATEGORY
SUBPART H - ZINC FORMING SUBCATEGORY [RESERVED]
PRETREATMENT STANDARDS FOR NEW SOURCES (PSNS)
NONFERROUS METALS FORMING CATEGORY
SUBPART H - ZINC FORMING SUBCATEGORY C-22
C-19 PRETREATMENT STANDARDS FOR EXISTING SOURCES (PSES)
NONFERROUS METALS FORMING CATEGORY
SUBPART I - ZIRCONIUM/HAFNIUM FORMING SUBCATEGORY C-23
C-20 PRETREATMENT STANDARDS FOR NEW SOURCES (PSNS)
NONFERROUS METALS FORMING CATEGORY
SUBPART I - ZIRCONIUM/HAFNIUM FORMING SUBCATEGORY C-24
C-21 PRETREATMENT STANDARDS FOR EXISTING SOURCES (PSES)
NONFERROUS METALS FORMING CATEGORY
SUBPART J - METAL POWDERS SUBCATEGORY C-25
C-22 PRETREATMENT STANDARDS FOR NEW SOURCES (PSNS)
NONFERROUS METALS FORMING CATEGORY
SUBPART J - METAL POWDERS SUBCATEGORY C-26
APPENDIX D PRETREATMENT COORDINATORS D-l
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LIST OF TABLES
Table Page
1-1 CITATIONS AND DATES OF PROPOSAL AND PROMULGATION OF
PRETREATMENT STANDARDS 1-7
2-1 CORE OPERATIONS AND ANCILLARY OPERATIONS APPLICABLE TO
EACH SUBCATEGORY OF THE ALUMINUM FORMING CATEGORY 2-5
3-1 OPTIONS SELECTED AS THE MODEL TECHNOLOGY BASES FOR PSES
AND PSNS FOR THE NONFERROUS METALS FORMING AND METAL
POWDERS SUBCATEGORIES 3-8
4-1 COMBINED WASTESTREAM FORMULAS 4-13
4-2 FLOW-WEIGHTED AVERAGING (FWA) FORMULAS 4-14
5-1 CALCULATION OF THE 1982 REPRESENTATIVE MONTHLY PRODUCTION
RATE FOR THE COLD ROLLING WITH NEAT OILS ALUMINUM
forming OPERATION 5-12
5-2 CALCULATION OF LONG-TERM AVERAGE PRODUCTION RATE FOR AN
ALUMINUM FORMING FACILITY 5-14
5-3 ALLOWABLE MASS LOADINGS FROM OPERATIONS REGULATED BY METAL
MOLDING AND CASTING CATEGORICAL PRETREATMENT STANDARDS -
COPPER CASTING SUBCATEGORY 5-19
5-4 ALLOWABLE MASS LOADINGS FROM OPERATIONS REGULATED BY COPPER
FORMING CATEGORICAL PRETREATMENT STANDARDS 5-20
5-5 CHARACTERIZATION OF WASTEWATER FLOWS FROM A COPPER CASTING
AND FORMING FACILITY 5-23
5-6 ALTERNATIVE MASS-BASED DISCHARGE LIMITS FOR A COPPER
CASTING AND FORMING FACILITY 5-26
5-7 ALLOWABLE MASS LOADINGS FROM PROCESS OPERATIONS REGULATED
BY NONFERROUS METALS FORMING AND METAL POWDERS CATEGORICAL
STANDARDS - LEAD-TIN-BISMUTH SUBCATEGORY 5-29
LIST OF FIGURES
Figure Page
3-1 PSES TREATMENT TRAIN FOR ALUMINUM FORMING CATEGORY 3-2
3-2 PSNS TREATMENT TRAIN FOR ALUMINUM FORMING CATEGORY 3-3
3-3 PSES TREATMENT TRAIN FOR COPPER FORMING CATEGORY 3-5
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LIST OF FIGURES (Continued)
Figure Page
3-4 PSNS TREATMENT TRAIN FOR COPPER FORMING CATEGORY 3-6
3-5 PSES/PSNS OPTION 1 AND 2 TREATMENT TRAIN FOR THE NONFERROUS
METALS FORMING AND METAL POWDERS CATEGORY 3-10
3-6 PSES/PSNS OPTION 3 TREATMENT TRAIN FOR THE NONFERROUS
METALS FORMING AND METAL POWDERS CATEGORY 3-11
5-1 ALUMINUM FORMING FACILITY PROCESS DIAGRAM 5-10
5-2 PROCESS FLOW DIAGRAM OF A COPPER CASTING AND FORMING FACILITY 5-17
5-3 PROCESS FLOW DIAGRAM FOR A LEAD PIPE FORMING FACILITY 5-28
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1. INTRODUCTION
The National Pretreatment Program establishes an overall strategy for
controlling the introduction of nondomestic wastes to publicly owned treatment
works (POTWs) in accordance with the overall objectives of the Clean Water
Act. Sections 307(b) and (c) of the Act authorize the Environmental Protec-
tion Agency to develop national pretreatment standards for new and existing
dischargers to POTWs. The Act made these pretreatment standards enforceable
against dischargers to POTWs.
The General Pretreatment Regulations (40 CFR Part 403) establish admini-
strative mechanisms requiring nearly 1,500 POTWs to'develop local pretreatment
programs to enforce general prohibitions, specific prohibitions, and categori-
cal pretreatment standards. Categorical pretreatment standards are designed
to prevent the discharge of pollutants that pass through, interfere with, or
are otherwise incompatible with the operation of POTWs. The standards are
technology-based for removal of toxic pollutants and contain specific
numerical limits based on an evaluation of specific technologies for the
particular industrial categories addressed. As a result of a settlement
agreement between EPA and the Natural Resources Defense Council (NRDC), EPA
was required to develop categorical pretreatment standards for 34 industrial
categories, with primary emphasis on 65 classes of toxic pollutants.
This manual provides guidance to POTWs on the implementation and enforce-
ment of the categorical pretreatment standards for the aluminum forming,
copper forming, and nonferrous metals forming and metal powders categories.
This guidance is based primarily on two sources: Federal Register notices,
which contain the official announcements of the categorical standards, and the
final development documents for aluminum forming, copper forming, and nonfer-
rous metals forming and metal powders categories, which provide a summary of
the technical support for the regulations. Additional information on the
regulations, industrial manufacturing processes, and wastewater control
technologies can be found in these sources.
This manual has been formatted to provide a brief introduction to the
aluminum forming, copper forming, and nonferrous metals forming and metal
powders categories in the first chapter (the Introduction). Chapter 2
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provides a more in-depth explanation of each category and the subcategories
established within each regulation. Chapter 2 also discusses the core and
ancillary operations associated with the three forming categories. The
treatment technologies upon which the regulations for each category have been
based are discussed briefly in Chapter 3 with references to the development
documents for more information. Chapter 4 of this manual summarizes the
requirements of the General Pretreatment Regulations with emphasis on the
reporting requirements applicable to all industrial users that are subject to
categorical pretreatment standards. In addition, Chapter 4 introduces the
mechanisms and provisions by which categorical pretreatment standards may be
or must be revised [e.g., through removal credits authority, through
fundamentally different factors (FDF) variances, or through use of the
combined wastestream formula (CWF) and flow-weighted averaging (FWA)].
Chapter 4 concludes with a brief discussion of local limits. Finally,
Chapter 5 provides examples of the application of categorical pretreatment
standards for the forming categories illustrating the calculation of mass
discharge allowances from production-based standards and the use of the CWA
and FWA. The information provided in the appendices of this manual include a
list of the references used during development of this guidance manual
(Appendix A), a glossary of terms with which the reader should be familiar
(Appendix B), a summary of the pretreatment standards for existing and new
sources for each forming category (Appendix C), and a list of the EPA
Regional, EPA Headquarters and State pretreatment coordinators and contact
persons (Appendix D).
1.1 DESCRIPTIONS OF THE METALS FORMING CATEGORIES
Forming is the deformation of a metal or metal alloy into specific shapes
by hot or cold working. The major forming operations include rolling (both
hot and cold), extruding, forging, and drawing. Additional operations that
are common to all three categories include casting, heat treatment, and
surface treatment. For a description of these and other technical terms used
in this document, refer to the Glossary of Terms provided in Appendix B.
Because of the diversity of the nonferrous metals forming industry, EPA has
divided it into three categories for regulation: aluminum forming, copper
forming, and nonferrous metals forming and metal powders.
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Forming of aluminum and aluminum alloys is covered by the aluminum
forming regulation. The forming of copper and copper alloys is covered by the
copper forming regulation. Discharges from the forming of all other
nonferrous metals (except beryllium) are covered by the nonferrous metals
forming regulation. As a result of a settlement agreement, EPA will regulate
beryllium and all beryllium alloys in a separate subcategory under copper
forming at a later date. The nonferrous metals forming regulation also
includes metal powder production operations that produce metal powders using
mechanical methods.
1.1.1 Aluminum Forming Category
Aluminum forming is the deformation of aluminum or aluminum alloys into
specific shapes by hot or cold rolling, drawing, extruding, or forging.
Aluminum is used in a wide variety of products because it is lightweight,
strong, resistant to corrosion, and has high electrical conductivity. Many of
the products manufactured at aluminum forming facilities are sold to other
manufacturers for further fabrication or incorporation into consumer goods.
Major industrial users of formed aluminum products include building and
construction, transportation, electrical, and container and packaging
industries.
Aluminum forming has become widespread since the commercial development
of aluminum in the 1880s. The demand for formed aluminum products has
increased greatly in the past 30 years. Two of the larger markets are the
manufacturing of aeronautical and automobile components, where aluminum
reduces weight and increases fuel efficiency.
There are approximately 271 aluminum forming facilities throughout the
United States, the majority of which are located east of the Mississippi
River. The aluminum forming industry employs an estimated 31,200 people and
total production is estimated to be 11 billion pounds per year. There are 59
direct dischargers, 72 indirect dischargers, and 140 facilities with no
discharge of process wastewaters.
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1.1.2 Copper Forming Category
Copper forming facilities produce seven types of copper or copper alloy
products: (1) plates, wide rigid pieces of metal over 1/4 inch thick normally
used for copper structural parts; (2) sheets, wide flexible pieces of metal
less than 1/4 inch thick with little rigidity; (3) strips, usually handled as
coils of copper and used for roof gutters, gaskets, radio parts, trim, weather
strip, washers, and diaphragms; (4) wires, which are circular in cross-section
and flexible; (5) rods, which are circular in cross-section, rigid, and used
for screening, fasteners, jewelry, welding rods, chains, hooks, and electrical
conductors; (6) tubings, which are long hollow cylinders generally used for
transporting fluids and heat transfer applications; and (7) forgings, which
take virtually any shape and are formed by exerting pressure on dies or rolls
of metal.
Approximately two-thirds of all formed copper and copper alloy products
are rod and wire. Building construction and electrical and electronic
products manufacturers are the largest users of formed copper materials,
followed by industrial machinery and equipment, consumer products, and
transportation. Only a small number of plants practice forging.
There are approximately 176 copper forming facilities in the United
States, employing about 43,000 employees. Most of the copper forming
facilities are located in the northeastern United States and the remainder are
distributed throughout the country. Copper forming is a mature industry and
has not grown substantially during the last decade. Of the 176, facilities,
45 discharge to POTWs, 37 discharge directly to surface waters, and 94 do not
discharge process wastewaters.
1.1.3 Nonferrous Metals Forming and Metal Powders Category
The nonferrous metals forming and metal powders category includes plants
engaged in the forming of nonferrous metals and their alloys, with the
exception of copper, aluminum and beryllium. Nonferrous metals are formed by
a variety of operations, and the product of one operation is often the
starting material for a subsequent operation. Cast ingots and billets are the
starting (or raw) material for making sheets, plates, extrusions, forgings,
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and rods. Rolled sheets and plates can be the starting material for
stampings, can blanks, finished products in building and aircraft
construction, or foil. Extrusions can be used as starting material for
forgings and drawings or can be sold as final products, such as beams and
extruded tubing. Forgings are either sold as consumer products or are used as
parts in the production of machinery, aircraft, and engines.
Some forming operations are more commonly used on specific metals. The
forming and associated operations in common use for a particular metal depend
on the limiting physical properties of the metal and the requirements for a
specific application. For example, lead, tin and bismuth are generally
extruded and alloys of these metals are drawn into solder wire. Bismuth is
rolled into strip for use in fuses. Hafnium is formed into control rods for
nuclear reactors. Lead can be extruded and swaged into bullets. Magnesium is
extruded into structural shapes. Nickel alloys are formed into tubing for use
in steam and gas turbines and in jet engines. Zinc is rolled into sheet for
architectural uses and is stamped into penny blanks. Precious metals (silver,
gold, platinum, and palladium) are often used as a thin layer clad to a layer
of base metal (usually copper or nickel), which is rolled into strip and
stamped into electrical contacts. Pure and clad precious metals are also
drawn into wire that is used to fabricate jewelry. Refractory metals
(columbium, molybdenum, rhenium, tantalum, tungsten, and vanadium) must be
formed at high temperatures or as powders. Columbium is used as a structural
material in nuclear reactors. Molybdenum is drawn into semiconductor wires.
Tantalum is used in very small capacitors and heat transfer and furnace
equipment. Tungsten is used widely in filaments for electric light bulbs.
The nonferrous metals forming category employs an estimated 40,000 people
and total production is estimated to be 470,000 tons per year. Although
nonferrous metals forming plants are not limited to any one geographical area,
the majority of these plants are located east of the Mississippi River. There
are approximately 334 plants in the United States that form the nonferrous
metals regulated under this category; 37 are direct dischargers, 121 are
indirect dischargers, and 176 do not discharge process wastewater.
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1.2 HISTORY OF THE ALUMINUM FORMING, COPPER FORMING, AND NONFERROUS METALS
FORMING AND METAL POWDERS CATEGORICAL PRETREATMENT STANDARDS
Table 1-1 lists the dates on which the pretreatment standards for new and
existing facilities in the three forming categories were first proposed and
subsequently promulgated.
Following promulgation of the aluminum forming regulation, the Aluminum
Association, Inc., the Aluminum Extruders Council, Inc., and other parties
filed petitions for review challenging portions of the regulation. A
settlement agreement resulted in amendments to the regulation. These
amendments affect the pretreatment standards for existing sources (PSES) for
cleaning and etching rinse discharges under Subpart C, Extrusion Subcategory
(467.35) and Subpart D, the Forging Subcategory (467.45); PSES for oil and
grease discharges under all subcategories; and the classification of hot water
(e.g., a cleaning or etching rinse) discharges.
Following promulgation of the copper forming regulation, Brush Wellman,
Inc., Cerro Copper Products Company, and the Village of Sauget filed petition
for review challenging segments of the regulation. The Seventh Circuit Court
of Appeals upheld all provisions of the regulation challenged by Cerro (Cerro
Copper Products Company v. Ruckelshaus, 7th Cir., July 1, 1985). A settlement
agreement with Brush Wellman, Inc. resulted in an amendment modifying the
copper forming regulation to exclude the forming of beryllium copper alloys
under Subpart A of the regulation and to create a new subcategory reserved for
the forming of beryllium and its alloys.
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TABLE 1-1. CITATIONS AND DATES OF PROPOSAL AND PROMULGATION
OF PRETREATMENT STANDARDS
TYPE OF RULE
DATE
FEDERAL REGISTER CITATION
Aluminum Forming Category
Proposed Rule
November 22, 1982
47
FR 52626
Final Rule
October 24, 1983
48
FR
49126
Technical Correction
March 27, 1984
49
FR
11629
Proposed Amendments
March 19, 1986
51
FR
9618
Final Rule
December 27, 1988
53
FR
52366
Copper Forming Category
Proposed Rule
November 12, 1982
47
FR
51278
Final Rule
August 15, 1983
48
FR
36942
Technical Correction
November 3, 1983
48
FR
50717
Proposed Rule
June 24, 1985
50
FR
26128
Technical Amendment
August 23, 1985
50
FR
34334
Final Rule
March 5, 1986
51
FR
7568
Technical Correction
June 20, 1986
51
FR
22520
Nonferrous Metals Forming and Metal Powders Category
Proposed Rule
March 5, 1984
49
FR
8112
Final Rule
August 23, 1985
50
FR
34242
Technical Correction
January 22, 1986
51
FR
2884
Proposed Rule
June 9, 1988
53
FR
21774
Metal Finishing Category
Final Rule
July 15, 1983
48
FR
32462
Technical Amendment
September 15, 1983
48
FR
41409
Correction
September 26, 1983
48
FR
43680
Correction
October 3, 1983
48
FR
45105
Technical Amendment
September 4, 1984
49
FR
34823
Technical Amendment
November 7, 1986
51
FR
40420
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2. CATEGORICAL PRETREATMENT STANDARDS FOR THE ALUMINUM, COPPER,
AND NONFERROUS METALS FORMING AND METAL POWDERS CATEGORIES
(40 CFR PARTS 467, 468, AND 471)
2.1 AFFECTED CATEGORIES
2.1.1 Aluminum Forming
The aluminum forming pretreatment standards apply to wastewaters
discharged from any of the core and core-related forming operations, including
rolling, drawing, extruding, and forging. Raw materials for aluminum forming
can be pure aluminum or alloys of aluminum. Alloys of aluminum are used to
improve the machinability, castability, hardness, strength and resistance to
corrosion of a metal. Discharges from ancillary operations, such as heat
treatment, casting, and surface treatment, are also regulated by this category
because they are usually an integral part of aluminum forming and contribute
pollutants to discharged wastewaters. Surface treatment operations (called
cleaning and etching for the purpose of this regulation) are considered part
of aluminum forming whenever they are performed at the same plant site. As
such, these surface treatment discharges are regulated by aluminum forming
categorical standards rather than by provisions of the electroplating or metal
finishing categorical standards (40 CFR Parts 413 and 433, respectively).
Wastewater discharges from processes for casting aluminum or aluminum
alloy conducted at plants that manufacture aluminum and also form aluminum may
be subject to different categorical standards. Discharges from casting
processes conducted at plants that manufacture and form aluminum are regulated
by the nonferrous metals manufacturing categorical standards for casting if
the processes cast primary or secondary aluminum without cooling (Federal
Register, Vol. 49, p. 8742, March 8,- 1984). If the aluminum cast at these
plants is a remelted primary aluminum product made from refined ore or
recycled aluminum and if these facilities also form aluminum, discharges from
the casting processes subsequent to remelting are regulated by the aluminum
forming categorical standards.
The facilities regulated under the aluminum forming category are gener-
ally included within SIC codes 3353, 3354, 3355, and 3463.
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2.1.2 Copper Forming
The copper forming pretreatment standards apply to wastewater discharges
from any of the copper forming operations. Raw materials can be pure copper
or alloys of copper that contain copper as the major constituent by weight,
with the following exceptions: alloys that contain 30 percent or greater
precious metals by weight are considered precious metal alloys, and alloys
that contain 0.1 percent or greater beryllium by weight are considered
beryllium alloys. Alloys of copper are used to improve electrical
conductivity, thermal conductivity, corrosion resistance, machinability,
formability, and strength of a metal, all of which are properties significant
to the end uses of copper. Examples of copper alloys are brass (copper/zinc)
and bronze (copper/tin).
The facilities regulated by the copper forming category are generally
included within SIC Codes 3351 and 3357.
2.1.3 Nonferrous Metals Forming and Metal Powders
The nonferrous metals forming standards apply to wastewater discharges
from any of the nonferrous metals forming operations. Raw materials for this
category can be any nonferrous metal or alloy of a nonferrous metal with the
following exceptions: aluminum (covered under 40 CFR Part 467), copper
(covered under 40 CFR Part 468) and beryllium and alloys of beryllium (to be
regulated with beryllium copper alloys). The nonferrous metals forming
category also includes metal powder production operations that produce metal
powders using mechanical methods such as milling, abrading, and atomizing.
Discharges from the casting of nonferrous metals are regulated in the
nonferrous metals forming category if casting is conducted as an integral part
of the nonferrous metals forming process at the same site the metal is formed.
Discharges from surface treatment of nonferrous metals are regulated under the
nonferrous metals forming category when surface treatment is performed at the
same site the nonferrous metal is formed. Under these circumstances,
discharges from surface treatment are excluded from regulation under the
electroplating category (40 CFR Part 413) or the metal finishing category (40
CFR Part 433).
2-2
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The facilities regulated under the nonferrous metals forming category are
generally included within SIC Codes 3356, 3357, 3463, and 3497.
2.2 SUBCATEGORIES
The aluminum forming category and the nonferrous metals forming and metal
powders category are subcategorized to facilitate description of the
regulation of wastewater discharges from the various process operations.
Division of a category into subcategories provides a mechanism within the
regulation for addressing process and produce variations which result in
distinct wastewater characteristics. The copper forming category is not
currently subcategorized. However, the regulation of beryllium and beryllium
alloy forming operations may later lead to subcategorization within the copper
forming category. The following sections describe the various subcategories
within each regulation and identify the corresponding applicable process
operations.
2.2.1 Aluminum Forming
The aluminum forming category is subcategorized on the basis of the
principal forming operations characteristic of aluminum forming facilities.
The principal or core operations as they are called in this category consist
of rolling, extruding, forging and drawing forming operations and various
related operations that almost always occur in conjunction with those forming
operations. Typically, but not exclusively, an aluminum forming facility will
conduct only one of these core operations at each individual site but will
also conduct a number of ancillary operations. Ancillary operations are unit
operations that may or may not be conducted at all facilities that carry out
the same core operation (e.g., drawing) but do contribute significant volumes
of wastewater and loadings of pollutants to a facility's discharge. Ancillary
operations will be discussed in more detail in Section 2.3.2. In order to
account for the variability of the core operations and ancillary operations
that may be conducted at each facility, the categorical standards have
established pollutant allowances for discharges from operations that are
considered to be the "core" or principal operation of each subcategory and
separate allowances for discharges from the various ancillary operations that
may or may not be used by individual forming facilities. Therefore, an
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aluminum forming facility would be permitted to discharge a mass of a
pollutant that is equivalent to the sum of the mass limitations established
for the core operation and for each of the individual ancillary operations
conducted at that facility. The six subcategories under the aluminum forming
category, in addition to the core and ancillary operations of each
subcategory, are discussed belov and summarized in Table 2-1.
• Rolling with neat oils is applicable to all wastewater discharges
resulting from or associated with aluminum rolling operations in which
neat oils are used as a lubricant. Many of the plants in this
subcategory are also associated with one or more additional subcate-
gories. The most common case is overlap with the subcategory of
rolling with emulsions. Rolling of aluminum with emulsions is
frequently followed by rolling using neat oils. Also, in some plants,
aluminum is first rolled and then drawn to form the desired product.
If the drawn product is then etched or heat treated, the etching or
heat treating operations are associated with drawing subcategory
rather than with rolling subcategory. The core forming operations of
this subcategory include rolling using neat oils, roll grinding,
sawing, annealing, stationary casting, homogenizing, artificial aging,
degreasing, and stamping. Ancillary operations regulated under this
subcategory include continuous rod casting, continuous sheet casting,
solution heat treatment, and cleaning or etching.
Aluminum annealing operations do not use process water. However, some
furnaces are equipped with wet scrubbers to remove contaminants from
off gases. Discharge allowances have been established in the rolling
with neat oils subcategory of the aluminum forming category for core
operations that do have or do not have annealing furnace scrubbers.
• Rolling with emulsions is applicable to all wastewater discharges
resulting from or associated with aluminum rolling operations in which
oil-in-water emulsions are used as lubricants. The core forming
operations of this subcategory include rolling with emulsions, roll
grinding, stationary casting, homogenizing, artificial aging,
annealing, and saving. The ancillary operations regulated under this
subcategory include direct chill casting, solution heat treatment,
cleaning or etching, and degassing.
• Extrusion is applicable to all wastewater discharges resulting from or
associated with aluminum extrusion operations. The core forming
operations of this subcategory include extrusion die cleaning, dummy
block cooling, stationary casting, artificial aging, annealing,
degreasing, and sawing. Ancillary operations regulated under this
subcategory include direct chill casting, press or solution heat
treatment, cleaning or etching, degassing, and extrusion press
hydraulic fluid leakage.
• Forging is applicable to all wastewater discharges resulting from or
associated with aluminum forging operations. The core forming
operations of this subcategory include forging, artificial aging,
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TABLE 2-1. CORE OPERATIONS AND ANCILLARY OPERATIONS APPLICABLE TO EACH
SUBCATEGORY OF THE ALUMINUM FORMING CATEGORY
Aluminum Forming Subcategories
Core Operations and
Ancillary Operations
Rolling
with
Neat Oils
Rolling
with
Emulsions
Extrusion Forging
Drawing
with
Neat Oils
Drawing
with
Emulsions
or Soaps
Core Operations;
Annealing X
Artificial aging X
Degreasing X
Drawing with emulsions
or soaps
Drawing with neat oils
Dummy block cooling
Extrusion die cleaning
Forging
Homogenizing X
Roll grinding X
Rolling with emulsions
Rolling with neat oils X
Sawing X
Stamping X
Stationary casting X
Swaging
Miscellaneous waste-
water sources* X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Ancillary Operations:
Cleaning or etching**
Continuous rod casting
Continuous sheet
casting
Degassing
X
X
X
X
X
X
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TABLE 2-1. CORE OPERATIONS AND ANCILLARY OPERATIONS APPLICABLE TO EACH
SUBCATEGORY OF THE ALUMINUM FORMING CATEGORY (Continued)
Aluminum Forming Subcategories
Drawing
Rolling
Rolling
Drawing
with
Core Operations and
with
with
with
Emulsions
Ancillary Operations
Neat Oils
Emulsions
Extrusion Forging Neat Oils
or Soaps
Ancillary Operations (Continued):
Direct chill casting X X
Extrusion press
hydraulic fluid
leakage X
Forging air pollution
control X
Press heat treatment X
Solution heat
treatment X X XXX X
^Wastewaters from one or more of the following miscellaneous sources are to be
grouped under the aluminum forming category into a single allowance and included
with the allowances provided for other core operations: maintenance, clean-up,
ultrasonic testing, processing area scrubbers, ingot scalping, roll grinding of
caster rolls, and dye solution baths and seal baths (along vith any other cleaning
or etching baths, except a hot water seal) when not followed by a rinse.
**A hot water seal is classified as a cleaning or etching rinse.
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annealing, degreasing, and saving. Ancillary operations under this
subcategory include forging air pollution scrubbers, solution heat
treatment, and cleaning or etching.
• Drawing with neat oils is applicable to all wastewater discharges
resulting from or associated with aluminum drawing operations in which
neat oils are used as a lubricant. The drawing with neat oils
subcategory is the second largest aluminum forming subcategory. The
majority of the plants in the drawing with neat oils subcategory
conduct only the core operations alone. Heat treatment contact
cooling water and cleaning or etching baths and rinses are the most
common ancillary streams in this subcategory. The core forming
operations of this subcategory include drawing using neat oils,
stationary casting, artificial aging, annealing, degreasing,' sawing
and swaging. Ancillary operations regulated under this subcategory
include continuous rod casting, solution heat treatment, and cleaning
or etching.
• Drawing with emulsions or soaps is applicable to all wastewater
discharges resulting from or associated with the aluminum drawing
operations which use oil-in-water emulsion or soap solution
lubricants. The core forming operations of this subcategory include
drawing using emulsions or soaps, stationary casting, artificial
aging, annealing, degreasing, sawing and swaging. Ancillary opera-
tions regulated under this subcategory include continuous rod casting,
solution heat treatment, and cleaning or etching.
In addition to the core operations specified above for each subcategory,
the following wastewater sources shall be regulated as a single core opera-
tion, as established in the preamble of the aluminum forming regulations
setting forth categorical standards (Federal Register, Vol. 48, p. 49140,
October 24, 1983).
2.2.2 Copper Forming
The copper forming standards are applicable to wastewater discharges from
the five principal operations used to form copper and copper alloys:
• Processing area scrubbers
• Ultrasonic testing
• Maintenance
• Dye solution baths and seal baths
(along with any other cleaning
and etching bath, except a hot
water seal) when not followed by
a rinse
• Roll grinding of caster rolls
• Ingot scalping
• Cleanup.
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• Hot rolling
• Cold rolling
• Extrusion
• Drawing
• Forging.
In addition, twelve ancillary surface treatment and heat treatment
processes used to give desired surface and physical properties to the metal
being formed also generate wastewater.
•
Annealing with oil
•
Alkaline rinse
•
Annealing with water
•
Solution heat treatment
•
Pickling bath
•
Extrusion press heat treatment
•
Pickling rinse
•
Tumbling or burnishing
•
Pickling fume scrubber
•
Surface coating
•
Alkaline bath
•
Miscellaneous (includes hydrotesting,
sawing, surface milling, and
maintenance).
Although copper forming processes are used in different combinations
within the category, the wastewater discharges from all plants are similar in
both the type and concentration of pollutants discharged. Therefore, this
category is not currently subcategorized. However, regulation of beryllium
and beryllium alloy forming operations may lead to subcategorization within
this category.
2.2.3 Nonferrous Metals Forming and Metal Powders
The nonferrous metals forming and metal powders category is
subcategorized primarily on the basis of the type of metal being formed. Some
subcategories contain more than one type of metal because metals that have the
same metallurgical properties tend to be formed using the same processes at
the same facilities, or are frequently combined together in alloys. The
subcategories cover the major, minor and ancillary forming operations integral
to the forming of metals. The ten nonferrous metals forming subcategories and
their associated processes are listed below:
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• Lead, tin, and bismuth forming consist of rolling, drawing, extrusion,
and swaging processes. Some plants conduct casting operations as an
integral part of the forming processes. Products made from lead
forming include bullets made by extrusion and swaging lead; solder
formed by extrusion and drawing of lead, tin, and bismuth in various
alloy combinations; and sheathed cable in which lead is extruded over
insulated copper cable.
• Magnesium forming consists of forging, rolling, and extrusion
processes. Water is used in post-extrusion etching, chromating, and
rinsing processes.
• Nickel and cobalt forming consists of rolling, drawing, extrusion, and
forging processes, with extrusion being the least common forming
process. Nickel and cobalt are commonly formed at the same plant and
are frequently combined together in alloys.
• Precious metals forming includes processes used to form gold, silver,
platinum, and palladium. Most plants in this subcategory form more
than one of the precious metals using the same equipment and cleaning
operations. In addition, the metals are alloyed with each other and
other metals in many combinations. The precious metals subcategory
includes any alloy of gold, platinum, palladium, or silver that
contains 30 percent or greater of that metal (even if another metal
occurs in a larger percentage). The most common forming operations
are rolling and drawing. Extrusion and forging are practiced to a
much smaller extent.
The cladding of precious metals to base metals is closely associated
with precious metals forming. Typically, a gold or silver overlay
is roll bonded to a copper-alloy base. Nickel and stainless steel are
also used as base metals. Since the clad metals are formed by the
same techniques and on the same equipment as pure metals, precious
metal cladding is grouped with precious metals forming.
• Refractory metals forming includes processes used to form molybdenum,
tungsten, vanadium, rhenium, tantalum, and columbium. Most of the
plants that form one refractory metal also form one or more other
refractory metals and the resulting wastestreams are commonly
commingled. The end product of refining these metals is metal powder
that is consolidated into finished products or mill shapes. Only
production of metal powders using mechanical methods such as milling,
abrading, and atomizing, which do not significantly increase their
purity, are included in this subcategory. Production of refractory
metal powders in operations that significantly increase their purity
is included in the nonferrous metals manufacturing category. The
powders can be arc or electron beam melted and cast into ingots. The
mill shapes and ingots are shaped into finished form by rolling,
drawing, extrusion, and forging.
• Titanium forming consists of rolling, drawing, extrusion, and forging
processes. Forging is practiced by many plants that primarily forge
steel. Rolling is the second most common forming operation; drawing
the least. Titanium is often acid-etched to remove a hard oxide
surface layer that forms at elevated temperatures.
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• Uranium forming consists of forging, rolling, and extrusion
operations. Water is used in post-forming surface treatment steps.
There are no existing uranium forming plants discharging process
wastewaters to POTWs. Therefore, no PSES standards have been
promulgated for this subcategory.
• Zinc forming consists of rolling, drawing, and forging operations.
Zinc is surface treated and cleaned with alkaline detergents following
forming. No PSES standards have been promulgated for this
subcategory on the basis of the economic impact to zinc forming
facilities by the promulgating of technology-based standards.
• Zirconium and hafnium forming consists of rolling, drawing, and
extrusion. One common manufacturing process is tube reducing
(roll-rocking or pilgering), a special type of cold rolling. Post-
forming operations include annealing and (dry) sand blasting, acid and
alkaline cleaning, and conversion coating. All of the plants that
form hafnium also form zirconium by similar processes.
• Metal Powders production by mechanical processes is regulated under
the appropriate metals forming subcategory. However, since aluminum,
copper and iron forming are not regulated under the nonferrous metals
forming category, a separate subcategory has been established for
metal powders produced from these metals. Therefore, the metal
powders subcategory includes operations for producing iron, copper,
and aluminum powders and metal parts from iron, copper, and aluminum
powders. Powders are produced by wet or dry atomization and mechan-
ical grinding. Pressing and sintering, the major manufacturing
processes in powder metallurgy, ordinarily use no process water. Most
of the wastewater from operations in this subcategory is generated by
post-forming surface treatment.
Major or minor forming operations in nonferrous metals forming and metal
ers production include:
Rolling
Drawing
Extrusion
Forging
Cladding
• Tube reducing
• Swaging
• Metal powder production
• Milling
• Abrading
• Atomizing.
Ancillary operations include:
• Casting for subsequent forming
• Cleaning or etching
• Sawing or grinding
• Hydrostatic or ultrasonic testing
Tumbling or burnishing
Electrocoating
Heat treatment
Surface treatment.
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2.3 PROCESS OPERATIONS
The major and ancillary forming operations introduced in the previous
sections and their associated wastewater characteristics are described below.
2.3.1 Forming Operations
The major operations associated with the aluminum, copper and nonferrous
metals forming categories are:
• Rolling • Forging
• Drawing • Cladding
• Extrusion • Metal powder production.
Rolling is used to transform cast metal into various intermediate or
final products. Pressure exerted by cylindrical rollers as metal is passed
between them reduces the thickness in the metal. It is necessary to use a
cooling and lubricating compound during rolling to prevent excessive wear on
the rolls, to prevent adhesion of metal to the rolls, and to aid in main-
taining a suitable and uniform rolling temperature.
Lubricants (usually oil-water emulsions or water alone) are used in hot
rolling operations. Evaporation of the lubricant as it is sprayed on the hot
metal surface cools the equipment and the metal. The lubricant eventually
degrades and must be eliminated from circulation. Wastewater discharges
contain toxic organics and oil and grease that originate in the lubricants and
suspended solids and toxic metals that originate from contact of the water or
lubricant solution with the metal products or rolls.
Cold rolling occurs at temperatures below the recrystallization point of
the metal. The metal is harder and less ductile, requiring more lubrication
than in hot rolling. The lubricant also functions as a cooling medium, but to
a lesser extent than in hot rolling. The lubricants used in cold rolling
consist of more concentrated oil-water mixtures, mineral oil, kerosene-based
lubricants (neat oils), or graphite-based lubricants. Cold rolling lubricants
are recycled with sediment removal or filtration. After extended use, the
rolling oils are periodically reclaimed, incinerated, or discharged in
batches. Pollutants in the spent lubricant discharge are toxic organics,
toxic metals, oil and grease, and suspended solids.
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Drawing, when applied to the manufacture of tube, rod, bar, or wire,
refers to the pulling of metal through a die or succession of dies to reduce
the metal's diameter, to alter the cross sectional shape, or to increase its
hardness. In the drawing of tubing, one end of the extruded tube is swaged to
form a solid point and is then passed through the die. A clamp, known as a
bogie, grips the swaged end of tubing. A mandrel is then inserted into the
die orifice, and the tubing is pulled between the mandrel and die, reducing
the outside diameter and the wall thickness of the tubing. Wire, rod, and bar
drawing is accomplished in a similar manner, but the metal is drawn through a
simple die orifice without using a mandrel. For example, copper wire is drawn
(pulled) through a series of tungsten carbide dies decreasing the diameter in
each draw. Diamond dies are used for fine copper wire.
In order to ensure uniform drawing temperatures and to avoid excessive
wear on the dies and mandrels used, lubricants are applied during drawing. A
wide variety of lubricants are used for this purpose. Heavier draws, which
produce a larger reduction in diameter or cross-sectional area, may require
oil-based lubricants (neat oils), but oil-in-water emulsions are used for many
applications. Graphite, ground glass, and soap solutions can also be used for
some of the lighter draws. Drawing oils are usually recycled until their
lubricating properties are exhausted. Water-based lubricants are periodically
discharged and replaced. Pollutants present in the discharge include toxic
organics, toxic metals, oil and grease, and suspended solids. Toxic organics
and oil and grease present in the discharge originate in the lubricants used
or are generated by the action of pressure and heat imposed on the lubricant
during the forming process. Toxic metals and suspended solids appear in the
spent lubricants as a result of the direct contact with the metal and dies
during the drawing process.
Intermediate annealing is frequently required between draws in order to
restore the ductility of the metal which is lost by cold working of the drawn
product. Degreasing of the metal may be required to prevent burning of heavy
lubricating oils in the annealing furnaces.
Extrusion is the process of forcing metal to flow through a die orifice
by applying high pressure to a cast billet of metal. The resulting product is
an elongated shape or tube of uniform cross section. Extrusions are
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manufactured using either a mechanical or a hydraulic extrusion press. A
heated cylindrical billet is placed into the ingot chamber, and the dummy
block and ram are placed into position behind it. Pressure is exerted on the
ram by hydraulic or mechanical methods, forcing the metal to flow through the
die opening. The extrusion is saved off next to the die, and the dummy block
and ingot butt are released. Although some metals, such as lead, can be
extruded cold, most metals are heated first to reduce adhesion of the die to
the extruded metal. Heat treatment is frequently used after extrusion to
attain desired mechanical properties.
Sources of wastewater from the extrusion process include extrusion die
cleaning and wet scrubbers for the die cleaning baths. In aluminum forming,
die cleaning is generally performed by immersion in caustic solutions. Wet
scrubbers are usually used to control caustic fumes from the die cleaning
bath. Wastewater is also generated from hydraulic fluids which are sometimes
comprised of oil-water emulsions and from contact cooling waters.
Forging is a process in which metal is formed, usually hot, into shapes
by employing compressive forces. The actual forging process is a dry opera-
tion. There are five basic methods of forging practiced in the forming
categoriesj
• Closed die forging
• Open die forging
t Rolled ring forging
• Impacting
• Swaging.
In all of these techniques, pressure is exerted on dies or rolls, forcing the
heated stock to take the desired shape. The first three processes are types
of hot working; the other two are cold working.
Closed die forging is accomplished by hammering or squeezing the metal
between two steel dies; one fixed to the hammer or press ram, and the other to
the anvil. Forging hammers, mechanical presses, and hydraulic presses can be
used for the closed die forging of metals. The heated stock is placed in the
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lower die and, by one or more blows of the ram, forced to take the shape of
the die set. Open die forging is similar to that described above, but in this
method the shape of the forging is determined by turning the stock and
regulating the blows of the hammer or strokes of the press. Rolled ring
forging is used in the manufacture of seamless rings. A hollow cylindrical
billet is rotated between a mandrel and pressure roll to reduce its thickness
and increase its diameter.
Impacting is performed by placing a cut-off piece of metal in a bottom
die. A top die consisting of a round or rectangular punch and fastened to the
press ram is driven into the slug, causing the metal to be driven up around
the top punch. Swaging is the process of forming a taper or a reduction on
metal products, such as rods or tubing. When swaging is the initial step in
drawing tube or wire, a solid point is formed by repeated blows of opposing
dies. Swaging can also be used to reduce the diameter of tube or wire without
a subsequent drawing operation. The process of making tapered bullets from
lead wire is also called swaging.
Lubricants are not required when forging copper. Consequently, there is
no discharge of wastewater from copper forging processes. Proper lubrication
of the dies is essential in forging aluminum and most nonferrous metals.
Colloidal graphite in either a water or an oil medium is usually sprayed onto
the dies for this purpose. Particulates and smoke may be generated from the
partial combustion of oil-based lubricants as they contact the hot forging
dies. ,In those cases, air pollution controls may be required. Baghouses, wet
scrubbers, and commercially available dry scrubbers are in use at aluminum and
nonferrous metals forming facilities.
Cladding is the process of forming a composite metal containing two or
more layers that have been bonded together. The bonding may have been
accomplished by roll bonding (co-rolling), solder application (brazing), or
explosion bonding. In the roll bonding process, a permanent bond between two
metals is obtained by rolling under high pressure in a bonding mill. The high
pressure increases the temperature of the metals, promoting fusion so that a
metallurgical bond forms at the interface. The solder application or brazing
process is also used to make clad metals. The term soldering is used where
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the temperature range falls below 425°C (800°F). The term brazing is used
where the temperature exceeds 425°C (800°F). In this process, a thin layer
(film or foil) of a metal with a low melting point is placed between two
layers of metal to be bonded. The three-layer assembly is then placed into a
furnace at the melting temperature of the filler metal. Bonding results from
the intimate contact produced by the mingling of a small amount of the base
metal and the top metal in the molten filler metal, without direct fusion of
the two metal layers. Upon cooling, the clad material can be formed by any of
the forming operations previously described.
Pressure bonding is a combination of roll bonding and solder bonding. A
three-layer assembly of solder and the metals to be bonded is placed into a
furnace, just as in solder bonding. However, the heating is accompanied by
the application of pressure, as in roll bonding. The bonded metal may be
cooled by a water spray after it is removed from the bonding furnace. In
explosion bonding, the metallurgical joining of two or more metals is accom-
plished by the force of a carefully detonated explosion. The explosion moves
progressively across the surface of the ladder metal, accelerating it across a
"standoff distance" and against the backer metal. The force of the explosion
shears away the oxide- and nitride-containing surface layers of both metals,
producing metallurgically clean surfaces which, under extreme pressure, allow
normal interatomic and intermolecular forces to create an electron-sharing
bond. The result is a cold veld.
Metal powder production, except beryllium powder production, is included
in the nonferrous forming category to facilitate implementation of the
regulations. Atomization is the most common method of producing metal
powders. In this process, a stream of fluid, usually water or gas, impinges
upon a molten metal stream, breaking it into droplets that solidify as powder
particles. The size and shape of atomized powder is determined by jet
configuration, jet design, composition of the impinging medium, and
composition of the metal. Powders are also produced by disintegration of
solid metal into powder by mechanical combination. This process is used for
brittle ores or chemically embrittled metals. It is also used to produce
powder from turnings and other scrap of more ductile metals. The most
commonly utilized pieces of mechanical reduction equipment are ball mills,
vortex mills, hammer mills, disc mills, and roll mills.
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2.3.2 Ancillary Operations
The principal ancillary operations associated with the three forming
categories are:
• Casting
• Heat treatment
• Surface treatment
• Degassing
t Miscellaneous operations.
Casting consists of filling a shaped container or mold with molten metal
so that the shape of the mold is reproduced upon solidification. The choice
of casting method depends on the metal or ,alloy being cast and the ultimate
use of the cast form. The casting methods used in nonferrous metals forming
consist of the following four classes:
• Stationary casting
• Direct chill casting, including arc casting
• Continuous or semi-continuous casting
• Shot casting.
The method of casting most widely practiced at nonferrous metals forming
plants is stationary or pig casting, which allows for recycling of in-house
scrap. In this process, molten metal is poured into cast iron molds and
allowed to air cool. Lubricants are not usually required. Although water may
be sprayed onto the molten metal to increase the cooling rate, this generally
does not result in any discharge.
Direct chill casting is a widely used method of casting aluminum for
subsequent forming. Direct chill casting is characterized by continuous
solidification of the metal while it is being poured. The length of an ingot
cast using this method is determined by the vertical distance it is allowed to
drop rather than by mold dimensions. Molten metal is tapped from the melting
furnace and flows through a distributor channel into a shallow mold. Noncon-
tact cooling water circulates within this mold, causing solidification of the
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metal. The base of the mold is attached to a hydraulic cylinder that is
gradually lowered as pouring continues. As the solidified metal leaves the
mold, it is sprayed with contact cooling water to reduce the temperature of
the forming ingot. The cylinder continues to descend into a tank of water,
causing further cooling of the ingot as it is immersed. When the cylinder hai
reached its lowest position, pouring stops and the ingot is lifted from the
pit. The hydraulic cylinder is raised and positioned for another casting
cycle. In direct chill casting, lubrication of the mold is required to ensure
proper ingot quality. Much of the lubricant volatilizes on contact with the
molten aluminum, but contamination of the contact cooling water with oil and
oil residues does occur.
Arc casting is a form of direct chill casting used for refractory metals
(tungsten, molybdenum, tantalum, columbium, vanadium, and rhenium) because the
melting points of these metals are too high for them to be easily cast by
conventional techniques. Under vacuum in an appropriate furnace consisting of
a water-cooled copper crucible, performed bars, made of compacted and sintered
powder, form an electrode for striking a high current, low voltage arc between
the bar and a starting pad of metal. As the bar is progressively melted,
molten metal falls through the arc and forms an ingot that gradually
solidifies.
Continuous casting, unlike direct chill casting, is not constrained in
the length of the casting. It is not necessary to interrupt production to
remove the cast product. The use of continuous casting eliminates or reduces
the degree of subsequent rolling required. Because continuous casting
incorporates casting and rolling into a single process, rolling lubricants may
be needed. Frequently, oil emulsions similar to those used in conventional
hot rolling are used for this purpose. Graphite solutions may be suitable for
roll lubrication of some continuous casting processes. In other instances,
aqueous solutions of magnesia are used.
Heat treatment is performed to give the metal the desired mechanical
properties. The general types of heat treatment include annealing, solution
heat treatment, homogenizing, artificial aging, and press heat treatment.
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Annealing is used to remove the effects of strain hardening or solution
heat treatment. After raising the metal to its recrystallization temperature,
the metal is cooled at a slow, controlled rate. After annealing, the metal is
in a ductile, more workable condition suitable for subsequent forming opera-
tions. Plants commonly have multiple annealing units with several types of
equipment. Heat is transferred by direct radiation and convection from the
flame to the product. Combustion of the heating fuel also produces a reducing
atmosphere within the annealing furnace that reduces surface oxidation that
would otherwise occur at the elevated temperatures employed. The control of
surface oxidation in annealing not only reduces metal loss in production, but
also significantly reduces pickling that may be required at later points
during copper processing.
Aluminum and nonferrous metals annealing is a dry process. However, off
gases from furnace fuels may require cleaning with wet scrubbers if they are
used to create an inert atmosphere inside the furnace.
Copper annealing may incorporate a quenching step. Cooling water
quenches may consist of a tank through which cooling water flows, rapidly
dissipating the heat at the surface of the copper or copper alloy. This
continuous discharge contains toxic metals and suspended solids that result
from contact of the quench water with the heated copper product. Oil-water
quench solutions must be periodically discharged and replaced because of the
continuous build-up of contaminants. The spent oil-water quench solution is
contaminated with toxic organics, toxic metals, oil and grease, and suspended
solids. Toxic organics and oil and grease present in this discharge
apparently originate in the oil used in the quench solution. Toxic metals and
suspended solids present in the discharge result from contact of the quench
solution with the heated copper.
Solution heat treatment is accomplished by raising the temperature of a
heat treatable alloy to the eutectic temperature, where it is held for the
required length of time and quenched rapidly. As a result of this process,
the metallic constituents in the alloy are held in a super-saturated solid
solution, improving the mechanical properties. In copper forming, solution
heat treatment is practiced following all major forming operations; however,
2-18
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it is most commonly used following hot rolling and extrusion because of the
high temperatures at vhich these operations are performed. Quenching is
typically achieved by immersing the workpiece in a tank through which the
cooling water flows. Spray quenching is also practiced. Water is used
exclusively as the quenching medium for solution heat treatment of copper
products following all of the major forming operations except extrusion. In
the case of extrusion, an oil-water solution is sometimes used. Pollutants
present in the discharge from solution heat treatment water quenches include
toxic organics, toxic metals, oil and grease, and suspended solids. Toxic
organics and oil and grease present in the quench water discharge apparently
originate in the lubricants used in the forming operations that precede
solution heat treatment and also result from contact of the quench water with
the surface of the hot copper product.
Homogenizing is accomplished by heating the metal to an appropriate
temperature for four to 48 hours, then allowing the metal to air cool.
Homogenization of a cast ingot provides a more uniform distribution of
intermetallic compounds within the metal. This technique is commonly used in
nonferrous metals forming.
Artificial aging, also known as precipitation heat treatment, is applied
to some nonferrous metals in order to cause precipitation of super-saturated
constituents in the metal. The metal is heated to a relatively low tempera-
ture for several hours and then is air-cooled.
Press heat treatment is solution heat treating of metals immediately
following the extrusion process. In this procedure, the metal is extruded at
the required temperatures and is quenched as it emerges from the die or press.
The aluminum forming and nonferrous metals forming industries use contact
cooling water as a quenching medium. Copper forming industry uses emulsified
or soluble oils as quenching media. These oils are characteristically
recycled and reused.
Surface treatments are used to alter the surface of the metal for the
purpose of hardness, lubricity and appearance. Cleaning and etching treat-
ments are surface treatments applied after the forming of metal products.
2-19
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Solvents, acid and alkaline solutions, and detergents can be used to clean
soils such as oil and grease from the aluminum surface. Deoxidizing and
desmutting are accomplished with acid solutions. Surface treatments and their
associated rinses are usually combined in a single line of successive tanks.
Wastewater discharge from these lines is typically commingled prior to
treatment or discharge. In some cases, rinse water from one treatment is
reused in the rinse of another. These treatments may be used for cleaning
purposes or to provide the desired finish for a formed product, or they may
simply prepare the metal surface for subsequent coating by such processes as
anodizing, conversion coating, electroplating, painting, and porcelain
enameling.
The use of acids to treat the surface of metals is referred to as
pickling and often also involves the use of additional chemicals such as
sodium dichromate or hydrogen peroxide to produce a brighter and more tarnish-
resistant finish. Bright dips consist of combinations of sulfuric acid,
nitric acid, phosphoric acid, chromic acid, and hydrochloric acid. Periodic
discharge of pickling baths ensures that contaminant concentrations will not
affect product quality or reduce the effectiveness of the bath. The high
acidity of the bath results in high concentrations of dissolved metals in the
bath discharge that originate in the copper product. Discharges from pickling
baths also contain hexavelent chromium that originates in the dichromate added
to the baths. Water used for rinsing the pickled copper contains metals;
however, they are found at lower concentrations than in the bath. The rinse
water dilutes the concentration of toxic metal contaminants which are carried
over from the pickling bath on the surface of the copper product.
The layer of oxide scale formed from hot working operations on nickel,
cobalt, titanium, zirconium, and certain refractory metals is difficult to
remove with acid surface treatment alone. Molten salt baths can be used to
descale the metal prior to acid surface treatment. Molten salt baths are
oxidizing baths composed of sodium or potassium hydroxide and sodium or
potassium nitrate. The nitrate is the oxidizing agent in the bath, and the
chloride is added to depress the melting point of the bath to increase
fluidity and to inhibit attack on the metal itself. Sodium carbonate or
potassium carbonate may be added in small proportions to adjust the melting
2-20
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point of the mixture and to inhibit deleterious reactions. Molten salt baths
are maintained at 480°C to 540°C. The formed metal parts are dipped in the
baths for 15 minutes or longer, then rinsed and quenched in a water bath.
Anodizing and chemical conversion coating are used to change the
characteristics of the surface of formed metal by chemically or electrochemi-
cally depositing an inorganic coating on the surface of the metal. These
coatings are applied for corrosion protection and in preparation for painting.
Anodizing is an electrochemical oxidation process that forms an insoluble
oxide of the metal on the surface of the formed metal. It is applied by
immersing the metal form in an acid solution (containing fluoride, phosphate,
chromate, or sulfate ions) and passing an electrical current through the metal
form. After anodizing, parts are rinsed in cold, then hot, water to facilitate
drying.
Chemical conversion coatings are applied to previously-deposited metal or
base metal for increased protection, lubricity, or in preparation for another
special coating or to achieve a special surface appearance. Typical
operations include chromating and phosphating. Chromating forms a protective
film the metal surface with a solution containing hexavalent chromium and
active organic and inorganic compounds. When phosphating, the metal surface
is wetted, usually by immersion, with a phosphate solution which reacts with
the metal surface. Phosphating is used to provide a good base for paints and
other organic coatings, to lubricate the metal surface before cold forming or
drawing, or to impart corrosion resistance.
Electrocoating is depositing metal in an adherent form on the surface of
a formed piece of metal that acts as a cathode. The coating may be applied as
the finished surface. It may also act as a soft, lubricating coating for hard
metal alloys before cold working (tube reducing or extruding). Lubricating
coatings (often copper) are dissolved away in acid after the forming operation
has been completed.
Alkaline cleaning can precede annealing to limit the amount of oil that
is introduced into the furnace. It may also follow annealing and be used to
remove the resulting tarnish and smut. Vapor or solvent degreasing, which
2-21
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does not use water, can be used in place of alkaline cleaning. To properly
control the concentration of impurities, a portion of the alkaline cleaning
bath is continuously or periodically discharged. The discharge will contain
toxic organics, toxic metals, oil and grease, and suspended solids. The toxic
organics and oil and grease present in the discharge originate in the
lubricants that are cleaned from the surface of the product. Toxic metals and
suspended solids present in the discharge that originate in the forming
operation that precedes alkaline cleaning are also washed from the product
surface. Rinse water contains oil and grease and metals in much lower
concentrations than in the bath. The higher volume of water used in rinsing
dilutes the concentrations of these contaminants.
Degreasing generally consists of the use of solvent cleaners to remove
lubricants (oils and grease) applied to the surface of nonferrous metals
during mechanical forming operations. Solvents commonly used for vapor
degreasing are trichloroethylene, 1,1,1-trichloroethane, methylene chloride,
perchloroethylene, and various chlorofluorocarbons. Solvent selection depends
on the required process temperature (solvent boiling point), product
dimension, and metal characteristics. Contaminated vapor degreasing solvents
are frequently recovered by distillation. The sludge residue generated is
toxic and may be flammable, requiring appropriate handling and disposal
procedures.
Tumbling or burnishing is used to polish, to remove sharp corners, or to
smooth parts for cosmetic and functional purposes. Water or oil-water
lubricants are sometimes used to lubricate and cool the process, which is
usually performed in rotating barrels or vibrating drums. Water is also used
to rinse the finished parts and clean the abrasive media.
Degassing is performed during aluminum forming to remove hydrogen gas
that is trapped in molten metal due to complex reactions that occur in
furnaces. The metal is "degassed" by introducing a combination of nitrogen
and chlorine gas, chlorine gas alone, or other chemicals.
2-22
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Miscellaneous operations include hydrotesting, sawing, milling, and
maintenance. Hydrotesting is used to check parts for surface defects or
subsurface imperfections. Parts are submerged in a water bath and subjected
to ultrasonic signals, high pressure, or air pressure. Such baths are
periodically discharged. Sawing is performed on parts to remove defects and
for cutting to size. Surface irregularities and oxides from metal products
are removed by milling. Sawing and milling operations use water-soluble oil
lubricants to provide cooling and lubrication. Maintenance operations such as
machinery repair can generate wastewaters associated with the removal of
production-related soils and dirts.
2.4 EXCEPTIONS FROM REGULATION COVERAGE
2.4.1 Aluminum Forming
Casting of aluminum may be performed prior to forming operations at
aluminum forming plants or as the final step in the manufacture of primary and
secondary aluminum. Casting performed at a plant which manufactures aluminum
and also carries out aluminum forming is subject to the casting standards
established for the aluminum manufacturing subcategory of the nonferrous
metals manufacturing category (40 CFR Part 421) if the aluminum is cast
without cooling. However, if the aluminum that is cast is a remelted primary
aluminum product and the facility that performs the casting also conducts
forming operations, then the casting subsequent to the remelting is subject to
standards established for the aluminum forming category (40 CFR Part 467).
The manufacture of aluminum powders and the forming of parts from
aluminum or aluminum alloy powders^are not regulated under the aluminum
forming category. Instead, these processes are included in the metal powders
subcategory of the nonferrous metals forming regulation (40 CFR Part 471).
Surface treatment operations (e.g., pickling, anodizing, alkaline
cleaning) are considered to be a part of aluminum forming when one or more of
these operations are performed as an integral part of the forming process. An
operation is considered an integral part of the forming process when it is
performed at the same site at which the metal is formed. As such, surface
treatment operations are considered ancillary operations that are regulated by
2-23
I
-------
the limitations and standards for cleaning or etching baths, rinses, and
scrubbers established under the aluminum forming category and are not subject
to regulation under the electroplating (40 CFR Part 413) or the metal
finishing (40 CFR Part 433) categorical standards.
2.4.2 Copper Forming
Operations that are not covered by the copper forming regulations (40 CFR
Part 468) include the following:
• Casting of copper or copper alloys
• Manufacturing of copper powders and the forming of parts from copper
or copper alloy powders.
The casting of copper and copper alloys, even when conducted in conjunc-
tion with copper forming, is regulated under the metal molding and casting
regulation (40 CFR Part 464). The manufacture of copper powders and the
forming of parts from copper or copper alloy powders are regulated under the
nonferrous metals forming regulation (40 CFR Part 421).
2.4.3 Nonferrous Metals Forming and Metal Powders
The nonferrous metals forming and metal powders category regulates
facilities that are engaged in the forming of nonferrous metals and their
alloys with the exception of aluminum, copper, iron and steel, and beryllium.
Separate regulations have been promulgated for aluminum forming (40 CFR Part
467), copper forming (40 CFR Part 468), and iron and steel manufacturing
including regulation of forming processes (40 CFR Part 420). At the time of
this writing, standards were planned but had not promulgated to regulate
beryllium and beryllium alloy forming operations. These operations will be
regulated with beryllium copper alloys under amendments to the copper forming
regulation.
The forming of cadmium, chromium, gallium, germanium, indium, lithium,
manganese, neodymium, praseodymium, and alloys are also excluded from the
nonferrous metals forming regulation because the forming of these metals is
not carried out on a national basis or because the forming operations that are
conducted do not result in the discharge of wastewaters.
2-24
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The nonferrous metals forming category does not include the production of
metal powders by chemical methods, such as precipitation. The production of
metal powders as the final step in refining metal is regulated under the
nonferrous metals manufacturing regulation (40 CFR Part 421).
Surface treatment operations that are conducted as an integral part of
the nonferrous metals forming process are regulated by the limitations and
standards established for the nonferrous metals forming and metal powders
category. As such, discharges from these surface treatment operations are not
subject to regulation by the electroplating (40 CFR Part 413) or metal
finishing (40 CFR Part 433) categorical standards.
2.5 PRETREATMENT STANDARDS FOR THE ALUMINUM FORMING, COPPER FORMING, AND
NONFERROUS METALS FORMING AND METAL POWDERS CATEGORIES
The aluminum forming standards (40 CFR Part 467) establish pretreatment
limitations for existing and new sources (PSES and PSNS) for chromium,
cyanide, zinc, and total toxic organics (TTO) for six subcategories. Aluminum
is not regulated because aluminum is frequently used by POTWs as a flocculant
to aid in the settling and removal of suspended solids. Therefore, aluminum
in limited quantities does not pass through or interfere with a POTW; rather,
it aids in the operations of a POTV.
In establishing the aluminum forming production-based standards, effluent
flow data for the core and ancillary operations are production normalized
(e.g., million gallons flow per pound aluminum produced). The production-
based limits are established as the product of the production normalized flow
times the model treatment effectiveness limit, in mg/1 (also factoring in unit
conversion constants). An aluminum forming plant is permitted to discharge a
mass of pollutants equivalent to the sum of the mass limitations established
for the core and ancillary operation(s) that are performed at the plant.
The copper forming standards (40 CFR Part 468) establish PSES and PSNS
for chromium, copper, lead, nickel, zinc, and total toxic organics (TTO).
Copper forming is presently regulated as a single subcategory. The mass
standards vary for each process operation due to the differing water use
requirements in each of the copper forming process operations.
2-25
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The nonferrous metals forming and metal powders standards (40 CFR Part
471) establish PSES and PSNS for antimony, lead, chromium, zinc, ammonia,
fluoride, nickel, cadmium, copper, cyanide, silver, and molybdemum for ten
subcategories based on the type of metals formed.
For all three categories, PSES and PSNS are expressed in terms of mass
per unit of production. The units of production specified in the regulations
are "off-kilograms", or the kilograms of product removed at the end of a
forming or ancillary process cycle for transfer to a different machine or
process. For example, an industrial user forges 100,000 kg of aluminum per
year. Ninety percent of this forged aluminum is transferred to an annealing
process and the remaining ten percent is transferred to a heat treatment
system. In determining production-based standards, the production rate for
the forging operation would be 100,000 off-kg, the production rate for the
annealing operation would be 90,000 off-kg, and the production rate for the
heat treatment operation would be 10,000 off-kg. Mass-based limitations
reflect the use of flow reduction to reduce the amount of toxic pollutants
introduced into a P0TW.
Daily maximum and maximum monthly standards are established for each
process operation. These standards represent the best available technology
economically achievable. Summaries of the PSES and PSNS discharge standards
for the aluminum forming category, copper forming category, and nonferrous
metals forming and metal powders category are presented in Appendix C of this
manual. In the nonferrous metals forming and metal powders category, several
process operations in each of the subcategories do not have specific numerical
standards. Instead, the standard is.expressed as "no discharge of process
wastewater pollutants". This standard means there is no allowance for any
pollutant. In practical terms, for the industry to comply with this standard,
no discharge of any wastestream from the regulated process operation could be
allowed.
2.6 COMPLIANCE DATES
The compliance dates for existing and new aluminum forming, copper
forming, and nonferrous metals forming and metal powders industries are as
follows:
2-26
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Existing Sources (PSES)
Aluminum Forming Facilities
Copper Forming Facilities
Nonferrous Metal Forming Facilities
October 24, 1986
August 15, 1986
August 23, 1988
New Sources (PSNS)
From commencement of discharge
2.7 ALTERNATIVES TO MONITORING REQUIREMENTS
Because the analysis of wastewaters for toxic organics is costly and
requires sophisticated equipment, indirect dischargers regulated for total
toxic organics (TTO) in the aluminum forming and copper forming category may
monitor for oil and grease as an alternative to total toxic organics (TTO)
monitoring. Any indirect discharger in compliance with the alternate oil and
grease standards will be considered in compliance with the TTO standard. The
alternate oil and grease limits are also presented in the tables provided in
Appendix C. For more information on the requirements for reporting on TTO or
oil and grease, please refer to the discussion contained in section 4.3.1.
In addition, indirect industrial users subject to standards under the
aluminum forming category are regulated for cyanide. Periodic analysis for
cyanide may not be required if industrial users comply with both of the
following conditions: the first wastewater sample of each calendar year has
been analyzed and found to contain less than 0.07 mg/1 of cyanide, and the
owner or operator of the aluminum forming facility certifies in writing to the
POTW (or the Control Authority if the Control Authority is not a POTW) that
cyanide is not and will not be used in the aluminum process.
2-27
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3. TREATMENT TECHNOLOGIES
The treatment technologies described in this chapter are used by the
aluminum, copper, and nonferrous metals forming categories (also referred to
herein as the forming categories) to remove or recover wastewater pollutants
normally generated by the forming industrial processes. Included are brief
discussions of the technology basis of the pretreatment standards for existing
sources (PSES) and pretreatment standards for new sources (PSNS) for each
category. End-of-pipe and in-plant treatment techniques typically used in
each forming category are also described below.
3.1 ALUMINUM FORMING CATEGORY
The technology basis for the pretreatment standards for existing sources
(PSES) for the aluminum forming category includes end-of-pipe treatment
consisting of oil skimming, lime precipitation and settling. Preliminary
treatment, where necessary, consists of chemical emulsion breaking, chemical
reduction of hexavalent chromium, and cyanide removal. Flow reduction for
existing sources is limited to in-plant controls consisting of (1) recycle of
the solution heat treatment and annealing wastestreams through cooling towers,
(2) countercurrent rinsing of cleaning or etching rinses, (3) recycle of air
pollution control system streams associated with cleaning or etching and
forging operations, and (4) use of extrusion die cleaning rinse for bath
make-up water. Additional in-plant controls to eliminate discharges include
the use of alternative fluxing methods such as dry air pollution control and
in-line refining, hauling or regeneration of cleaning or etching baths,
wastewater segregation, and good housekeeping. The technology basis for
pretreatment standards for new sources (PSNS) is the same as for existing
sources with the addition of a multimedia polishing filter. Figure 3-1
illustrates the PSES treatment train and Figure 3-2 shows the PSNS treatment
train.
The treatment technologies discussed for the aluminum forming operations
are specifically geared toward the removal of significant concentrations of
toxic metals typically found in aluminum forming wastewaters. These metals
include chromium, aluminum, lead, nickel, and zinc. For more information on
3-1
-------
Chealcil Additloo
CO
I
{Extrusion Hydraulic Preaa Leakage)
Sawing Spent Lubricants
(Rolling and Drawing Spent toulaiona)
Eaulalon
Breaking
(god and Sheet Caatlng
Spent Lubrlcanta)
I
Reaoval of
fllX>ad .fircnc
I Chemical Addition
CheMicaI Addition
Discharge
Chemical
Precipitation
Cyanide
Precipitation
Chrcnlua
Reduction
Cleaning or Etching Ulnae
Sedimentation
Sklaing
(Die Cleaning
Bath and Rlnee)
Sludge
Cooling
Tower
Solution and Preaa Heat
Treatment Contact
Cooling Water
Reaoval of
Oil and
Greaaa
Cooling
Tower
Recycle
Sludge to
Dlapoaal
(Direct Chill and Contlnuoua Rod Caatln
Contact Cooling Water
Hiaceilaneoua Wastewater
Sludge Oewacerlng
(Degaaalng Scrubber Liquor)
(Forging Scrubber Liquor)
(Annealing Furnace Atmosphere Scrubber Liquor)
Cleaning or Etching Scrubber Liquor
pu
Adjustment
(Die Cleaning Scrubber Liquor)
(Preaa Scrubber Liquor)
NOTE: ( ) indicates waste streams not associated with all subcategories.
FIGURE 3-1. PSES TREATMENT TRAIN FOR ALUMINUM FORMING CATEGORY
-------
Chealcal Addition
Extrusion Hydraulic
freaa leakage) »
Sawing Sjwia Lubricants
(Killing und Spent EsHilsluna) ^
(Rod and Slwc't Casting .
Spent Lubricants)
J^Za3T)(a
Eaulalon
Breaking
Ski«l»i
{
| Chealcal Addition Chealcal AddltIon
Reaoval of
fllLjnd .Creiac
Backwash
I
I
L
(:leaijji»u or Etching Rinse ^
(Die Clemliig
Bath and Rinse)
w-b
Chroalua
* Reduction
Solution and Press lleat
Treataunt Contact —¦
Cooling Water
Recyc
(Direct Chi 11 and Contlnuoua Rod Cast
Contsct Cooling Water
\ Cooling /»—
A "-71
fde 4 '
Cyanide
PreclpltatIon
Recyc
Hlacellaneous Wastewater
(Degassing Scrubber Liquor)
(Forging Scrubber Liquor)
(Annealing Furnace Aluoanlwre Scrubber Liquor)
illeanlng or Scrubber Liquor
(Die Cleaning Scrubber Liquor)
(Press Scrubber Liquor)
leal Addltlou
Discharge
Multimedia
Filtration
Chealcal
FreeIpltatloo
ot>
Sedlaentat Ion
Sklaalng
Backwash
Sludge
Recycle
leaoval of
Oil and
C
Sludge to
Dlaposal
Sludge Dewaterlng
P«
Adjustment
NOTE: ( ) indicates waste streams riot associated with all subcategories
FIGURE 3-2. PSNS TREATMENT TRAIN FOR ALUMINUM FORMING CATEGORY
-------
the treatment technologies available to facilities subject to aluminum forming
standards, the reader should review EPA's Development Document for Effluent
Limitations Guidelines and Standards for the Aluminum Forming Point Source
Category, June 1984.
3.2 COPPER FORMING CATEGORY
The technology basis for the pretreatment standards for existing sources
(PSES) for the copper forming category includes end-of-pipe treatment con-
sisting of lime precipitation and settling and, when necessary, preliminary
treatment consisting of chemical emulsion breaking, oil skimming, and chemical
reduction of chromium. Flow reduction for existing sources is limited to
in-plant controls consisting of recycle of the solution heat treatment contact
cooling waters, annealing with water wastestreams, spray rinsing and
recirculation of all pickling rinse operations. The technology basis for the
pretreatment standards for new sources (PSNS) is the same for existing sources
with the addition of a multimedia polishing filter. Additional flow reduction
is achieved by new sources with the addition of countercurrent cascade
rinsing. Figure 3-3 diagrams the PSES treatment technology and Figure 3-4
shows the PSNS treatment process. The treatment technologies discussed for
the copper forming category are specifically geared toward removal of toxic
metal pollutants, such as chromium, copper, lead, nickel, and zinc. These
toxic metals are found in copper forming wastewaters at significant
concentrations. For more information the treatment technologies for copper
forming facilities, the reader should refer to EPA's Development Document for
Effluent Limitations Guidelines and Standards for the Copper Forming Point
Source Category, March 1984.
3.3 NONFERROUS METALS FORMING AND METAL POWDERS CATEGORY
Treatment technologies and controls selected for each subcategory of the
nonferrous metals forming and metal powders category to achieve the
pretreatment standards for existing sources (PSES) and the pretreatment
standards for new sources (PSNS) are based on the pretreatment options listed
below.
3-4
-------
Hot Rolling Spent Lubricant
Gold Rolling Spent Lubricant
Drawing Sprat Lubricant
btronton Preaa lut Treatment
Altai 1m CIim1*| ktb
Alkaline Cloning linn*
Alkaline Cleaning Rlnea lor Porged Parti
Tiabltng or Rnralahlog
Surface Coating (Mot Coating)
Hlacellaaeoua llaiUKriaM
s.>luiiu« Heat Trraimt
J «*»•'"» /
~\ Tsmr
1 '
¦Mycin .4—I
SklBPlng
Chealcal
¦aulalou
J|jraaklp»
CJ
u%
Pickling Bath
Pickling Rlnae
(Spray Rlnalog)
Pickling Rlnan lor Forged Part*
(Spray Rlnnlng)
Cbroalua
Reduce ton
Annealing
Hater
' V
Recycle ^ |
leal
Praclplta
tlon
fife
Sedlnaata
tloo
Dlachargr
Recycle
Sludge
Sludge
Dewaterlng
Sludge
to
Dlapoaal
Pickling
Fuae
Scrubber
Annealing oil Contract lUullng
FIGURE 3-3. PSES TREATMENT TRAIN FOR COPPER FORKING CATEGORY
-------
list Rolling Spent Mr (cant
Cold HoiIlag Spent Lubricant
Drawing Spoilt Lubricant
Extrusion Frau Heat Traataant
Alkaline Claaalag lath
Alkallna Claanlng Blnaa
Alkallna Cleaning Rtnaa far Porged Parta
Tuabllng or BurnluliiiiS
Surface Coating (Hot Coating)
(fiscallanaova Maatastrcaaa
Solution Heat Traataant
Cooling L
vr:r
la M J
/
'W
jtjerf
(Wlcal
Oil
EauUloo
Skimming
•peaking
Recycle
Pickllng Bath
Pickling ftloaa
(Countarcurrant Caacada. Has lag)
I'lclcllng ilnae for Forged Parts
(Countarcurrant Caacada Rinsing)
AA^A
ChrdUua
Reduction
A
Annealing Water
—fX Cooling Z—
\ Tower /
I
Recycle J
Pickling Puaa Scrubber
Cbeaical
Precipita-
tion
J&
AA.AA.
Sedlaanta-
tloa
Sludge
Recycle
Sludge
Devataring
Contract"Haullng
Annealing Oil
FIGURE 3-4. PSHS TREATMENT TRAIS FOR COPPER FORMING CATEGORY
-------
Pretreatment Option 1 is based on:
• Oil skimming
• Lime and settle (chemical precipitation of metals followed by
sedimentation)
• pH adjustment.
In addition, Pretreatment Option 1 includes the following, where required:
Iron co-precipitation
Chemical emulsion breaking
Ammonia steam stripping
Cyanide reduction precipitation
Hexavalent chromium reduction.
Pretreatment Option 2 is based on Ptetreatment Option 1, plus process
wastewater flow minimization by the following methods:
Contact cooling water recycle through cooling towers or holding tanks
Air pollution control scrubber liquor recycle
Countercurrent cascade rinsing or other water efficient methods
applied to surface treatment rinses and alkaline cleaning rinses
Use of periodic batch discharges or decreased flow rate for molten
salt rinsewater
Recycle of equipment cleaning wastewater; tumbling, burnishing, and
cleaning wastewater; and other wastewater streams through holding
tanks with suspended solids removal, if necessary.
Pretreatment Option 3 is based on Pretreatment Option 2, plus multimedia
filtration at the end of the Pretreatment Option 2 treatment train.
The options selected as the model technology bases for PSES and PSNS for
each nonferrous metals forming subcategory are given in Table 3-1. The
corresponding schematic diagrams showing the treatment processes for each
3-7
-------
TABLE 3-1. OPTIONS SELECTED AS THE MODEL TECHNOLOGY BASES FOR
PSES AND PSNS FOR THE NONFERROUS METALS FORMING AND
METAL POWDERS SUBCATEGORIES
SUBCATEGORY PSES PSNS
Lead-Tin-Bismuth Forming
Option 2
Option 2
Magnesium Forming
Option 2
Option 3
Nickel-Cobalt Forming
Option 3
Option 3
Precious Metals Forming
Option 2
Option 2
Refractory Metals Forming
Option 2
Option 3
Titanium Forming
Option 2
Option 2
Uranium Forming
Exempted
Option 3
Zinc Forming
Exempted
Option 3
Zirconium-Hafnium Forming
Option 2
Option 2
Metal Powders
Option 1
Option 2
Option 1 - Flow Normalization, Lime and Settle
Option 2 - Flow Reduction, Lime and Settle
Option 3 - Flow Reduction, Lime and Settle, Multimedia Filtration.
3-8
-------
option are given in Figures 3-5 and 3-6. Differences exist between the
potential preliminary treatment requirements for each nonferrous metals
forming subcategory. For a breakdown of the various potential preliminary
treatment requirements the reader should review EPA's Development Document for
Effluent Limitations Guidelines and Standards for the Nonferrous Metals
Forming and Metal Powders Point Source Category, September 1986.
PSES are promulgated for each of the nonferrous metals forming and metal
powders subcategories except for the uranium, zinc, and refractory metals
forming subcategories. EPA is excluding the uranium forming subcategory from
from regulation of PSES because there are no existing indirect dischargers in
the uranium forming subcategory. EPA did not promulgate categorical PSES for
zinc forming due to economic impacts. PSES treatment technology for the
refractory metals subcategories includes lime and settling, but does not
include filtration because of potential economic impacts to industrial users
caused by installation of this technology.
Nonferrous metals forming wastewaters characteristically contain sub-
stantial concentrations of cadmium, chromium, copper, lead, nickel, silver,
zinc, cyanide, ammonia, and fluoride. The wastestreams may be acidic or
alkaline and contain oils and emulsions and trace concentrations of toxic
organics.
3.4 END-OF-PIPE TREATMENT TECHNOLOGIES
The model end-of-pipe treatment technologies used by the aluminum,
copper, and nonferrous metals forming categories to remove toxic pollutants
include oil removal (skimming, emulsion breaking, and flotation), chemical
precipitation and sedimentation, chemical reduction, and filtration. Most
toxic metals are effectively removed by precipitation of metal hydroxides or
carbonates utilizing the reaction with lime, sodium hydroxide, or sodium
carbonate. In some cases, improved removals can be achieved by the use of
sodium sulfide or ferrous sulfate to precipitate the pollutants as sulfide
compounds with very low solubilities.
3-9
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The major end-of-pipe technologies discussed here include chemical
reduction of chromium, chemical precipitation, cyanide precipitation, granular
bed filtration, pressure filtration, settling, skimming, chemical emulsion
breaking, and thermal emulsion breaking. Each technology is applicable for
all forming categories (aluminum, copper, and nonferrous metals), unless
otherwise noted in the discussion.
Chemical reduction of chromium is used in aluminum forming for rinses of
chromic acid etching solutions and chromium conversion coating processes. In
the copper forming industry, chemical reduction of chromium is used for
treating pickling baths and pickling rinses. Surface treatment baths and
rinses are treated by this method in the nonferrous metals forming industry.
The treatment of hexavalent chromium involves reducing the chromium to its
trivalent form, and removal with a conventional lime precipitation-solids
removal system. A pH of 2 to 3 is necessary for complete chromium reduction.
The reduction allows removal of chromium from solution in conjunction with
other, metallic salts by alkaline precipitation. In most cases, gaseous sulfur
dioxide is used as the reducing agent in the reduction of chromium from its
hexavalent form to its trivalent form, which enables the trivalent chromium to
be precipitated out from solution.
Chemical precipitation is used in the forming categories for precipita-
tion of dissolved metals. It can also be used to remove metal ions as
hydroxides and any substance that can be transformed into an insoluble form,
such as fluorides, phosphates, or sulfides. Alkaline compounds, such as lime
or sodium hydroxide, can be used to precipitate toxic metal ions as metal
hydroxides so they can be removed by physical means such as sedimentation,
filtration, or centrifugation. The addition or presence of iron in
wastewaters aids in the removal of toxic pollutants such as molybdenum through
co-precipitation. Other treatment chemicals include soluble and insoluble
sulfides, ferrous or zinc sulfate, or carbonate precipitates.
Cyanide precipitation is used as a preliminary treatment in the forming
. categories for the removal of cyanide. Cyanide precipitation is used as the
model technology because it achieves lower cyanide levels than other
treatments and is applicable when cyanide destruction is not feasible because
3-12
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of the presence of cyanide complexes that are difficult to destroy. Cyanide
can be precipitated and settled out of wastewaters by the addition of zinc
sulfate or ferrous sulfate at a pH of 9.0. Although precipitation of cyanide
is a method of treating cyanide in wastewaters, the cyanide is retained in the
sludge that is formed and the sludge must be properly disposed.
Granular bed filtration is used for polishing aluminum, copper, and
nonferrous metals forming wastewaters after clarification, sedimentation, or
other similar solids removal operations. Filter media, such as silica sand,
anthracite coal, and garnet, supported by gravel are commonly used to remove
suspended solids and colloidal particles. The typical granular bed filter
operates by gravity flow.
Pressure filtration can be used in aluminum, copper, and nonferrous
metals forming for sludge dewatering and for direct removal of precipitated
and other suspended solids from wastewater. Pressure filtration works by
pumping the liquid through a filter material that is inpenetrable to the solid
phase. The positive pressure exerted by the feed pumps or other mechanical
methods provides the pressure differential or force necessary to drive the
liquid through the retained solids.
Settling and clarification are used in aluminum, copper, and nonferrous
metals forming for removal of metals and other suspended materials. Settling
removes suspended solid particles from a liquid by gravitational force and is
accomplished by reducing the velocity of the feed stream in a large volume
tank or lagoon so that suspended solids are able to settle out. Long
retention times are normally required for settling. Therefore, the process is
often preceded by chemical precipitation, which converts dissolved pollutants
to a solid form, and by coagulation, which enhances settling by coagulating
suspended precipitates into larger, faster settling particles.
Skimming is most often used in the forming categories to remove free oil,
grease, soaps, or other pollutants with a specific gravity less than water.
Skimming is often found in conjunction with air flotation or clarification to
increase its effectiveness. Skimming normally takes place in a tank designed
to allow the floating material to rise and remain on the surface, while the
3-13
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liquid flows to an outlet below the floating layer. Common skimming mecha-
nisms include the rotating drum type skimmer, the belt type skimmer, which
pulls a belt laterally through the water to collect oil, and the API (or other
gravity-type) separator, which skims a floating oil layer from the surface of
the wastewater.
Chemical emulsion breaking is applicable to all forming wastestreams
containing emulsified oils or lubricants, such as rolling and drawing emul-
sions. Chemical treatment is used to break the stable oil-in-water emulsions,
allowing the oil to float to the surface of the water. Chemicals such as
polymers, alum, ferric chlorides, and organic emulsion breakers are used most
often. Long retention times and proper mixing result in a more complete
separation between the oil, water, and solids.
Thermal emulsion breaking is used for the treatment of spent emulsions in
the aluminum and copper forming categories. Dispersed oil droplets in a spent
emulsion can be destabilized by the application of heat to the waste by use of
an evaporation-decantation-condensation process. As the water evaporates, the
oil concentration increases, thereby enhancing agglomeration and gravity
separation of oils.
3.5 IN-PLANT CONTROL TECHNOLOGIES
In-plant control techniques are used in aluminum, copper, and nonferrous
metals forming plants for the purpose of eliminating or reducing the quantity
of wastewaters requiring end-of-pipe treatment. Flow reduction, in
conjunction with end-of-pipe treatment, can further reduce the mass of
pollutants discharged. The primary .flow reduction techniques applicable to
forming plants ares 1) process water recycle and reuse, 2) alternative
rinsing techniques (particularly countercurrent cascade and spray rinsing),
3) regeneration of chemical baths, 4) wastewater segregation, 5) oil and
solvent recovery, 6) dry air pollution control, 7) contract hauling, 8)
reduction of water use, and 9) good housekeeping practices. These in-plant
controls are discussed below.
Recycling of some process wastewater streams is practiced at most forming
plants. The most commonly recycled streams include spent lubricating solu-
tions, annealing contact cooling water, solution heat treatment contact
cooling water, casting contact cooling water, rolling emulsions, and scrubber
3-14
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liquors. Some treatment may be required to allow process wastewater recycle;
however, the degree of treatment is less than would be necessary for discharge
and most often includes suspended solids removal, oil skimming, and cooling.
Alternative rinsing techniques reduce the amount of water used and
discharged in forming plants. Rinsing is used to decrease the concentration
of contaminants adhering to the surface of a workpiece to an acceptable level
before the workpiece passes on to the next step of a cleaning, etching, or
pickling operation. These rinsing techniques are alternatives to flowing
rinses and can result in water cost savings, reduced chemical treatment, and
improved waste treatment efficiency. Process variations, such as counter-
current cascade rinsing, decrease process water use by introducing clean water
in the last rinse stage, and routing the more contaminated water stage by
stage up the rinsing line. Spray rinsing, whereby water is sprayed onto the
surface of the workpiece, as opposed to submerging it in a tank, reduces the
amount of water necessary to achieve the required cleanliness of the
workpiece. Water use and discharge rates can be further reduced through
recirculation of the rinse water.
Regeneration of chemical baths is sometimes used in the forming
categories to remove contaminants and recover and reuse the bath chemicals.
The process minimizes the chemical requirements of the bath while achieving
zero discharge. Chemical bath regeneration is applicable in the aluminum
forming category to recover and reuse chemicals associated with caustic
cleaning or etching baths, sulfuric acid etching baths, conversion coating or
anodizing baths, chromic acid etching baths, and alkaline cleaning baths.
Chemical bath regeneration can be used in nonferrous metals forming for
treatment baths consisting of caustic, sulfuric acid, and chromic acid baths,
and alkaline solutions. Regeneration methods which may be employed include
applying a temperature change or addition of chemicals (such as lime) to
precipitate metal salts from the baths. Ultrafiltration can be used to remove
oils and particulates from alkaline cleaning baths. Advantages of regenera-
tion include a reduction in the volume of discharge of bath water, and an
increase in the efficiency of surface treatment, cleaning, or etching opera-
tions because the bath can be kept at a relatively constant strength. Costs
savings can also achieved through reductions in maintenance labor and chemical
usage.
3-15
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Wastewater segregation, whereby dissimilar wastestreams are prevented
from mixing, is a valuable control technology for the forming categories and
may reduce treatment costs. Individual process wastestreams may exhibit very
different chemical characteristics, and separating the steams may allow
application of the most effective method of treatment or disposal to each
stream. Segregation should be based on the type of treatment to be performed
for a given pollutant.
Lubricating oil and deoiling solvent recovery is a common practice in
aluminum and nonferrous metals forming. The degree of recycle is dependent on
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, 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.
Dry air pollution control devices allow control of air emissions without
generating a wastewater stream. 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.
Contract hauling of low-volume, high concentration wastestreams reduces
the amount of wastewater discharged by forming operations. Wastestreams often
transported off site from aluminum forming operations include etching baths,
drawing lubricants, cold rolling lubricants, annealing oil, and extrusion
press solution heat treatment wastes. Nonferrous metals forming operations
contract haul wastestreams such as pickling bath wastewater, drawing lubri-
cants, and cold rolling lubricants to off site disposal facilities.
3-16
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Reduction of water use by simple actions requiring little or no cost is
an effective approach for forming operations to reduce treatment costs and
pollutant discharges. Practices include shutting off process wastestreams
during inoperative periods and adjustment of flow rates during periods of low
activity, changes in production techniques and equipment, improved design of
spray quenches to ensure that a high percentage of water contacts the product,
the use of drag-out reduction techniques, and improved operator performance.
Good housekeeping practices, including proper equipment maintenance, are
necessary methods to reduce wastewater loads to treatment systems. These
techniques can be implemented by all forming operations. Control of acciden-
tal 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 or control these wastes.
Leaks in pump casing, process piping, etc., should be minimized to
maintain efficient water use. One particular type of leakage that can 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 create
uncontrolled releases to the environment 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 by forming
operations can also be an effective method of curtailing unnecessary waste-
water flows. Judicious use of washdown water and avoidance of unattended
running hoses can significantly reduce water use.
3-17
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4. REQUIREMENTS OF THE GENERAL PRETREATMENT REGULATIONS
4.1 INTRODUCTION
This section provides a brief overview of the General Pretreatment
Regulations for Existing and New Sources (40 CFR Part 403) and identifies
those provisions of the regulations that have direct bearing on the applica-
tion and enforcement of categorical pretreatment standards for the aluminum
forming, copper forming and nonferrous metals forming and metal powders
categories.
The General Pretreatment Regulations (40 CFR 403) establish the framework
and responsibilities for implementation of the National Pretreatment Program.
The effect of these regulations is three-fold:
• The regulations establish general and specific discharge prohibitions
as required by Sections 307(b) and (c) of the Clean Water Act. The
general and specific prohibitions are described in 403.5 of the
pretreatment regulations and apply to all nondomestic sources intro-
ducing pollutants into a P0TW, regardless of whether or not the source
is subject to categorical pretreatment standards.
• The regulations establish an administrative mechanism to ensure that
national pretreatment standards (prohibited discharge standards and
categorical pretreatment standards) are applied and enforced upon
industrial users. Approximately 1,500 POTWs are required to develop
locally administered pretreatment programs to ensure that nondomestic
users comply with applicable pretreatment standards and requirements.
• Most importantly for the purposes of this guidance manual, the General
Pretreatment Regulations contain provisions relating directly to the
implementation and enforcement of the categorical pretreatment
standards. Provisions governing basic reporting requirements, local
limits, compliance monitoring activities, and the procedures associ-
ated with categorical determinations are set out in the regulations.
P0TW representatives are referred to 40 CFR Part 403 for specific
language and requirements.
EPA is considering making a number of changes to the General Pretreatment
Regulations. These changes may affect some of the provisions of the pre-
treatment regulations discussed in this section and could alter the guidance
in this section. Therefore, the reader is advised to keep abreast of changes
to the General Pretreatment Regulations.
4-1
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4.2 REQUESTS FOR CATEGORICAL DETERMINATIONS
An existing industrial user or its POTff can request written certification
from EPA or the delegated state specifying whether or not the industrial user
falls within a particular industry subcategory and is subject to a particular
categorical pretreatment standard. Although the deadlines for submitting
categorical determination requests by existing industrial users subject to the
aluminum forming, copper forming, or nonferrous forming and metal powders
categorical pretreatment standards have passed, new industrial users can
request this certification for a category determination any time before
commencing its discharge. Similarly, a POTV can request the certification on
behalf of an industrial user. Requests should be directed to the EPA Regional
Water Management Division Director or to the State Director, as appropriate,
using the procedures set out in 40 CFR 403.6(a). Additional assistance in
determining the proper category for wastewaters from such operations can be
obtained by contacting the Industrial Technology Division at U.S. EPA
Headquarters.
4.3 MONITORING AND REPORTING REQUIREMENTS OF THE GENERAL PRETREATMENT
REGULATIONS
In addition to any specific monitoring or reporting requirements con-
tained in the aluminum forming, copper forming or nonferrous forming and metal
powders categorical pretreatment standards, industrial users must fulfill the
reporting requirements contained in 403.12 of the General Pretreatment
Regulations. These requirements include the submission of baseline monitoring
reports, compliance schedule progress reports (when necessary), periodic
compliance reports and notices of slug loading, as well as a three year
record-keeping requirement. Each of these reporting requirements is briefly
summarized below.
4.3.1 Baseline Monitoring Reports
All industrial users subject to categorical pretreatment standards must
submit a baseline monitoring report (BMR) to the Control Authority. The
purpose of the BMR is to provide information to the Control Authority to
document the industrial user's compliance status with applicable categorical
pretreatment standards. The Control Authority is defined as the POTV if it
4-2
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has an approved pretreatment program, the state regulatory agency if the state
has an approved state pretreatment program, or the EPA regional office if
neither the POTW or the State have an approved pretreatment program. Addi-
tional guidance on BMR reporting is available from the state agencies or from
EPA regional pretreatment coordinators. A complete listing of current EPA and
state pretreatment coordinators is provided in Appendix D.
BMR Due Dates
Section 403.12(b) requires that BMRs be submitted to the Control Author-
ity vithin 180 days after the effective date of a nevly promulgated cate-
gorical pretreatment standard or 180 days after the final administrative
decision is made on a categorical determination request (see section 4.2
above), whichever is later. The BMR due dates for existing facilities in the
three forming categories are listed below:.
Aluminum Forming June 4, 1984
Copper Forming March 25, 1984
Nonferrous Metals Forming and Metal Powders April 5, 1986
At least 90 days prior to commencement of disharge, new sources shall
submit a BMR.
BMR Content
A BMR must contain the following information as required by §403.12(b).
• Name and address of the facility, including names of operator(s) and
owner(s).
• List of all environmental control permits held by or for the
facility.
• Brief description of the nature, average production rate, and SIC
code of each of the operations conducted, including a schematic
process diagram that indicates points of discharge from the regulated
processes to the POTW.
• Average daily and maximum daily flow data (in gallons per day) for
regulated process streams discharged to the POTW. Flow measurements
of other wastestreams will be necessary if application of the
combined wastestream formula is anticipated (see section 4.4, below).
• Identification of the applicable pretreatment standards for each
regulated process wastestream and the results of measurements of flow
4-3
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rates and pollutant concentrations. This information must include an
analysis of the nature and concentration (or mass where so specified
by the categorical standard or the Control Authority) expressed in
terms of daily average and daily maximum values. These analyses must
be performed in accordance with the procedures contained in 40 CFR
Part 136, or as otherwise directed and approved by EPA. Samples must
be representative of daily operations. For most pollutants, 24-hour
composite samples must be obtained through flow-proportional
composite sampling techniques where feasible. For pH, cyanide, total
phenols, oil and grease, sulfide, and volatile organics, a minimum of
four (4) grab samples must be used. If the industrial user
demonstrates that flow-proportional sampling is infeasible, the
Control Authority may waive flow-proportional sampling and instead
obtain samples through time-proportional composite sampling
techniques or through a minimum of four (4) grab samples where the
user demonstrates that this will provide a representative sample of
the effluent being discharged. The user must take a minimum of one
representative sample (or set of samples, where grab samples are
used). Prior to November 16, 1988, the effective date of the recent
revisions to the Federal pretreatment regulations where the flow of
the regulated stream being sampled was less than or equal to 250,000
gallons per day, the industrial user was required to take three
samples within a two week period. Where the flow of the stream was
greater than 250,000 gallons per day, the industrial user was
required to take six samples within a two week period. Note that the
Control Authority may accept historical flow data if it provides
sufficient information to determine the industrial user's (IU's) need
for new or additional pretreatment controls. These samples are to be
taken immediately downstream from the existing treatment or, if no
treatment has been installed, immediately downstream from the
regulated process. If other wastewaters are mixed with the regulated
process, the industrial user should measure flows and concentrations
of the appropriate wastestreams to allow use of the combined
wastestream formula (see Section 4.4, below).
• The dates, times and sampling locations as well as the analytical
methods used to derive the testing results.
• An authorized representative of the IU [see 40 CFR 403.12(1)] must
certify as to whether the facility is currently meeting the pre-
treatment standards. In the event the standards are not being
achieved, the certification must contain a compliance schedule which
% identifies the additional operation and maintenance measures and/or
abatement technology necessary to bring the IU into compliance and a
timetable for completing those actions necessary to achieve such
compliance. The final date for completing the actions and achieving
compliance must not exceed the compliance deadline established by the
standard. Industrial users are referred to 40 CFR §403.12(b)(7) and
(c) for more specific instructions on preparing this compliance
schedule.
• For new sources the report must contain information on the method of
pretreatment intended to be used to meet the applicable pretreatment
4-4
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standards and an estimate of the average daily and maximum daily flow
and pollutant concentrations.
BMR Reporting of Toxic Organics
Unlike the metal finishing categorical standard for TTO, industrial users
regulated by standards for the aluminum forming and copper forming categories
cannot sample and analyze for only those compounds that are reasonably
expected to be in their vastestreams. Industrial users must sample and
analyze for all the toxic organic compounds identified as comprising total
toxic organics (TTO) under the categorical standards for the aluminum forming
or copper forming category, as appropriate. The term "total toxic organics" is
the sum of the masses or concentrations of each of the regulated toxic organic
compounds found at a concentration greater than 0.01 mg/1 in a regulated
vastestream.
The toxic organic compounds regulated under the TTO standards for the
aluminum forming subcategories are:
•
P-chloro-m-cresol
• Toluene
•
2-Chlorophenol
• Trichloroethylene
•
2,4-Dinitrotoluene
• Endosulfan sulfate
•
1,2-Diphenylhydrazine
• Bis(2-ethyl hexyl)phthalate
•
Ethylbenzene
• Diethylphthalate
•
Fluoranthene
• 3,4-Benzofluoranthene
•
Isophorone
• Benzo(k)fluoranthene
•
Napthalene
• Acenaphthylene
•
N-ni trosodiphenylamine
• Anthracene
•
Phenol
• Chrysene
•
Benzo(a)pyrene
• Di-n-butyl phthalate
•
Benzo(gh i)perylene
• Endrin
•
Fluorene
• Endrin aldehyde
•
Phenanthrene
• PCB 1242, 1254, 1221
•
Dibenzo(a,h)anthracene
• PCB 1232, 1248, 1260, 1016
•
Indeno(1,2,3,-c,d)pyrene
• Acenaphthene
•
Pyrene
•
Tetrachloroethylene
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The toxic organic compounds identified as comprising TTO under the
categorical standards for copper forming are:
•
Benzene
•
Napthalene
•
1,1,1-Trichloroethane
•
N-ni trosodiphenylamine
•
Chloroform
•
Anthracene
•
2,6-dini trotoluene
•
Phenanthrene
•
Ethylbenzene
•
Toluene
•
Methylene chloride
•
Tri chloroe thylene
Section 468.01(b) of the copper forming regulation limits the applicabil-
ity of the TTO pretreatment standards for drawing spent lubricant discharges
[40 CFR Section 468.14(c) and 468.15(c)J. These TTO standards apply only to
those copper forming facilities that discharge this spent lubricant waste-
stream to their POTV. These standards do not apply when this spent lubricant
is hauled off site for disposal or is otherwise not discharged from the
facility.
The tables contained in Appendix C present the applicable TTO limits for
each subcategory in the aluminum forming and copper forming categories. There
are no TTO standards for the nonferrous metals forming and metal powders
category.
As an alternative to monitoring for TTO, industrial users can monitor for
oil and grease (O&G) and meet the O&G categorical standards. When an indus-
trial user elects the alternative O&G monitoring, the facility is subject to
the O&G standard and is not subject to the TTO standard. The TTO or O&G
monitoring results must be submitted in the BMR and subsequent 90-day com-
pliance report and periodic reports on continued compliance. Additional
guidance on the application of TTO standards is provided in EPA's Guidance
Manual for Implementation Total Toxic Organics (TTO) Pretreatment Standards,
September 1985.
4-6
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4.3.2 Compliance Schedule Progress Reports
In the event the industrial user certifies that it is not meeting the
appropriate categorical standard on a consistent basis, a compliance schedule
must be submitted with the BMR that describes the actions the industrial user
will take and a timetable for completing those actions in order to achieve
compliance with the standard. The completion date in the schedule must not be
later than the compliance date established for the particular categorical
standard. The compliance schedule must contain increments of progress and
dates for completion of each increment. Further, no increment of progress
shall exceed nine months.
Within 14 days of each milestone date in the compliance schedule, the
user must submit a progress report to the Control Authority. The compliance
schedule progress report must indicate whether or not the user complied with
the increment of progress intended to be met. If the milestone date was not
met, the report must indicate a revised date on which it expects to comply,
the reasons for the delay, and the steps to be taken to return to the
scheduled established in the BMR.
4.3.3 Report on Compliance
Within 90 days of the respective compliance dates, or following commence-
ment of the introduction of wastewaters into the POTW in the case of a new
source, any industrial user subject to the standards must submit to the
f
Control Authority a compliance report that provides the nature and concen-
tration of all regulated pollutants in the facility's regulated process
wastestreams; the average and maximum daily flows of the regulated streams; a
reasonable measure of the long term production rate if equivalent mass or
concentration limits have been imposed, or the actual average production rate
for the reporting period if subject to categorical standards expressed only in
terms of allowable pollutant discharge per unit of production (or other
measure of production); and, a statement as to whether compliance is consis-
tently being achieved and, if not, what additional operation and maintenance
or pretreatment is necessary to achieve compliance [see 40 CFR 403.12(d)].,
4-7
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4.3.4 Periodic Reports on Continued Compliance
Unless required more frequently by the Control Authority, all industrial
users subject to categorical pretreatment standards must submit a biannual
"periodic compliance report" during the months of June and December. The
Control Authority may change the months during which the reports must be
submitted. The report must indicate the precise nature and concentrations
(and/or mass if required by the Control Authority) of the regulated pollutants
in its discharge to the POTW during the reporting period, the average and
maximum daily flow rates, a reasonable measure of the long term production
rate if equivalent mass or concentration limits have been imposed, or the
actual average production rate for the reporting period if subject to
categorical standards expressed only in terms of allowable pollutant discharge
per unit of production (or other measure of production), and a certification
of the accuracy and completeness of the information submitted, [see 40 CFR
403.12(e)].
4.3.5 Notice of Potential Problems, Including Slug Loading
Section 403.12(f) requires IUs to notify the POTW immediately of all
discharges that could cause problems to the POTV, including slug loading
(i.e., discharge of any pollutant, including oxygen demanding pollutants,
released to the POTW system at a flow rate or pollutant concentration that
might cause interference with the POTW).
4.3.6 Monitoring and Analysis to Demonstrate Continued Compliance
Section 403.12(g) states that industrial user reports must contain the
results of sampling and analysis of the user's discharge. This sampling and
analysis may be performed by the Control Authority in lieu of the industrial
user. If sampling by the industrial user indicates a violation, the
industrial user must notify the Control Authority within 24 hours of learning
of the violation. In addition, the industrial user must repeat the sampling
and analysis and submit the results to the Control Authority within 30 days
after becoming aware of the violation, unless Control Authority sampling takes
place in that time period.
4-8
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While Section 403.12(g) does not specify any particular frequency of
monitoring, it states that a frequency sufficient to assure compliance with
applicable pretreatment standards and requirements must be maintained.
Further, the data on which these reports are based must be obtained through
appropriate sampling and analysis, which is performed during the period of the
report and is representative of conditions occurring during the reporting
period. The pretreatment standards for the aluminum forming, copper forming,
and nonferrous metals forming and metal powders category also do not establish
monitoring frequencies. Therefore, the appropriate Control Authority must
establish the monitoring frequency deemed adequate to demonstrate that
indirect dischargers subject to these pretreatment standards are in compliance
with the applicable standards. EPA has issued guidance on suggested
monitoring frequencies for the first year until sufficient baseline data are
collected (see Pretreatment Compliance Monitoring and Enforcement Guidance,
July 1986).
Sampling and analysis shall be in accordance with the procedures esta-
blished in AO CFR Part 136. When Part 136 techniques are not available or are
inappropriate for any pollutant, sampling and analysis shall be conducted in
accordance with procedures established by the Control Authority or using any
validated procedure. However, all procedures for sampling and analysis not
included in Part 136 must be approved in advance by EPA.
A.3.7 Notification of Changed Discharge
Section 403.12(j) requires that all industrial users shall promptly
notify the Control Authority in advance of any substantial change in the
volume or character of pollutants in their discharge.
A.3.8 Signatory Requirements for Industrial User Reports
All reports submitted by industrial users (i.e., BMR, Initial Report on
Compliance, and Periodic Reports, etc.) must be signed by an authorized
representative in accordance with Section 403.12(1) and include the certifi-
cation statement set forth in Section 403.6(a)(2)(ii). Note that false state-
ments or misrepresentations in the aforementioned reports are punishable by a
fine of up to $10,000, by imprisonment for up to two years, or by both under
Section 309(c)(4) of the Clean Water Act.
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4.3.9 Recordkeeping Requirements
Records of all sampling activities required under the regulations above
must include dates, times, exact place(s), and methods of sampling, as veil as
identify the person(s) collecting the sample. In addition, analytical reports
must indicate the dates and person(s) performing the sample analysis, the
analytical techniques used, and the results thereof. These records must be
maintained for a minimum of three years [see 40 CFR §403.12(o)(2)] and must be
available for inspection and copying by the Control Authority.
4.4 THE COMBINED VASTESTREAM FORMULA
The combined vastestream formula (CVF) [40 CFR §403.6(e)] is a method for
calculating appropriate discharge limitations for combined vastestreams, The
CWF was developed to account for the dilutional effect of mixing one regulated
vastestream with other regulated, unregulated, or dilution streams prior to
treatment. The following definitions and conditions are important to proper
use of the CWF.
Definitions
• Regulated process vastestream - ?in industrial process vastestream
regulated by national categorical pretreatment standards.
• Unregulated process vastestream - an industrial process vastestream
that is not regulated by a categorical standard and is not a dilute
vastestream as defined belov.
• Dilute vastestream - boiler blovdovn, noncontact cooling vater, and
sanitary vastevater (unless regulated by the categorical pretreatment
standard). The Control Authority has discretion to classify boiler
blovdovn and noncontact cooling vater as unregulated vastestreams vhen
these streams contain a significant amount of a regulated pollutant.
A decision to combine contaminated (unregulated) vastestreams vith
regulated process vastestreams prior to treatment vill result in a
substantial reduction in the amount of pollutant discharged to the
POTW.
Note: These definitions apply to individual pollutants. Therefore, a
vastestream from a process may be "regulated" for one pollutant and
"unregulated" for another.
• Mass-based production related standard - a standard setting for the
the quantity (mass) of a pollutant alloved to be discharged per unit
of production. This standard is usually expressed in the forming
categorical standards as milligram per off-kilogram (pounds per
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million off-pounds). An off-kilogram or off-pound, as previously
described in Section 2.5, is defined as the mass of metal or metal
alloy removed from a forming or ancillary operation at the end of a
process cycle for transfer to a different machine or process.
• Mass-based limit - a limitation setting forth the quantity (mass) of a
pollutant which may be discharged in a specific wastestream.
• Concentration-based limit - a limit based on the relative strength of
a pollutant in a wastestream, usually expressed in mg/1 (lbs/gal).
CWF Conditions
The regulations specify that the following conditions must be met by a
POTW and its industrial users industries when applying the CVF:
• Alternative discharge limits calculated in place of a categorical
pretreatment standard must be as enforceable as the categorical
standards themselves.
• Calculation of alternative limits must be performed by the Control
Authority (generally the POTW) or by the industrial user with written
permission from the POTW.
• Alternative limits must be established for all regulated pollutants in
each of the regulated processes.
• The Control Authority and/or the industrial user must use mass-based
limitations rather than concentration-based limitations when only
production-based mass standards are provided by the applicable
categorical pretreatment standard.
• Both daily maximum and long-term average (usually monthly average)
alternative limits must be calculated for each regulated pollutant.
• An industrial users operating under an alternative limit derived from
the CWF must immediately report to the Control Authority any signi-
ficant or material changes in the regulated, unregulated or dilution
wastestreams or any changes in production rates.
• If a facility institutes process changes or production rate changes
and if the changes warrant, the Control Authority can recalculate the
alternative limits at its discretion or at the request of the indus-
trial user. The new alternative limits will be calculated within 30
days of receiving notice of the process change.
• The Control Authority can impose stricter alternative limits but
cannot impose alternative limits that are less stringent than the
calculated alternative limits.
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• A calculated alternative limit cannot be used if it results in a
discharge limit below the analytical detection level for that pollu-
tant. If a calculated limit is below the detection limit, the
industrial user must either: (1) not combine the dilute streams
before they reach the combined treatment facility, or (2) segregate
all wastestreams entirely.
• The categorical standards of the regulated wastestreams which are
applied to the CWF must be consistent in terms of the number of
samples on which the standard is based.
Monitoring Requirements for Industrial Users Using the CWF
Self-monitoring requirements by an industrial user are necessary to
ensure compliance with the alternative discharge limit. Because the categori-
cal pretreatment standards for aluminum forming, copper forming, and nonfer-
rous metals forming and metal powders do not include self-monitoring require-
ments, the Control Authority will establish minimum self-monitoring
requirements.
Application of the CWF
The combined wastestream formulas used to adjust the categorical pre-
treatment standards are presented in Table 4-1. When two or more regulated
wastestreams from different regulated categories are mixed before treatment,
it is necessary to determine which pretreatment regulation applies to each
separate regulated wastestream. All dilution and unregulated wastestreams
need to be identified.
Flow-Weighted Averaging
The CWF is applicable to situations where wastestreams are combined
before treatment. However, for facilities that combine regulated process
wastewaters with nonregulated waters after treatment but prior to monitoring
by the Control Authority (usually at the discharge point to the sanitary
sewer), a flow-weighted average or more stringent approach must be used to
adjust categorical pretreatment standards. The flow-weighted averaging
formula for use in these circumstainces is set out in Table 4-2.
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TABLE 4-1. COMBINED VASTESTREAM FORMULAS
FORMULA 1 — ALTERNATIVE CONCENTRATION LIMIT FORMULA
cwf
N
I
i = 1
C. x ?i
N
I
I i = 1
F - F
rt d
Ccwf- alternative concentration limit for the pollutant
C£ - Categorical" Pretreatment Standard concentration limit for the pollutant
in regulated stream i
F£ - average daily flow (at least 30 day average) of regulated stream i
Fd - average daily flow (at least 30 day average) of dilute vastestream(s)
Ft - average daily flow (at least 30 day average) through the combined
treatment facility (including regulated, unregulated and dilute
wastestreams)
N
- total number of regulated streams
FORMULA 2 — ALTERNATIVE MASS LIMIT FORMULA
cwf
N
E
U = 1
M.
r f.
N
E
U = 1
cwf
- alternative mass limit for the pollutant
- Categorical Pretreatment Standard mass limit for the pollutant in
regulated stream i
- average daily flow (at least 30 day average) of regulated stream i
- average daily flow (at least 30 day average) of dilute wastestream(s)
- average daily flow (at least 30 day average) through the combined
treatment facility (including regulated, unregulated and dilute
wastestreams)
N
- total number of regulated streams
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TABLE 4-2. FLOW-WEIGHTED AVERAGING (FWA) FORMULAS
FORMULA 1 — ALTERNATIVE CONCENTRATION-BASED LIMIT
wa
' CCWf
X
F' )
+
L: ic- *
V
F
fnri
F.'
CtMa - alternative pollutant concentration limit in combined wastestreams
after treatment derived using FWA
Ccwf - alternative pollutant concentration limit in treatment unit
effluent, derived using the CWF
Ffc - average daily flow (at least 30 day average) through the combined
treatment facility
Cnri - concentration of nonregulated vastestream i
Fnri - average daily flow (at least 30 day average) of nonregulated
wastestream i
Ffc' - average daily flow (at least 30 day average) into regulated
monitoring point (generally point of discharge to sanitary sewer)
N - total number of regulated streams
FORMULA 2 — ALTERNATIVE MASS-BASED LIMIT
M = M + M
fwa "cwf + "nr
Mfwa - alternative pollutant limit in combined wastestreams after treatment
derived using FWA
M . - alternative pollutant mass limit in treatment unit effluent, derived
CM using the CWF
Mnr ~ mass the pollutant in nonregulated wastestreams
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4.5 REMOVAL CREDITS
A removal credit allows a POTW to provide its industrial users with a
credit (in the form of adjusted categorical pretreatment standards) for
consistent removal of pollutants by the POTW. Industrial users receiving such
a credit are allowed to discharge to the POTW greater quantities of regulated
pollutants than otherwise permitted by applicable categorical standards.
Section 403.7 of the General Pretreatment Regulations establishes the con-
ditions under which a POTW can obtain authorization to grant removal credits.
Removal credits are pollutant-specific (i.e., may only be granted on a
pollutant-by-pollutant basis).
In order to qualify for removal credit authority, a POTW must satisfy the
conditions set out in the regulations, including a demonstration of the POTW's
ability to "remove" the pollutant in question on a long-term or consistent
basis; that is, the removal of the pollutant is not subject to significant
seasonal or other periodic variations.
Removal credits can only be granted for indicator pollutants regulated by
a categorical pretreatment standard and only where the standard expressly
provides that removal credits are obtainable.
Approval for removal credits cannot be granted if resulting discharges
would cause the POTW to violate its NPDES permit. Even though the POTW may be
located in an NPDES state which has an approved state pretreatment program,
final approval of the POTW's request for removal credit authority rests with
EPA, unless EPA has granted/delegated to the state through a State/EPA
Memorandum of Agreement (MOA) this final approval authority.
Note: The regulatory basis for the criteria and procedures governing removal
credits is in a state of uncertainty at the time of this writing. EPA regula-
tions governing removal credits have had a long and complex history. EPA has
revised the removal credits regulations four times (1973, 1978, 1981 and
1984). The central objective of all versions of these regulations has been to
establish the conditions by which POTWs can demonstrate consistent removal of
pollutants and, in so doing, extend removal credits to industries on a
pollutant-specific basis to prevent redundant treatment.
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The 1984 revision of the removal credits regulations (49 FR 31212, 1984)
was challenged as being too lenient by the National Resources Defense Council
(NRDC), and as being too stringent by an industry, Cerro Copper Products Co.,
and by a POTW, the Village of Sauget, in a consolidated petition before the
United States Court of Appeals for the Third Circuit [NRDC v. U.S. EPA, 16 ELR
20693 (3rd Cir. 1986)]. In addition, the Chemical Manufacturers Association,
the Chicago Association of Commerce and Industry, the Illinois Manufacturers
Association, and the Mid-America Legal Foundation intervened in this lawsuit.
The Third Circuit Court of Appeals ruled in favor of NRDC, concluding that
EPA's 1984 removal credit rule fails to meet the requirements mandated by
Section 307 of the Clean Vater Act.
On November 5, 1987 EPA replaced those portions of the 1984 regulatory
revision which had been invalidated by the U.S. Third Circuit Court of Appeals
with language from the previously upheld 1981 version of the regulations and
made other minor revisions thereto. However, the removal credit rules remain
ineffective pending the promulgation of technical sludge criteria (proposal
expected in the Fall of 1988). As a matter of policy, EPA will not approve
new applications until these sludge regulations have been promulgated.
4.6 FUNDAMENTALLY DIFFERENT FACTORS (FDF) VARIANCE
A fundamentally different factors (FDF) variance is a mechanism available
under Section 402(n) of the CWA and 40 CFR 403.13, by which a categorical
pretreatment standard can be adjusted, making it more or less stringent, on a
case-by-case basis. If an industrial user believes that the factors relating
to its processes or other circumstances are fundamentally different from those
factors considered during development of the relevant categorical pretreatment
standard and that the existence of those factors justifies a different
discharge limit from that specified in the categorical standard, the party can
submit a request to EPA within 180 days after the effective date of the
standard for such a variance (see 40 CFR §403.13). Note that the deadlines
for submitting FDF variances for the copper forming, aluminum forming, and
nonferrous metal forming and metal powders categories have passed.
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4.7 LOCAL LIMITS
Local limits are pollutant concentration-based or mass-based values that
are developed by a POTW for controlling the discharge of conventional,
nonconventional, or toxic pollutants into its sewer system. They differ from
national categorical pretreatment standards in that categorical pretreatment
standards are developed by EPA and are based on the demonstrated performance
of available pollutant control technologies (for specific categorical indus-
tries). These national technology-based categorical standards do not consider
local environmental criteria or conditions and are developed only to assure
that each point source within a specified category meets a minimum discharge
standard that is consistent across the United States for all POTWs.
Local limits, on the other hand, are developed to address specific
localized impacts and factors that are unique to the POTV. Local limitations
are typically designed to protect the POTW from:
t The introduction of pollutants into the POTW that could interfere with
its operation (the term "interference" is defined in 40 CFR §403.3).
• Pass through of inadequately treated pollutants that could violate a
POTW's NPDES permit or applicable water quality standards (the term
"pass through" is defined in 40 CFR §403.3).
• The contamination of a POTW's sludge which would limit sludge uses or
disposal practices.
Local limits are required under 40 CFR §403.5 and must be developed when
it is determined that categorical pretreatment standards are not sufficient to
enable the POTW to meet the above three pretreatment program objectives.
To assist municipalities in developing defensible and technically sound
numerical effluent limitations, EPA has provided guidelines on the development
of local limits in its document, Guidance Manual On the Development and
Implementation of Local Discharge Limitations Under the Pretreatment Program .
This manual is available from EPA Regional offices and NPDES states and should
be carefully followed when developing local limits. Although a detailed
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discussion of local limits development is beyond the scope of this document,
the general development process involves the following four steps:
Step 1 - Screening for pollutants of concern
Step 2 - Derivation of allowable headworks loadings
Step 3 - Allocation of allowable headworks loadings
Step 4 - Evaluating collection system impacts
A pollutant of concern is defined as any pollutant which might reasonably
be expected to be discharged to the POTV in quantities which could pass
through or interfere with the POTW, contaminate the sludge, or jeopardize POTW
worker health or safety. Derivation of allowable headworks loadings must be
performed for each pollutant of concern based on POTV removal efficiencies and
criteria which regulate or provide guidance concerning pollutant levels at the
POTW. Detailed instructions on identifying pollutants of concern, deriving
and allocating headworks loadings and evaluating collection system effects are
provided in the guidance manual mentioned earlier.
EPA has also developed a computer software program (PRELIM) that incor-
porates the general methodology required to develop local limits and that
alleviates a substantial amount of the tedious calculations required to
develop these limits. This computer program has the following capabilities to
aid the POTV in developing discharge limits:
• Performs the four-step limit setting analysis on microcomputer.
• Supplements POTV site specific data with default files containing data
on industrial/municipal wastewater characteristics, POTV removal
rates, and biological process inhibition data.
• Allocates controllable pollutant loads using several methodologies.
POTVs can obtain information on this computer program by contacting any of the
ten EPA regional offices. Instructions will be provided on how to use the
computer program and how to access a compatible computer system.
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5. APPLICATION OF PRODUCTION-BASED CATEGORICAL PRETREATMENT STANDARDS
5.1 INTRODUCTION
The standards issued for the aluminum forming, copper forming, and non-
ferrous metals forming and metal powders categories are production-based.
Production-based standards are expressed in terms of allowable pollutant mass
discharge per unit of production (e.g., allowable pounds of pollutant per
1,000 pounds of product). To determine compliance with production-based stan-
dards, the Control Authority must collect a wastewater sample, measure the
concentration of the regulated pollutant(s), measure the flow of each regu-
lated wastestream, determine the corresponding production rate(s), and compare
the results to the standards.
Rather than measure the production rate each time that compliance moni-
toring is performed, Control Authorities may use equivalent mass or equivalent
concentration limits as a tool for routine monitoring and enforcement pur-
poses. Equivalent mass or equivalent concentration limits use an industrial
facility's average production and average flow rates to derive limits that are
essentially equivalent to the applicable production-based standards but that
are expressed as mass per day or as a concentration (e.g., lb/day or mg/1).
The following sections provide a brief overview of the use of equivalent
limits and the information required for implementation. Additional informa-
tion on the application of production-based standards and equivalent limits
may be obtained from a review of EPA's Guidance Manual for the Use of
Production-Based Pretreatment Standards and the Combined Wastestream Formula.
5.2 USE OF EQUIVALENT MASS LIMITS
Production-based standards are applied directly to an industrial user's
manufacturing process unless equivalent limits are established. Direct appli-
cation of production-based standards requires the Control Authority or the
industrial user to make direct measurements of the current production and flow
rates each time that monitoring is performed. There are many instances in
which this approach is impractical from the standpoints of cost and technical
feasibility. As an alternative, the Control Authority is encouraged to use an
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average daily production rate or other estimate based on a reasonable measure
of the actual production rate to develop equivalent mass limits, using the
formula below:
production-based standard x regulatory production rate* = equivalent mass
conversion factor limit
"average or other reasonable estimate
The same production rate is multiplied by both the daily maximum and
maximum monthly average standards to produce equivalent daily maximum mass per
day and maximum monthly average mass per day standards. A long-term average
production value, usually a 12-month average, that will be representative
during the life of the permit or control mechanism should be used. For
example, for a five-year permit, the Control Authority should evaluate enough
production data to determine if it is possible to select an average production
level that will be representative for the next five years. The advantage of
using equivalent mass limits instead of applying production-based standards
directly is that it eliminates the need to routinely conduct exhaustive
studies of plant production rates and wastewater detention times. For routine
monitoring purposes, it is necessary for the Control Authority to measure only
flow and concentration of pollutants.
5.3 USE OF EQUIVALENT CONCENTRATION LIMITS
Direct measurement of flow on a routine basis by either the industrial
user or the Control Authority is often more feasible from a cost and technical <.
standpoint than is direct measurement of production. In this case, the
Control Authority may decide, on the basis of cost, technical or managerial
considerations, to develop equivalent concentration limits using an average
daily flow rate based on a reasonable measure of actual flow rates. Equiva-
lent concentration limits eliminate the need to directly measure flow and
production each time that monitoring is performed and permit the Control
Authority to routinely measure only pollutant concentrations to assess com-
pliance with production-based standards.
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An equivalent concentration limit is developed using both an average
production rate and an average flow rate. The average daily production rate
is multiplied by the appropriate production-based standard, then this product
is divided by the average daily flow rate, according to the formula below:
production-based standard x regulatory production rate* = equivalent
average flow rate x conversion factor concentration
limit
*average or other reasonable estimate
It is proper to use the same long-term average production and flow values
to derive both daily maximum and monthly average limits. It is important to
select average production and flow rates that will be representative during
the life of the permit. When using equivalent concentration limits, it is
also important to ensure that dilution will not be used by an industrial user
to achieve compliance with the limits. If dilution is an expected problem, it
may be better to impose mass per day limits and to routinely measure actual
flow rates.
5.4 OBTAINING PRODUCTION AND FLOW RATE INFORMATION
Industrial users subject to production-based standards are required to
submit production and flow irate information in the baseline monitoring report
(BMR) which is to be submitted within 180 days after the effective date of a
categorical pretreatment standard or 180 days after the final administrative
decision on a category determination request under 40 CFR 403.6(a)(4), which-
ever is later. Similarly, discharge permit applications should request pro-
duction and flow rate information from industrial users subject to production-
based standards. After the compliance deadline of a categorical standard,
industrial users are required to submit production and flow rate information
in the 90-day compliance report and in periodic reports on continued compli-
ance.
Upon receiving baseline monitoring reports, 90-day compliance reports,
reports on continued compliance, or other information from industrial users,
Control Authorities may be approached by industrial users requesting that
information submitted be held as confidential so as not to divulge trade
secrets. Section 403.14 of the General Pretreatment Regulations discusses the
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confidentiality of industrial information submitted to the Control Authority.
Information, which is considered "effluent data" cannot be confidential under
the Clean Water Act. In AO CFR 2.302(a), effluent data are defined to include
information on the manner or rate of operation of a regulated process to the
extent necessary to determine compliance with a standard. Therefore, indus-
trial users must submit necessary production and flow rate data to the Control
Authority or be liable for an enforcement action. Information which is deter-
mined to be "effluent data" is to be made available to the public in accor-
dance with the procedures in 40 CFR Part 2.
Once the production and flow rate-data have been collected, and the
production-based standards translated to impose equivalent mass limits or
equivalent concentration limits, it is strongly recommended that the equi-
valent limits be applied through a permit or other control document that is
transmitted to an industrial user. The document should clearly spell out:
1) all equivalent mass or equivalent concentration limits, 2) flow and
production rates upon which the equivalent limits are based, 3) a requirement
that the industrial user provide the Control Authority with current average
production and flow rates in periodic self-monitoring reports, and 4) a
requirement to notify the Control Authority of significant changes in flow or
production rates which would require revision of the equivalent limits. As a
general rule, a change in the long-term average production or flow rate of
greater than 20 percent is considered significant. Unless there is such a
control document, it may be difficult to determine compliance with the
standard or to enforce production-based standards.
The Control Authority must maintain records for three years on each
industrial user to which equivalent "mass or equivalent concentration limits
have been issued that reveal how the production and flow levels were
established and how the calculations were performed to derive the equivalent
limits. These records are generally reviewed by EPA or delegated State
officials during visits to the POTW for pretreatment program inspections and
audits.
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5.5 DETERMINING AN APPROPRIATE PRODUCTION RATE
Categorical standards are expected to be achievable even with normal
variation in day-to-day production rates and the effect that routine variation
has on effluent quality. When using equivalent mass or equivalent concen-
tration limits to implement production-based standards, the objective is to
determine a production rate that approximates the long-term average rate that
can reasonably be expected to occur during,the term of a permit or other
control mechanism. Long-term average shall mean an average based on the pro-
duction over an extended period of time that captures a normal range of varia-
tion in production. Using data for a short period of high production is
likely to result in equivalent limits that are unnecessarily high, resulting
in more pounds of pollutant being discharged than is allowed by the standards.
Therefore, basing an equivalent limit on the production rate for a high day,
week, or month should be avoided.
Equivalent limits should be based on an industrial user's actual produc-
tion rate, not on design production capacities. Historical information, if
available, generally provides the best basis and should be given more weight
than projections of future production, which are often unreliable. To deter-
mine a long-term average production rate, several years (preferably 3 to 5) of
production data should be examined, if possible. Data that are not represen-
tative of normal operation or that are due to specific events which are not
expected to recur should be disregarded. In order to verify the accuracy and
reliability of production data submitted by an industrial user, the Control
Authority can and should periodically inspect the facility's production (and
similarly, flow) records and measuring techniques. The Control Authority may
also require the industrial user to perform actual measures of production
(and flow) in the presence of a Control Authority representative.
Generally, the daily average production rate is calculated by dividing
the annual (or monthly) production rate by the number of production days per
year (or month). However, if the number of wastewater discharge days is
different from the number of production days, the former number should be used
to calculate the daily average production rate. As described previously, this
daily average production rate is used to develop equivalent mass or equivalent
concentration limits.
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5.6 DETERMINING AN APPROPRIATE FLOW RATE
When using equivalent concentration limits to implement production-based
standards, it is necessary to determine an appropriate average flow rate on
which to base the equivalent limits. The considerations for determining an
appropriate flow rate are very similar to those for determining an appropriate
production rate. In both cases, it is important to:
• Determine reasonable estimates of actual long-term rates; for example,
the normal daily average during a representative year.
• Use actual rates rather than design rates; emphasize historical data
rather than future projections.
• Use the same average rates to calculate both daily maximum and maximum
monthly average alternative limits.
• Establish rates that are expected to be representative during the
entire term of the permit or control mechanism.
• Avoid the use of data for too short a time period. In particular,
estimating the average rate based on data for a few high days, weeks,
or months is not appropriate.
• Re-evaluate equivalent limits every six months using additional moni-
toring data. If actual average rates change by more than 20 percent
from the estimated rates used as the basis of the equivalent limits,
then the limits should be revised.
• If an average flow rate is determined based on historical data, it
should be based on the same time period as used to determine the
average production rate.
As a minimum, it is always necessary to determine the average daily flow
for regulated process wastestreams. In addition, when the combined waste-
stream formula and flow-weighted averaging are used, not only are flow rates
for the regulated wastestreams required, but flow rates of unregulated and
dilution streams are required as well when these streams combine with
regulated process wastestreams. It is often necessary to conduct a water
balance of the entire plant which accounts for all water entering and leaving
the facility. For example, incoming water may be determined from meter
readings or water bills; measuring equipment may be installed at accessible
points; flow volumes for batch processes may be estimated from a knowledge of
tank sizes and number of batches. A water balance is useful to verify that
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flow rates have been accurately determined for use of the combined wastestream
formula and flow-weighted averaging or to enable estimation of certain flows
which are difficult to measure.
5.7 CATEGORIZATION OF ALUMINUM, COPPER AND NONFERROUS FORMING FACILITIES
The categorization and subcategorization of integrated industrial facili-
ties and the process operations they conduct is often a complex and difficult
task. Categorical standards for a variety of industrial categories and sub-
categories can apply to the various wastestreams produced within such facili-
ties. As this guidance alluded to during previous discussions of metal form-
ing operations, some facilities perform manufacturing, forming, and finishing
operations at one location. Vastewaters generated by these operations are
regulated by different categorical standards.
As a rule, a facility that (re) melts, casts, and cools base metal
(aluminum, copper, or other nonferrous metals), without associated forming
operations, is subject to metal molding and casting categorical standards (40
CFR Part 464). Ancillary operations at these facilities may be covered under
metal molding and casting categorical standards (40 CFR Part 464) or electro-
plating or metal finishing categorical standards (40 CFR Part 413 and 40 CFR
Part 433, respectively).
A facility that performs aluminum forming operations is subject to the
aluminum forming categorical standards. Any re(melting), casting, and cooling
operations performed at this aluminum forming facility are covered under the
aluminum forming categorical standards (40 CFR Part 467).
However, a facility that performs copper (re)melting, casting and cooling
operations and forming operations is subject to two sets of standards. The
(re)melting, casting, and cooling operations are still subject to metal
molding and casting categorical standards while the forming operations and
associated ancillary operations are covered under the copper forming
categorical standards (40 CFR Part 468).
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A facility that conducts nonferrous metals forming operations is covered
under the nonferrous metals forming and metal powders categorical standards.
Any re(melting), casting and cooling operations conducted at this facility
would also be covered under the nonferrous metals forming and metal powders
categorical standards (40 CFR Part 471).
5.8 APPLICATION OF PRETREATMENT STANDARDS TO METAL FORMING FACILITIES
This section provides examples of metal forming facilities and the
application of categorical standards to those facilities. Example 5-1
illustrates one method of using historical production data to calculate
long-term daily average production rates. Other methods for deriving
long-term production values are discussed in EPA's Guidance Manual for the Use
of Production-Based Standards and the Combined Wastestream Formula. Example
5-2 illustrates the calculation of equivalent limits for a copper casting and
copper forming facility. This example also involves the use of the combined
wastestream formula. Finally, Example 5-3 provides an example of the appli-
cation of categorical standards to a facility regulated by the nonferrous
metal forming and metal powders category. This example includes the use of
the flow-weighted averaging formula to calculate equivalent pollutant
discharge limits.
Each of the following examples involves the calculation of equivalent
limits from average production values. In the aluminum forming, copper form-
ing, and nonferrous metals forming and metal powders categories, categorical
pretreatment standards have been established in units of milligrams of pollu-
tant discharge allowed per off-kilogram of product (mg/off-kg). As previously
discussed in Section 2.5, an off-kilogram refers to the mass of metal or metal
alloy product (aluminum, copper, or other nonferrous metal or metal alloy)
removed from one forming operation (e.g., rolling) at the end of the process
cycle to be transferred to another operation or process (e.g., annealing).
Categorical standards established for each of the forming categories include
separate milligram per off-kilogram standards for primary and ancillary
forming operations. The Control Authority must use production data gathered
from each primary and ancillary operation to calculate equivalent discharge
standards, as illustrated in Examples 5-1 through 5-3.
5-8
-------
Example 5-1
An industrial facility conducts cold rolling of aluminum alloys
using neat oils as a lubricating agent. Rolling processes are
intermingled with heat treatment operations. Solution heat treat-
ment operations are performed to improve the mechanical properties
of the metal, followed by annealing to soften the work-hardened
aluminum alloys and to stabilize metal properties. This facility
utilizes wet furnace scrubbers to treat off-gases of annealing
furnace fuels for the high sulfide levels of the fuels. After
annealing, the aluminum alloy products are passed through vapor
degreasing units to remove residual lubricants. Finally, the alloys
undergo chemical brightening of product surfaces.
A process diagram of this facility is provided in Figure 5-1.
No major operational changes have occurred during the past five
years nor are any planned for the future. The Control Authority
must first determine the appropriate daily average production rates
(for each industrial process) before calculating equivalent mass or
concentration limits that could be issued to this facility in a
5-year discharge permit.
To make such a determination, the following sequence of steps has been
used to complete this example. For additional explanation of other methods
that could be used to determine appropriate production rates, the Control
Authority should refer to the Guidance Manual for the Use of Production-Based
Standards and the Combined Wastestream Formula.
Assume for the purpose of this example, that the Control Authority has
obtained actual monthly plant production data by each forming operation for
the past 5 years and these data have already been converted to measures of
off-kg of aluminum alloy processed. A representative long-term average daily
production rate is then determined for each regulated forming operation
conducted at the facility as outlined in the steps below.
5-9
-------
Raw
Material
(cast
billets)
Cold Rolling
of Aluminum
Alloys using
Neat Oils
Solution
Heat
Treatment
Annealing
(with furnace
Scrubbers)
Vapor
D^greasing
Chemical
Brightening
Bath
Chemical
Brightening
Rinse
4, 4, 4, 4,
Waste oils to Quench and contact Annealing furnace Spent solvents
reclaimers cooling water scrubber liquor to reclaimers
to POTW
to poiw
4, 4,
Bath periodically Rinse water
batch discharged to POIW
to POIW
un
H
O
Sampling Point
4.
4-
4.
4.
I
4.
Treatment
H ... .i
To POIW
FIGURE 5-1. ALUMINUM KBHEG FACEUT PROCESS EOGRAH
-------
Step 1 - An average monthly production rate should be calculated for the
entire year as shown below using the 1982 production data shown in Table 5-1.
Annual Production Rate 1,014,000 off-kg/yr
Average Monthly = =
Production Rate Operating Months in Year 12 mo/yr
= 84,500 off-kg/mo
Step 2 - The average monthly production rate calculated for the year
should then be independently compared with each monthly production value of
the year to determine a positive or negative percent difference from the
average monthly production rate. This step is illustrated in Table 5-1 and
shown below.
Percent Difference
from Average Monthly
Production Rate
Monthly Rate - Average Monthly Rate"
Average Monthly Rate
x 100%
81,000 off-kg/mo - 84,500 off-kg/mo'
84,500 off-kg/mo
x 100%
= - 4.1%
The percent difference from the average monthly production rate will provide
an indication of the representativeness of the monthly values and should alert
the Control Authority to question the industrial user about possible process
changes or about nonrepresentative production conditions.
Step 3 - Calculated percent differences from the average monthly rate
should be reviewed and nonrepresentative monthly production rates (indicated
by percent differences that are substantially out of line with those of other
months) should be excluded from further consideration. Note in Table 5-1 the
production data for December is significant higher (27.8 percent) than the
average monthly production rate for the entire year and after consultation
with the industrial user is determined to not be typical of normal production.
5-11
-------
TABLE 5-1. CALCULATION OF THE 1982 REPRESENTATIVE MONTHLY PRODUCTION
RATE FOR THE COLD ROLLING WITH NEAT OILS ALUMINUM
FORMING OPERATION
Monthly Production
Average Monthly
Difference
Representative Monthl;
Month
Rate
Production Rate
from Average
Production Rate
(off-kg/mo)
(off-kg/mo)
<%)
(off-kg/mo)
January
81,000
-4.1
February
76,000
-10.1
March
83,000
-1.8
April
91,000
+7.7
May
93,000
+10.1
June
87,000
84,500
+3.0
July
84,000
-0.6
August
82,000
-3.0
September
78,000
-7.7
October
75,000
-11.2
November
76,000
-10.1
December
108,000
+27.81
1,-014,000
1Data discarded
as determined
to be nonrepresentative.
5-12
-------
Thereafter, the highest monthly production rate should be chosen as the
representative monthly production rate (May - 93,000 off-kg/mo.). Selection
of the highest representative monthly production rate will account for
nonsignificant (less than 20 percent) increases in production anticipated
during the life of the permit or control mechanism.
Step 4 - After selecting representative monthly production rates for each
of the five years, an average of the values is calculated as shown below and
in Table 5-2. This average value using the representative monthly production
rate is referred to as the long-term average Monthly Production Rate.
Long-term Average Monthly £ (Representative Monthly Production Rates)
Production Rate ¦
Number of Representative Monthly
Production Rates
= (93,000 + 82,000 + 94,000 + 86,000 + 90,000)
5
= 89,000 off-kg/mo.
Step 5 - The Control Authority should calculate the percent difference
between the long-term average monthly production rate and the representative
monthly production rates. Significant differences should again alert the
Control Authority to question the individual user as to process changes or
other nonrepresentative conditions. The Control Authority may exclude a
monthly production rate if this rate is significantly higher or lower than the
average and determined to be atypical of process conditions.
Step 6 - The representative long-term average monthly production rate
should be divided by the average number of production days per month (in this
example, it was assumed to be 20 production days per month) to calculate a
long-term average daily production rate as illustrated below.
Long-term Average Daily Representative Long-term Monthly Production Rate
Production Rate =
Average Number of Production Days Per Month
89,000 off-kg/mo
= 4,450 off-kg/day
20 days/mo
5-13
-------
TABLE 5-2. CALCULATION OF LONG-TERM AVERAGE PRODUCTION RATE FOR AN ALUMINUM FORMING FACILITY
Aluminum Representative
Forming Monthly
Operation Year(s) Production Rate
(off-kg/mo)
Long-Term
Average Monthly
Production Rate
(off-kg/mo)
Difference
from Average
(X)
Representative
Long-Term
Average Monthly
Production Rate
(off-kg/mo)
Long-Term
Average Daily
Production Rate
(off-kg/day)
Cold Rolling
with Neat Oils
(off-kg aluminum
alloy rolled)
1982
1983
1984
1985
1986
93,000
82,000
94,000
86,000
90,000
89,000
+4.5
-7.9
+5.6
-3.4
+1.1
89,000
4,450
Solution Heat
Treatment (off-kg
aluminum alloy
annealed)
1982-1986
Data not
Shown
78,500
78,500
3,925
Annealing (off-kg
aluminum alloy
annealed)
1982-1986
Data not
Shown
59,500
59,500
2,975
Vapor Degreasing
(off-kg aluminum
alloy degreased)
1982-1986
Data not
Shown
59,500
29,800
1,490
Chemical Brightening
Bath (off-kg aluminum
alloy brightened)
1982-1986
Data not
Shown
29,800
44,500
2,225
Chemical Brightening
Rinse (off-kg aluminum
alloy brightened)
1982-1986
Data not
Shown
44,500
44,500
2,225
-------
In some instances, the number of operating days and the corresponding
production rates may vary significantly from month to month although the
average daily production rate per operating day may or may not vary con-
siderably. Under these circumstances, the monthly average daily production
rate should be calculated prior to Steps 1 through 5 for each month as shown
below.
Monthly Average Daily Monthly Production Rate
Production Rate =
Operating Day in Month
Production Rate
Operating Day
All other calculations remain the same except that all monthly values have
been adjusted to daily values prior to Step 6 (Step 6 is no longer necessary).
The average daily production rates calculated would now be applied by the
Control Authority during development of equivalent mass and equivalent
concentration limits for regulated core and ancillary aluminum forming
operations.
Example 5-2
An industrial facility obtains pure copper ingots from a
primary copper refinery to use in the production of brass wire. The
copper ingots are remelted and molten zinc is added to produce
brass, an alloy of copper. The alloy is cast and cooled into
billets using direct chill casting methods [i.e., molten brass is
poured into a mold and allowed to solidify with the aid of
noncontact cooling water that circulates within the mold. As the
solidified billet emerges from the mold, it is sprayed or quenched
with contact cooling water, then immersed in a tank of water for
further cooling. The mold noncontact cooling water is recycled with
some blowdown (bleeding discharge) to the POTW]. The brass billets
are sawed and thereafter extruded into rods. The rods are solution
heat treated, then drawn into brass wire. The wire is cleaned to
remove oils and other residues using an alkaline cleaning solution,
then rinsed several times. The wire is annealed then quenched
(cooled) in an oil-water mixture to remove the effects previously
induced by solution heat treatment of the brass rod prior to
drawing. Finally, the brass wire is pickled to remove surface
oxides then rinsed.
5-15
-------
Regulated process wastewaters discharged by this facility include the
following:
• Direct chill casting contact cooling waters
• Casting quench wastewaters
• Extrusion press solution heat treatment (quench) wastewaters
• Spent drawing lubricants
• Spent alkaline cleaning baths (periodically batch discharged and
replaced)
• Alkaline cleaning rinse wastewaters
• Spent annealing oil-water quench mixtures (periodically batch
discharged and replaced)
• Spent pickling baths (periodic bleed discharges from the baths to
reduce contaminant levels)
• Pickling rinse wastewaters
• Billet saw cooling water .
A process flow diagram of this facility's operations including
representative production levels has been provided in Figure 5-2. As
illustrated by the diagram, hand wash, floor wash, and employee shower waters
are combined with regulated casting and forming process wastestreams prior to
treatment. Using the information provided, daily maximum and monthly average
discharge allowances must be calculated for each regulated pollutant as the
first step to deriving equivalent limits. Due to the fact that regulated,
unregulated and dilution wastestreams are combined prior to treatment, the
combined wastestream formula must be used to adjust the discharge allowances
previously calculated. Finally, the Control Authority would need to convert
the adjusted daily and monthly discharge allowances to equivalent mass or
equivalent concentration limits by multiplying the calculated discharge
allowances by the appropriate categorical pretreatment standards. In this
case, the Control Authority has chosen to apply equivalent mass limits to the
industrial user.
Step 1 - A process diagram of the facility should be developed. This
step has been completed in this example as illustrated in Figure 5-2. The
process diagram should identify all regulated process wastestreams as well as
all other wastestreams that are combined prior to treatment. In this example
this facility has wastestreams regulated by two different categorical pre-
treatment regulations: copper forming and metal molding and casting, copper
casting subcategory. The Control Authority will also need to gather produc-
tion rates and discharge flow data for each regulated category or subcategory
wastestream.
xThe miscellaneous wastestreams applies when any or all of the following
operations are performed: hydrotesting, sawing, surface milling and
maintenance.
5-16
-------
COPPER FORMING
Billet Saw Cooling Water
(10,000 off-kg/day of copper alloy sawed)
Extrusion Press Solution Heat Treatment Cooling Water
(65,000 off-kg/day of copper alloy heat treated)
.0001 mgd
.018 mgd
Drawing Spent Lubricants
(59,000 off-kg/day of copper alloy drawn)
Alkaline Cleaning Bath
.0001 mgd
.002 mgd
—>
(55,000 off-kg/day of copper alloy cleaned)
Alkaline Cleaning Rinse
(55,000 off-kg/day of copper alloy rinsed)
.017 mgd
Annealing Oil-Water Quench Wastes
(42,000 off-kg/day of copper alloy annealed)
.002 mgd
Pickling Bath
(38,000 off-kg/day of copper alloy pickled)
.0016 mgd
.013 mgd
Pickling Rinse
(38,000 off-kg/day of copper alloy pickled)
METAL MOLDING AND CASTING - COPPER CASTING SUBCATEGORY
.0583
Treatment
Direct Chill Casting of Inhouse Scrap
(2.8 kky/day of metal poured)
Casting Quench Wastewaters
.001 mgd
.003 mgd
(2.8 kky/day of metal poured)
Mold Noncontact Cooling Water Blowdown
.001 mgd*
.004
Sampling Point
To P0TW
.0048 mgd*
Hand Wash, Floor Wash,
Employee Shower Waters
mgd
*Dilution
FIGURE 5-2. PROCESS FLOW DIAGRAM OF A COPPER CASTING AND FORMING FACILITY
-------
Step 2 - Develop a table (as illustrated in Tables 5-3 and 5-4 for this
example) for each regulated industrial category (e.g., copper forming, metal
molding and casting) which identifies applicable regulated process segments,
appropriate production values, all regulated pollutants, and the corresponding
categorical discharge standards, and which provides space for the mass dis-
charge allowances to be calculated. Note that adjusted discharge allowances
are only calculated for copper and chromium for the regulated wastestreams in
Table 5-4. This was done strictly to shorten the example. A list of
regulated pollutants is included in the footnotes under the appropriate
category.
Step 3 - Determine discharge allowances for all regulated pollutants by
multiplying the appropriate production values by the applicable daily maximum
and monthly average categorical standards. Discharge allowances should be
calculated for pollutants regulated by all applicable industrial categories
and subcategories. Categorical pretreatment standards for copper forming
processes of existing sources (PSES) can be found in Appendix C-3 of this
manual, which summarizes the standards established in 40 CFR Part 468.
Pretreatment standards for use in calculating allowable mass loadings and
equivalent limits for copper casting operations are loadings and
equivalent limits for copper casting operations are established in the metal
molding and casting categorical standards (40 CFR Part 464) (refer to Federal
Register, Vol. 50, October 30, 1985). Note that oil and grease is an
alternative standard to monitoring for and complying with total toxic organics
in both the copper forming and metal molding and casting categories.
During this calculation, the Control Authority must verify that all units
of production correspond with those established in the categorical standard
and make changes if needed. For example, to calculate mass discharge allow-
ances for this facility's copper casting operations, the facility's production
data must be converted from units of kkg/day to 1,000 kkg/day (by dividing
each production value by 1,000) to correspond with categorical standards—
established units of kg of pollutant/1,000 kkg of copper aloy poured. A
second example would have been illustrated if, as part of the casting opera-
tions, this facility were to have employed dust collection scrubber
operations. Pretreatment standards for dust collection scrubber operations
5-18
-------
TABLE 5-3. ALLOWABLE MASS LOADINGS FROM OPERATIONS REGULATED BT METAL MOLDING AND
CASTING CATEGORICAL PRETREATMENT STANDARDS - COPPER CASTING SUBCATEGORY
Production
Categorical Limit1
Discharge
Allowance
Adjusted Discharge
Allowance
Regulated Vastestream
(Regulated Pollutants)
(1,000 kkg/day
of Metal
Poured)
Sample
Pollutant
Daily Maximum and
Monthly Average
(kg/1,000 kkg)
Daily
Maximum
(kg/day)
Monthly
Average
(kg/day)
Daily
Maximum
(mg/day)
Monthly
Average
(mg/day)
Direct Chill Casting
Operations
0.0028
Cu
0.928
0.506
0.00260
0.00142
2,600
1,420
Casting Quench Operations
0.0028
Cu
0.0307
0.0168
0.000086
0.00005
86
50
Totals
Cu
0.002686
0.00147
2,686
1,470
1Pretreatment standards for existing sources (PSES) for the metal molding and casting category, copper casting
subcategory (40 CFR Part 464).
2Regulated parameters are Cu, Pb, Zn for direct chill casting operations and Cu, Pb, Zn, TTO, and oil and grease4 for
casting quench operations.
3No pretreatment standards have been established for TTO and oil and grease for direct chill casting operations.
40il and grease (O&G) is an alternative standard to monitoring for and complying with total toxic organics (TTO).
-------
TABLE 5-4. ALLOWABLE MASS LOADINGS FROM OPERATIONS REGULATED BY
COPPER FORMING CATEGORICAL PRETREATMENT STANDARDS
Regulated Wastestream
(Regulated Pollutants)
Production
Sample
Pollutant
Categorical
Limit1
Daily Max.
and Monthly
Average
(mg/off-kg)
Discharge Allowance
Monthly
Daily Max. Average
(mg/day) (mg/day)
Extrusion Press Solution
65,000 off-kg/day of
Cr
0.00088
57
Heat Treatment
copper alloy heat
0.00036
23
treated on an
extrusion press
Cu
0.0030
195
130
0.0020
Drawing Spent Lubricant
59,000 off-kg/day of
Cr
0.037
2,183
copper alloy drawn
0.015
885
Cu
0.161
9,499
0.085
5,015
Alkaline Cleaning Bath
55,000 off-kg/day of
Cr
0.020
1,100
copper alloy
0.0084
462
alkaline cleaned
Cu
0.088
4,840
0.046
2,530
Alkaline Cleaning Rinse
55,000 off-kg/day of
Cr
1.854
101,970
copper alloy
0.758
41,690
alkaline cleaned
Cu
8.006
440,330
4.214
231,770
Annealing With Oil3
42,000 off-kg/day of
Cr
0
0
copper alloy
0
0
*
annealed with
oil
Cu
0
0
0
0
-------
TABLE 5-4. ALLOWABLE MASS LOADINGS FROM OPERATIONS REGULATED B7
COPPER FORMING CATEGORICAL PRETREATMENT STANDARDS (Continued)
Regulated Vastestream
(Regulated Pollutants)
Production
Sample
Pollutant
Categorical
Limit1
Daily Max.
and Monthly
Average
(mg/off-kg)
Discharge
Daily Max.
(mg/day)
Allowance
Monthly
Average
(mg/day)
Pickling Bath
38,000 off-kg/day of
Cr
0.051
1,938
copper alloy
0.020
760
pickled
Cu
0.220
8,360
0.116
4,408
Pickling Rinse
38,000 off-kg/day of
Cr
0.574
21,812
copper alloy
0.235
8,930
pickled
Cu
2.481
94,278
1.306
49,628
Miscellaneous Vastestreams
10,000 off-kg/day of
Cr
0.009
90
30
(Billet sav cooling water)
copper alloy sawed
0.003
410
210
Cu
0.041
0.021
Totals
Cr
129,410
52,780
Cu
557,912
293,691
1Pretreatment standards for existing sources (PSES) for the copper forming category (40 CFR Part 468).
2Regulated parameters are Cr, Cu, Pb, Ni, Zn, TTO, and oil and grease.4
3Zero discharge standards have been established for annealing vith oil vastestreams under the copper forming
categorical pretreatment standards. This means that no pollutant discharge allowance for the regulated
pollutant can be established by the Control Authority although a flov discharge may be allowed.
40il and grease (O&G) is an alternative standard to monitoring for and complying vith total toxic organics
fTTM.
-------
established in the metal molding and casting operations are based upon the
volume of air scrubbed (kilograms of pollutant per 62.3 billion standard cubic
meters or pounds of pollutant per billion standard cubic feet of air
scrubbed).
Note that no categorical standards have been established for chromium,
nickel, total toxic organics (TTO) or oil and grease (O&G) in the direct chill
casting operations of the copper casting subcategory of the metal molding and
casting regulation. Also note that zero allowance standards have been
established for all pollutants regulated in the copper forming annealing with
oil process. This means that no discharge allowance for pollutants is allowed
although a flow discharge may be allowed. Calculation of mass discharge
allowances is illustrated below.
Pollutant discharge allowance = average production rate x pollutant limit
Metal molding and casting - direct chill casting of copper alloy
(pollutant: copper)
Daily maximum (Cu) = 2.8 kkg/day x 0.928 kg/1,000 kkg
1,000
= 0.0026 kg/day
Copper forming - extrusion press solution heat treatment (pollutant:
chromium)
Daily maximum (Cr) = 65,000 off-kg/day x 0.00088 mg/off-kg
=57.2 mg/day*
Step 4 - Individually sum the daily maximum and monthly average mass
allowances for each pollutant within each category to derive total daily
maximum and monthly average mass discharge allowances for each regulated
category (see Tables 5-3 and 5-4).
Step 5 - Make a distinction (possibly with the aid of a format such as
that used in Table 5-5) between all regulated, unregulated, and dilution
wastestreams discharged by this facility. The flows of all wastestreams
should be summarized to facilitate calculation of alternative or equivalent
5-22
-------
TABLE 5-5. CHARACTERIZATION OF WASTEWATER FLOWS FRO*
A COPPER CASTING AND FORMING FACILITY
Vastestream
Flow
(MGD)
Flow
(1/day)
Regulated Wastestreams
(Metal Molding and Casting)
Direct Chill Casting Operations*
Casting Quench Operations
Total
(Copper Forming)
Extrusion Press Solution
Heat Treatment
Drawing Spent Lubricants
Alkaline Cleaning Bath
Alkaline Cleaning Rinse
Annealing With Oil
Pickling Bath
Pickling Rinse
Billet Saw Cooling Water
Total
Dilution Wastestreams
0.001
0.003
0.018
0.0001
0.002
0.017
0.002
0.0016
0.013
0.0001
0.0536
3,785
11,355
15,140
68,130
378.5
7,570
64,345
7,570
6,056
49,205
378.5
203,633.0
Hand Wash, Floor Wash, and
Employee Shower Vaters 0.0048
Mold Noncontact Cooling Water Blowdown 0.001
Total 0.0058
18,168
3,785
1Wastestream flows converted from million gallons pgr day (MGD) to liters per
day (1/day) using the conversion factor 3.785 x 10 1/MGD.
*Note that for Cr, Ni, TT0, and oil and grease this wastestream is considered
an unregulated wastestream.
5-23
-------
mass limits. Derive cumulative total flows from all regulated, unregulated,
and dilution wastestreams which are combined prior to treatment.
Step 6 - Using the total flows presented in Table 5-5 and the allowable
mass loadings presented in Table 5-3 and 5-4, derive alternative daily maximum
and monthly average mass-based limits for all regulated pollutants using the
combined wastestream formula for calculating alternative mass limits (Table
4-1, Formula 2). Calculation of these limits is illustrated in the examples
below for the pollutants, copper and chromium.
Alternative mass limit formula:
"cwf - 2 Mi X
IT
Daily maximum (copper):
M
Cu
(2,686 mg/day + 557,912 mg/day) x
(15,140 1/day + 203,633 1/day + 21,953 1/day - 21,953 1/day)
(15,140 1/day + 203,633 1/day)
Mcu = 560,598 mg/day x
(218,733 1/day)
(218,773 1/day)
Mcu = 560,598 mg/day
Monthly average (copper):
Mcu = (1,470 mg/day + 293,691 mg/day) x
(15,140 1/day + 203,633 1/day + 21,953 1/day - 21,953 1/day)
(15,140 1/day + 203,633 1/day)
MCu = 295,161 mg/day x
(218,733 1/day)
(218,773 1/day)
MCu = 295,161 mg/day
5-24
-------
Daily maximum (chromium):
MCr = (129,060 mg/day) x
15,140 1/day + 203,633 1/day + 21,953 1/day - 21,953 1 day)
MCr = 129,410 mg/day x
203,633 1/day
(218,733 1/day)
(203,633 1/day)
MCr = 139,006.1 mg/day
Monthly average (chromium):
MCr = 52,780 mg/day) x
(15,140 1/day + 203,633 1/day + 21,953 1/day - 21,953 1/day)
203,633 1/day
MCr = 52,780 mg/day x
MCr = 56,693.8 mg/day
(218,733 1/day)
(203,633 1/day)
These calculations must be performed for all pollutants regulated by the
categorical pretreatment standards for metal molding and casting and for
copper forming to which this facility is subject. Remember, however, during
the calculations of alternative mass limits for chromium (and nickel), that
wastestreams discharged from casting and associated quench operations are not
considered regulated for chromium (or nickel) as these pollutants are not
regulated by the metal molding and casting categorical pretreatment standards.
Calculations of alternative or equivalent limits must be made on a pollutant
by pollutant basis taking into consideration whether particular process or
category wastestreams are regulated for each of the pollutants of concern.
For example, although TT0 and oil and grease are regulated pollutants under
both the copper forming and metal molding and casting categories, wastewater
discharges from the direct chill casting operation should not be considered
regulated because standards for TT0 and oil and grease have not been
established for that process wastestream. Table 5-6 contains alternative mass
limits calculated for the pollutants of concern to this problem.
5-25
-------
TABLE 5-6. ALTERNATIVE MASS-BASED DISCHARGE LIMITS FOR
A COPPER CASTING AND FORMING FACILITY
Regulated Pollutant
Daily Maximum
Limits
(mg/day)
Monthly Average
Limits
(mg/day)
Chromium (Cr)
139,006
56,694
Copper (Cu)
560,598
285,161
Lead (Pb)
45,807
39,001
Nickel (Ni)
605,488
400,444
Zinc (Zn)
431,356
180,014
Total Toxic Organics (TTO)
187,611
98,011
Oil & Grease (O&G)
5,776,228
3,586,973
5-26
-------
Step 7 (Optional) - should the Control Authority desire, the alternative
mass discharge limits calculated in the previous step may be converted to
equivalent concentration limits by dividing the alternative mass limit by the
'industrial facility's total average discharge flow.
Problem 5-3
An industrial facility manufactures lead-tin solder and lead
piping (as illustrated in Figure 5-3). Lead and tin billets are
melted and cast into solder billets in a semi-continuous casting
operation. After casting, the solder billets are extruded,
degreased and cleaned. In a separate process, lead billets are
extruded into thick-walled piping le.g., 2" inside diameter (I.D.),
2 1/2" outside diameter (O.D.)J. Some of the thick-walled piping is
finished and sold. The remainder of the piping is swaged and drawn
into thinner-walled piping (e.g., 2 1/4" I.D., 2 1/2" O.D.).
All wastewater discharges from this facility are shown in the
process diagram in Figure 5-3. All discharges entering the treat-
ment system are regulated under the standards promulgated in Subpart
A of the nonferrous metals forming and metal powders categorical
pretreatment standards. All of the facility's process wastewater
discharges except one, a noncontact cooling water wastestream, are
combined prior to treatment. The noncontact cooling water waste-
stream is combined with wastewaters exiting the treatment unit prior
to the monitoring location. Representative production data for this
industrial facility are provided in Figure 5-3. Using the data
provided, the Control Authority will need to first calculate daily
maximum and monthly average discharge allowances for each regulated
pollutant. Next, the Control Authority will need to use the
flow-weighted averaging formula to account for the addition of the
unregulated wastestream. Finally, equivalent concentration limits
for the discharges from this facility can be calculated.
Step 1 - Develop a table that facilitates the calculation of daily
maximum and monthly average discharge allowances for each regulated pollutant
of all regulated wastestreams entering the treatment system. The table should
identify each regulated wastestream, production data used to calculate each
wastestream's mass discharge allowance, the pollutants regulated and their
corresponding categorical discharge standards, and the mass discharge allow-
ances calculated (see Table 5-7).
5-27
-------
OHGD
0.00001 M®
0.005 MOD
0.006HGD
0.12 MGD
0.09 MGD
0.00001 M3)
0.0001 H»
0.0001 M3)
0.05 M3D
Treatment
Contaminated
Noncontact
Cooling Water
Solder
Degreasing
(150,000
off-kg/day)
Solder Alkaline
Cleaiing Rinse
(150,000
off-kg/day)
Solder Alkaline
Cleaning Spent
Baths (150,000
off-kg/day)
Lead Pipe
Drawing Spent
Envisions
(25,000
off-kg/day)
Lead Billet
Extrusion Press
ffydraulic Fluid
Leakage (35,000
off-kg/day)
Solder Extrusion
Press Hydraulic
Fluid Leakage
(150,000
off-kg/day)
Solder Extrusion
Press Cooling
Water
(150,000
off-kg/day)
Lead Billet
Extrusion Press
Cooling Water
35,000
off-kg/day)
Semi-Continuous
Solder Casting
Cooling Water
(150,000
off-kg/day)
FIGURE 5-3. HtOCESS FIW DIAGRAM TOR A LEAD PIPE KXWIN3 FAdLEFr
-------
TABLE 5-7.
MLOUABLE MASS LQADQCS FROM PROCESS OPHWUCNS RHGULATED BY
NOTERR0U5 HEEALS POBMDG AID fCEAL POWERS WB30RICAL SKWMRES -
IEAD-TIN-BISHUm SUBCATHQCKY
Regulated
Wastestream
Production Bate
(off-kg*/day)
Pollutant
Limit
Daily Maximum
Monthly Average
(mg/off-kg*)
Discharge Allowance
Sb (mg/day) Pb
Daily Monthly Daily Monthly
Maximum Average Maxiirmi Average
Semi-continuous
Solder Casting
Cooling Water
(*of lead-tin solder
cast by semi-continuous
strip method)
150,000
Solder Extrusion
Press Cooling Water
(*of lead-tin solder
heat treated)
150,000
Sb
Pb
Sb
Pb
0.009
0.004
0.001
0.0006
0.414
0.185
0.061
0.029
1,350
600
62,100
27,750
150
9,150
90
4,350
Solder Extrusion 150,000
Press Hydraulic
Fluid Leakage
(*of lead-tin
solder-extruded)
Solder Degreasing 150,000
Sb
Pb
Sb
Pb
0.158
0.071
0.023
0.011
0'
o
23,700
10,650
3,450
1,650
Solder Alkaline
Cleaning Rinse
(*o£ lead-tin solder
alkaline cleaned)
150,000
Sb
Pb
0.678
0.302
0.099
0.047
101,700
45,300
14,850
7,050
Solder Alkaline
Cleaning Spent Bath
(*of lead-tin solder
alkaline cleaned)
Lead Billet
Extrusion Press
Cooling Water
(*of lead heat
treated)
150,000
35,000
Sb
Pb
Sb
Pb
0.345
0.154
0.051
0.024
0.414
0.185
0.061
0.029
51,750
23,100
14,490
6,475
7,650
2,135
3,600
1,015
5-29
-------
TABLE 5-7. ALLOWABLE MASS LCWUNGS HOf PROCESS OPERAHCNS REGULA3ED BT
NCNFERRCUS METALS FOMNG AND «EAL FOWBS GKTBQCRICAL STANDARDS -
LEAD-HN-BISMJIH SIBCA1BQCKY (Continued)
Regulated
Wastestream
Production Rate
(off-kg*/day)
Pollutant
Limit1
Daily Haxinun
Monthly Average
(mg/off-kg*)
Sb
Daily
Haxinun
Discharge Allowance
(rug/day) Pb
Monthly Daily
Average Haxinun
Monthly
Average
Lead Billet
Extrusion Press
Hydraulic Fluid
Leakage
(*of lead extruded)
35,000
Sb
Pb
0.158
0.071
0.023
0.011
5,530
2,485
805
385
Lead Pipe
Swaging Spent
Bnulsions
(*of lead swaged
vith emulsions)
25,000
Sb
Pb
0.005
0.002
0.0008
0.0004
125
50
20
10
Lead Pipe
Drawing Spent
Bnulsions
(*of lead drawn
vith emulsions)
25,000
Sb
Pb
0.076
0.034
0.011
0.005
1,900
850
275
125
TOTAL 262,645 117,260 35^555 18,275
1Pretreatment standards for existing sources (PSES) for ncnferrous metals forming and metal pcwders, subpart A -
lead/tin/bisnuth forming subcategory (40 CfR Bart 471).
2No discharge of process wastewater pollutants is allowed from degressing vastestresms. Any discharge of wastewater
from this process operation is a violation of the regulation.
5-30
-------
Step 2 - Calculate pollutant discharge allowances by multiplying the
appropriate production values (expressed in mg/off-kg) by the daily maximum
and monthly average standards (from Appendix C-5) for each regulated waste-
stream, as illustrated below for antimony for the semi-continuous solder
casting wastestream.
Pollutant discharge allowance = production rate x pollutant limit
Daily maximum (Sb) = 150,000 off-kg/day x 0.009 mg/off-kg
a 1,350 mg/day
Monthly average (Sb) « 150,000 off-kg/day x 0.004 mg/off-kg
» 600 mg/day
Note that the solder degreasing operation should not receive a discharge
allowance. Although wastewaters are received from this operation, the
categorical standards for the lead-tin-bismuth subpart state "no discharge of
process wastewater pollutants" from this operation.
Step 3 - Sum the daily maximum and monthly average mass allowances
individually to derive total daily maximum and monthly average mass discharge
allowances for each regulated pollutant.
Step 4 - Using the total daily maximum and monthly average mass limits
above and the flow-weighted averaging formula provided In Table 4-2 (Formula
2), calculate alternative daily maximum and monthly average mass discharge
limits to account for pollutants occurring in the contaminated noncontact
cooling water discharged after treatment. Assume that the results of
monitoring conducted by the industrial user indicate that an average of 215
mg/day of antimony and 145 mg/day of lead are discharged as contaminants in
the noncontact cooling water.
M = m + M
fwa cwf noncontact
Daily Maximum (Antimony) Monthly Average (Antimony)
M£wa = 262,645 + 215 = 262,860 mg/day Mfwa =117,260 + 215 = 117,475 mg/day
Daily Maximum (Lead) Monthly Average (Lead)
Mfwa = 38,485 + 145 = 38,630 mg/day Mfw# = 18,275 + 145 = 18,420 mg/day
5-31
-------
Step 5 - Finally, to convert the adjusted alternative mass discharge
limits to concentration limits, divide the alternative mass limits by the
total facility discharge flow including the flow from the noncontact cooling
wastestream.
Total facility = total flow + flow of noncontact
discharge to treatment cooling wastestream
= 0.30022 MGD + 0.05 MGD = 0.35022 MGD
alternative mass limit
Equivalent concentration limit • =
total plant discharge x conversion factor
Daily Maximum (Antimony) Monthly Average (Antimony)
262,860 mg/day 117,475 mg/day
C _ q _
Sb 0.35022 MGD x 3.7854 x 106 1/day Sb 0.35022 MGD x 3.7854 x 106 1/day
MGD MGD
= 0.198 mg/1 = 0.089 mg/1
Daily Maximum (Lead) Monthly Average (Lead)
38,630 mg/day 18,420 mg/day
0 _ 0 _
Pb 0.35022 MGD x 3.7854 x 106 1/day Pb 0.35022 MGD x 3.7854 x 106 1/day
MGD MGD
= 0.029 mg/1 = 0.014 mg/1
After developing equivalent concentration limits, the Control Authority
must verify that the limits calculated for each pollutant are within the
detection range of the analytical methods used by both the Control Authority's
and industrial user's in-house or contract laboratory.
5-32
-------
APPENDIX A
REFERENCES
-------
REFERENCES
Aluminum Forming - 40 CFR Part 467
Proposed Rule
Final Rule
Final Rule, Technical Correction
Final Rule, Technical Amendment
Proposed Rule, Amendments
Final Rule
Copper Forming - 40 CFR Part 468
Proposed Rule
Final Rule
Final Rule, Technical Amendment
Final Rule, Technical Correction
Proposed Rule,
Modifications to Final Rule
Amendment
Final Rule
Final Rule, Technical Correction
Metal Molding and Casting - 40 CFR Part 464
Proposed Rule
Final Rule
Correction
Nonferrous Metals Forming - 40 CFR Part 471
Proposed Rule
Final Rule
Final Rule, Technical Correction
Proposed Regulations, Amendments
General Pretreatment Regulations - 40 CFR Part 403
Proposed Rule
Final Rule
Deferral of Effective Dates
Final Rule
Final Rule; Postponement of Effective Date
Correction
Final Rule
Final Rule, Deadline Change
Denial of Petitions
Final Rule
Final Regulation
Final Rule
Federal Register Notice
11/22/82
47
FR
52626
10/24/83
48
FR
49126
03/27/84
49
FR
11629
01/31/85
50
FR
4513
03/19/86
51
FR
9618
12/27/88
53
FR
52366
11/12/82
47
FR
51278
08/15/83
48
FR
36942
09/15/83
48
FR
41409
11/03/83 •
48
FR
50717
06/24/85
50
FR
26128
08/23/85
50
FR
34334
03/05/86
51
FR
7568
06/20/86
51
FR
22520
11/15/82
47
FR
51512
10/30/85
50
FR
45212
06/16/86
51
FR
21760
03/05/84
49
FR
8112
08/23/85
50
FR
34242
01/22/86
51
FR
2884
06/09/88
53
FR
21774
10/29/79
44
FR
62260
1/28/81
46
FR
9404
4/2/81
46
FR
19936
10/13/81
46
FR
50502
2/1/82
47
FR
4518
2/5/82
47
FR
5413
9/28/82
47
FR
42688
1/21/83
48
FR
2774
6/3/83
48
FR
24933
2/10/84
49
FR
5131
5/17/84
49
FR
21024
7/10/84
49
FR
28058
A-l
-------
REFERENCES (Continued)
General Pretreatment Regulations
(ContTnueli
40 CFR Part 403 Federal Register Notice
Final Rule, Removal Credits
8/3/84
49
FR
31212
Final Rule
9/25/85
50
FR
38809
Final Rule
4/30/86
51
FR
16028
Final Rule, Technical Amendment
6/4/86
51
FR
20426
Correction
6/9/86
51
FR
20828
Proposed Rule
6/12/86
51
FR
21454
Final Rule, Correction
7/1/86
51
FR
23759
Extension of Comment Period
8/21/86
51
PR
29950
Final Rule, Appendix D Revision
10/9/86
51
FR
36368
Final Rule, Definition of Interference
and Pass Through
1/14/87
52
FR
1586
Development Document for Effluent Limitations Guidelines and Standards for the
Aluminum Forming Point Source Category. June 1984, EPA 440/1-84/073
NTISi Vol. It PB84-244425, Vol. lis PB84-244433
Development Document for Effluent Limitations Guidelines and Standards for the
Copper Forming Point Source Category. March 1984. EPA 440/1-84/074
NTISs PB84-292459
Development Document for Effluent Limitations Guidelines and Standards for the
Nonferrous Metals Forming Point Source Category. September 1986. EPA
440/1-86/019 NTIS: Vol. Is PB87-121760/AS Vol. lis PB87-121778
Vol. Ill: PB87-121786
Additional Guidance
Guidance Manual for POTW Pretreatment Program Development
Guidance Manual for Electroplating and Metal Finishing
Pretreatment Standards
Pretreatment Implementation Review Task Force (PIRT) Final
Report
Guidance Manual for Implementing Total Toxic Organics (TTO)
Pretreatment Standards
Guidance Manual for Use of Production-Based Pretreatment
Standards and the Combined Wastestream Formula
October 1983
February 1984
January 1985
September 1985
September 1985
RCRA Information on Hazardous Wastes for Publicly Owned
Treatment Works
September 1985
-------
REFERENCES (Continued)
Additional Guidance (Continued)
Guidance Manual for Iron and Steel Manufacturing
Pretreatment Standards
Pretreatment Compliance Monitoring and Enforcement Guidance
PRELIM 3.0: EPA Computer Model for Development of Local
Limits (user manual and computer disk for use on an
IBM compatible microcomputer)
Guidance Manual for Preventing Interference at POTWs
Copies of the technical development and economic documents may be
obtained from the National Technical Information Services (NTIS), Springfield,
VA 22161 (703-487-4650). Pretreatment program manuals may be obtained from
U.S. EPA, Permits Division (EN-336), Washington, DC 20460.
September 1985
September 1986
June 1987
September 1987
A-3
-------
APPENDIX B
GLOSSARY OF TEBMS
-------
GLOSSARY OF TERMS
The Act
The Federal Water Pollution Control Act Amendments of 1972 as amended by the
Clean Water Act of 1977 (PL 92-500).
Aging
A change in the properties of certain metals and alloys that occurs at ambient
or moderately elevated temperatures after hot working or heat treatment
(quench aging in ferrous alloys, natural or artificial aging in ferrous and
nonferrous alloys) or after a cold working operation (strain aging). The
change in properties is often due to a phase change (precipitation), but never
involves a change in chemical composition of the metal or alloy.
Alkaline Cleaning
A process where dirt, mineral and animal fats and oils are removed from the
metal surface by exposure at high temperatures to solutions containing
alkaline compounds, such as caustic soda, soda ash, alkaline silicates,
alkaline phosphates, ionic detergents, and nonionic detergents.
Alkaline Cleaning Bath
\
A bath consisting of an alkaline cleaning solution through which a workpiece
is processed.
Alkaline Cleaning Rinse
A rinse following an alkaline cleaning bath through which a workpiece is
processed. A rinse consisting of a series of rinse tanks is considered as a
single rinse.
Alloy
A substance having metallic properties and being composed of two or more
chemical elements of which at least one is an elemental metal.
Aluminum Forming
A set of manufacturing operations iri which aluminum and aluminum alloys are
made into semifinished products by hot or cold working.
Ancillary Operations
A manufacturing operation that has a large flow, discharges significant
amounts of pollutants, and may not be present at every plant in a subcategory,
but when present it is an integral part of the aluminum forming process.
Annealing
A generic term describing a metals treatment process that is used primarily to
soften metallic materials, but also to simultaneously produce desired changes
in other properties or in microstructure. The purpose of such changes may be
B-l
-------
improvement of machinability, facilitation of cold work, improvement of
mechanical or electrical properties, and increase in stability of dimensions.
Annealing consists of heating and cooling the metal at varying rates to
achieve the desired properties.
Annealing with Oil
The use of oil;to quench a vorkpiece as it passes from an annealing furnace.
Annealing with Vater
The use of a water spray or bath, of which water is the major constituent, to
quench a workpiece as it passes from an annealing furnace.
Approval Authority
The Director in an NPDES state with an approved state pretreatment program and
the Administrator of the EPA in a non-NPDES state or NPDES state without an
approved state pretreatment program.
Atomization
The process in which a stream of water or gas impinges upon a molten metal
stream, breaking it into droplets which solidify as powder particles.
Authorized Representative of Industrial User
An authorized representative of an industrial user may be: 1) a principal
executive officer of at least the level of vice-president, if the industrial
user is a corporation; 2) a general partner or proprietor if the industrial
user is a partnership or proprietorship, respectively; 3) a duly authorized
representative of the individual designated above if such representative is
responsible for the overall operation of the facilities from which the
indirect discharge originates.
Ball Mill
A mill in which materials are finely ground on a rotating cylinder containing
balls (usually steel).
Best Available Technology Economically Achievable
Level of technology applicable to toxic and nonconventional pollutants on
which effluent limitations are established.
Billet
A long slender cast product used as a raw material in subsequent forming
operations.
Biochemical Oxygen Demand (BOD)
The quantity of oxygen utilized in the biochemical oxidation of organic matter
under standard laboratory procedures, five (5) days at 20° centigrade
expressed in terms of weight and concentration [milligrams per liter (mg/1)].
B-2
-------
Blowdown
The minimum discharge of circulating water for the purpose of discharging
dissolved solids or other contaminants contained in the water, the further
buildup of which would cause concentration in amounts exceeding limits
established by best engineering practice.
Brazing
A process that bonds two metal pieces by heating them to a suitable tempera-
ture and by using a filler material which melts above 425°C (800°F) but below
the melting point of the metals being joined. The filler material is
distributed between the surfaces of the joint by capillary action.
Bright Annealing
Annealing in a protective medium to prevent discoloration of the bright
surface.
Brittleness
The quality of a metal that leads to crack propagation without appreciable
plastic deformation.
Burnishing
A surface finishing process in which minute surface irregularities are
displaced rather than removed.
Categorical Standards
National categorical pretreatment standards or pretreatment standard.
Chromate Conversion Coating (or Chromating)
Process of forming a conversion coating (protective coating) on a metal by
immersing or spraying with a hexavalent chromium compound solution to produce
a hexavalent and/or trivalent chromium compound coating. Also known as
chromate treatment. Most often applied to aluminum, zinc, cadmium or
magnesium surfaces.
Clad Metal
A composite metal containing two or more layers that have been metallurgically
bonded together by roll bonding (co-rolling), solder application (or brazing)
and explosion bonding.
Cleaning (see etching)
Cold Rolling
An operation that produces aluminum or copper sheet with a thickness between
6.25 cm and 0.015 cm (0.249 to 0.006 inches) by passing the metal through a
set of rolls. The process is an exothermic process and causes strain-
hardening of the product.
B-3
-------
Cold forking
Deforming metal plastically at a temperature lover than the recrystallization
temperature of the metal, generally at room temperature.
Contact Water
Any water or oil that comes into direct contact with nonferrous metal during
forming operations, whether the metal is raw material, intermediate product,
waste product, or finished product.
Continuous Casting
A casting process that produces sheet, rod, or other long shapes by
solidifying the metal while it is being poured through an open-ended mold
using little or no contact cooling water. Thus, no restrictions are placed on
the length of the product and it is not necessary to stop the process to
remove the cast product.
Continuous Treatment
Treatment of wastestreams operating without interruption as opposed to batch
treatment. Sometimes referred to as flow-through treatment.
Contractor Removal (Contract Hauling)
Disposal of oils, spent solutions, or sludge by a commercial firm.
Control Authority
The "Approval Authority", defined hereinabove; or the superintendent of a
municipality if the municipality has an approved pretreatment program under
the provisions of 40 CFR Part 403.
Conversion Coating
A coating produced by chemical or electrochemical treatment of a metallic
surface that gives a surface layer containing a compound of the metal.
Examples include chromate coatings on zinc and cadmium, and oxide coatings on
steel.
Core Stream
A wastestream generated by operations that always occur within a particular
subcategory.
Cooling Water
The water discharged from any use such as air conditioning, cooling or
refrigeration, or to which the only pollutant added is heat.
Corrosion
The deterioration of a metal by chemical or electrochemical reaction with its
environment.
B-4
-------
Countercurrent Cascade Rinsing
A staged process that employs recycled, often untreated, water as a rinsing
medium to clean metal products. Water flow is opposite to product flow such
that the most contaminated water encounters incoming product first.
Degassing
The removal of dissolved hydrogen from the molten aluminum prior to casting.
Chemicals are added and gases are bubbled through the molten aluminum.
Sometimes a wet scrubber is used to reduce opacity created by excess chlorine
gas. This process also helps to remove oxides and impurities from the melt.
Die
Various tools used to impart shape to metal primarily because of the shape of
the die itself. Examples are forging dies, drawing dies, and extrusion dies.
Direct Chill Casting
A method of casting where the molten metal is poured into a water-cooled mold.
The base of this mold is the top of a hydraulic cylinder that lowers the metal
first through the mold and then through a water spray and bath to cause
solidification. The vertical distance of the drop limits the length of the
ingot. This process is also known as semi-continuous casting.
Drag-out
The solution that adheres to the objects removed from a bath or rinse, more
precisely defined as that solution which is carried past the edge of the tank.
Drawing
Pulling metal through a die or succession of dies to reduce the metal's
diameter or alter its shape.
Ductility
The ability of a metal to deform plastically without fracturing.
Effluent
Discharge from a point source.
Effluent Limitation
Any standard (including schedules of compliance) established by a state or EPA
on quantities, rates, and concentrations of chemical, physical, biological,
and other constituents that are discharged from point sources into navigable
waters, the waters of the contiguous zone, or the ocean.
Electrochemical Finishing
Producing a desired finish on the surface of a metallic product by immersing
the workpiece in an electrolyte bath through which direct current is passed.
B-5
-------
Electroplating
The production of metal coatings on the surface of another material by
electrodeposition.
Emulsions
Stable dispersions of two immiscible liquids. In the aluminum forming and
nonferrous metals forming categories, this is usually an oil and water
mixture.
End-of-Pipe Treatment
The reduction of pollutants by wastewater treatment prior to discharge or
reuse.
Etching
A chemical solution bath and a rinse or series of rinses designed to produce &
desired surface finish on the work piece, either to remove surface imperfec-
tions, oxides or scratches or to provide surface roughness. Conversion
coating and anodizing when performed as an integral part of forming operations
are considered cleaning or etching operations. When conversion coating or
anodizing are covered under forming categorical standards, they are not
subject to regulation under the provisions of 40 CFR Parts 413 and 433,
electroplating and metal finishing.
Eutectic Temperature
The lowest temperature at which a solution (in this case, the solution is
molten metal and various alloying materials) remains completely liquid.
Extrusion
A process in which high pressures are applied to a metal billet, forcing the
metal to flow through a die orifice to form rods, tubes or special sections.
Extrusion Heat Treatment
The spray application of water to a workpiece immediately following extrusion
for the purpose of heat treatment.
Finishing
The coating or polishing of a metal surface.
Fluxes
Substances added to molten metal to help remove impurities and prevent
excessive oxidation, or to promote the fusing of the metals.
Foil Rolling
A process which produces aluminum foil less than 0.006 inches thick. Foil is
usually produced by cold rolling.
B-6
-------
Forging
Deforming metal (usually hot) with compressive forces into desired shapes,
with or without dies. Where dies are used, the metal is forced to take the
shape of the die.
Grinding
The process of removing stock from a workpiece by the use of a tool consisting
of abrasive grains held by a rigid or semi-rigid binder. Grinding includes
surface finishing, sanding, and slicing.
Hammer Forging
Forging in which the workpiece is deformed by repeated blows.
Hardness
Resistance of metal to plastic deformation by indentation, scratching,
abrasion or cutting.
Heat Treatment
A process that changes such physical properties of a metal as strength,
ductility, and malleability by controlled heating and cooling at specified
temperatures and durations. Such operations as tempering, carburizing,
cyaniding, nitriding, annealing, aging, normalizing, austenizing,
austempering, siliconizing, martempering, and malleablizing are included in
this definition.
Homogenizing
Holding solidified metal at high temperature to eliminate or decrease chemical
segregation by diffusion.
Hot Rolling
The process in which aluminum is heated to between 400°C and 495°C and passed
through a set of rolls which reduces the thickness of the metal to a plate 6.3
mm (0.25 inches) thick or less. Hot rolling does not strain-harden the
aluminum.
Hot Vorking
Deforming metal plastically at such a temperature and rate that strain
hardening does not occur. The low limit of temperature is the
recrystallization temperature of the metal.
Hydraulic Press
A press in which fluid pressure is used to actuate and control the ram.
B-7
-------
Impacting
Forming, usually cold, a part from a metal slug confined in a die, by rapid
single-stroke application of force through a punch, causing the metal to flow
around the punch.
In-Process Control Technology
Any procedure or equipment used to conserve chemicals and water throughout the
production operations, resulting in a reduction of the wastewater volume.
Indirect Discharge
The discharge or the introduction of nondomestic pollutants from any source
regulated under section 307(b) or (c) of the Act into the POTW.
Indirect Discharger
Any point source that discharges to a publicly owned treatment works.
Industrial User
A source of indirect discharge which does not constitute a "discharge of
pollutants" under regulations issued pursuant to section 402 of the Act.
Ingot
A large, block-shaped casting produced by various methods. Ingots are
intermediate products from which other products are made.
Interference
A discharge which, alone or in conjunction with a discharge or discharges from
other sources, both: 1) inhibits or disrupts the POTW, its treatment
processes or operations, or its sludge processes, use or disposal; and 2)
therefore is a cause of a violation of any requirement of the POTW's NPDES
permit (including an increase in the magnitude or duration of a violation) or
of the prevention of sewage sludge use or disposal in compliance with the
following statutory provisions and regulations or permits issued thereunder
(or more stringent State or local regulations): Section 405 of the Clean
Water Act, the Solid Waste Disposal Act (SWDA) (including Title II, more
commonly referred to as the Resource Conservation and Recovery Act (RCRA), and
including State regulations contained in any State sludge management plan
prepared pursuant to Subtitle D of the SWDA), the Clean Air Act, the Toxic
Substances Control Act, and the Marine Protection, Research and Sanctuaries
Act.
Jet
A stream of fluid (gas or liquid) discharged from a narrow opening or nozzle.
Mandrel
A rod used to retain the cavity in hollow metal products during working.
B-8
-------
Metal Povder Production
Any process operations which convert metal to a finely divided form without an
increase in metal purity.
National Categorical Pretreatment Standard or Pretreatment Standard
Any regulation containing pollutant discharge limits promulgated by the EPA in
accordance with section 307(b) and (c) of the Act which applies to a specific
category of industrial users.
National Pollutant Discharge Elimination System (NPDES)
National program for issuing, modifying, revoking and reissuing, terminating,
monitoring and enforcing permits, and imposing and enforcing pretreatment
requirements under sections 307, 402, 318 and 405 of the Act.
National Prohibitive Discharge Standard or Prohibitive Discharge Standard
Any regulation developed under the authority of 307(b) of the Act and 40 CFR
403.5.
Neat Oil
A pure oil, usually a mineral oil, with no or few impurities added. In
aluminum forming and nonferrous metals forming, its use is mostly as a
lubricant.
New Source
Any building, structure, facility, or installation from which there is or may
be a discharge of pollutants, the construction of which commenced after the
publication of proposed pretreatment standards under section 307(c) of the Act
which will be applicable to such source if such standards are thereafter
promulgated in accordance with that section.
Nonferrous Metal
Any pure metal other than iron, copper or aluminum, or metal alloy for which a
metal other than iron, copper, and aluminum is its major constituent in
percent by weight.
Nonferrous Metals Forming
A set of manufacturing operations in which nonferrous metals and nonferrous
alloys are made into semifinished products by hot or cold working. It also
includes metal powder production and powder metallurgy of all metals,
including iron, copper, and aluminum.
Off-Gases
Gases, vapors, and fumes produced as a result of an aluminum forming or
nonferrous metals forming operation.
B-9
-------
Off-Kilogram (Off-Pound)
The mass of a metal or metal alloy removed from a forming or ancillary
operation at the end of a process cycle for transfer to a different machine or
process.
Oil and Grease (O&G)
Any material that is extracted by freon from an acidified sample and that is
not volatilised during the analysis, such as hydrocarbons, fatty acids, soaps,
fats, waxes, and oils.
Pass Through
A discharge which exits the POTV into waters of the United States in
quantities or concentrations which, alone or in conjunction with a discharge
or discharges from other sources, is a cause of a violation of any requirement
of the POTW's NPDES permit (including an increase in the magnitude or duration
of a violation).
25
The pH is the negative logarithm of the hydrogen ion activity of a solution.
Forming an adherent phosphate coating on a metal immersed in a suitable
aqueous phosphate solution.
Pickle Liquor
A spent acid-pickling bath.
Pickling
The process of removing scale, oxide, or foreign matter from the surface of
metal by immersing it in a bath containing a suitable chemical reagent that
will attack the oxide or scale, but will not act appreciably upon the metal
during the period of pickling. Frequently it is necessary to immerse the
metal in a detergent solution or to degrease it before pickling.
Pickling Bath
Any chemical bath (other than alkaline cleaning) through which a workpiece is
processed.
Pickling Fume Scrubber
The process of using an air pollution control device to remove particulates
and fumes from air above a pickling bath by entraining the pollutants in
water.
B-10
-------
Pickling Rinse
A rinse, other than an alkaline cleaning rinse, through which a workplace is
processed. A rinse consisting of a series of rinse tanks is considered as a
single rinse.
A metal casting used in remelting.
Plate
A flat, extended, rigid body of metal having a thickness greater than or equal
to 6.3 mm (0.25 inches).
Pollutant
Any dredged spoil, solid waste, incinerator residue, sewage, garbage, s
-------
Process Water
Water used in a production process that contacts the product, raw materials,
or reagents.
Production Normalizing Parameter (PNP)
The unit of production specified in the regulations used to determine the mass
of pollutants that a production facility may discharge.
Production Normalized Water Discharge
The volume of vater discharged from a given process per mass of metal
processed. The water may be discharged to further treatment, discharged
without treatment, or removed by a contractor. Differences between the water
use and wastewater flows associated with a given stream result from recycle,
evaporation, and carryover on the product.
PSES
Pretreatment standards (effluent regulations) for existing sources, under
Section 307(b) of the Act.
PSNS
Pretreatment standards (effluent regulations) for new sources, under Section
307(c) of the Act.
Publicly Owned Treatment Works (POTW)
A waste treatment facility that is owned by a state or municipality. This
definition includes any severs that convey wastewater to the POTW treatment
plant, but does not include pipes, sewers or other conveyances not connected
to a facility providing treatment.
Quenching
Rapid cooling, in air, vapor or water.
Ram
The moving part of a hammer or press to which a tool is fastened.
Recrystallization Temperature
The minimum temperature at which a new, strain-free grain structure is formed
from that existing in a cold worked metal.
Returning treated or untreated wastewater to the production process from which
it originated for use as process water.
B-12
-------
Reuse
The use of treated or untreated process wastewater in a different production
process.
A forging process used to shape veldless rings from pierced disks or
thick-walled, ring-shaped blanks. The rings are forged between rolls or a
mandrel and hammer.
Reduction
A reaction in which there is a decrease in valence resulting from, a gain in
electrons.
Musing
The removal ;of impurities, contaminants, or solutions from the surface of a
workplace using water. Rinsing differs fro® cleaning in that no active
cleaning agents are utilised in rinsevater. Types of rinsing include
countercurrent cascade rinsing, stagnant dip rinsing, recirculating dip
rinsing, and spray rinsing.
Mi
An intermediate metal product having a solid, round cross section 9.5 mm (3/8
inches) or more in diameter.
The process by vhich a permanent bond is created between two metals by rolling
under high pressure in a bonding mill (co-telling).
Railing
Reducing the cross-sectional area of metal stock, or otherwise shaping metal
products, through the use of rotating rolls.
Saving
Cutting a vorkpiece with a band, blade, or circular disk having teeth.
Scale
ft thick layer of oxidation products formed on metals at high temperatures.
Also deposits of water-insoluble constituents formed on surfaces in cooling
towers and wet air pollution control equipment.
Scrubber Liquor
The untreated wastewater stream produced by wet scrubbers cleaning gases
produced by metal forming operations.
B-13
-------
Sheet
A flat-rolled metal product thinner than plate.
Shot
Small spherical particles of metal, larger in diameter than powder.
Shot Casting or Shooting
The production of shot by pouring metal In finely divided streams. Solidified
spherical particles formed during the descent are cooled in a tank el vater.
Sintering
The bonding of adjacent, surfaces of particles in a mass of metal povders or s
compact, by heating to & temperature less than th# melting point of the metal-.
Soldering
A process that bonds two metal pieces by heating them to a suitable
temperature and by using a filler material which melts belov 425°C (800*F),
The filler material is distributed betveen the surfaces of the joint by
capillary action.
Solution Heat Treatment
Heating an alloy to a suitable temperature, holding it at that temperature
long enough to cause one or more constituents to enter into solid solution,
arid then cooling rapidly enough to hold these constituents in solution.
Spent. Lubricant
.
Vater or an oil-water mixture which is used in forming operations to reduce
friction, heat and wear' snd ultimately discharged.
Stationary Casting
A process in which the molten metal- is poyred into molds and alloyed to cool.
It is often used to recycle in-house scrap.
Steel
An iron-base alloy, containing manganese< usually carbon, and often other
alloying elements.
Strip
A sheet of metal in which the length is many tines the breadth.
Subcategoryzation
The process of segmentation of an industry into groups of plants for which
uniform effluent limitations can he established..
8-14
-------
Operations such as pickling, etching, phosphating, and chromatins which
chemically alter the metal surface.
The total suspended matter that floats on the surface of or is susp-ended In
water, wastewater or other liquids and which is removable by laboratory-
filtering.
Swaging
Tapering bar, rod, wire or tubing by forging, hammering or squeezing with
dies; reducing s section by progressively tapering lengthwise until the entire
section attains the smaller dimesion of the taper.
The complete reuse of a stream vith makeup water added for evaporation losses.
There is no blovdown stream from a totally recycled flow and the process water
is not periodically or continuously discharged.
Total Toxic Qrganics (TTO)
The sum of the masses or concentrations of each of the toxic organic compounds
specified in the appropriate categorical standards vhich are found in the
discharge at a concentration greater than 0.010 mg/1.
Toxic Pollutant
Any pollutant or combination of pollutants listed as toxic in regulations
promulgated by the Administrator of the Environmental Protection Agency under
the provision of CVA 307(a) or other Acts.
Tube Reducing
Reducing both the diameter and vail thickness of tubing with a mandrel and a
pair of rolls with tapered grooves.
An operation in which castings, forgings, or parts pressed from metal powder
are rotated in a barrel with ceramic or metal slugs or abrasives to remove
scale, fins, or burrs. It may be done dry or with an aqueous solution.
Kser
Any person who contributes, causes or permits the contribution of wastewater
into a POTV.
-------
Water Use Factor
The total amount of contact water or oil entering a process divided by the
amount of metal product produced by this process. The amount of water
involved includes the recycle and makeup water.
Wastewater
The liquid and water-carried industrial or domestic wastes from dwellings,
commercial, buildings, industrial facilities, and institutions, whether
treated or untreated, which is discharged to a POTW.
Wastewater Discharge Factor
The ratio between water discharged from a production process and the mass of
product of that production process. Recycle water is not included.
Wet Scrubbers
Air pollution control devices used to remove particulates and fumes from air
by entraining the pollutants in a water spray.
Wire
A slender strand of metal with a diameter less than 9.5 mm (3/8 inches).
Work-Hardening
An increase in hardness and strength and a loss of ductility that occurs in
the workpiece as a result of passing through cold forming or cold working
operations. Also known as strain-hardening.
B-16
-------
' APPENDIX G
PRETREATMENT STANDARDS FOR EXISTING AND NEW SOURCES
-------
APPENDIX C-l. PRETREATMENT STANDARDS FOR EXISTING SOURCES (PSES)
ALUMINUM FORMING CATEGORY
Pollutant limits In mg/off-kg (pounds/million off-pounds)'' of Aluminum (40 CFR Part 467)
Subcategory
Chromium
Cyanide (T)
Zinc
TT0
011 and
4
Grease
Pollutant Unit Basis
Max2
3
Avg
Max
Avg
Max
Avg
Max
Avg
Max
Avg
Rolling with Neat Oils
- Core with annealing
.036
.015
.024
.010
.119
.050
.057
4.3
2.1
rolled w/neat oils
furnace scrubber
- Core without annealing
.025
.010
.016
.007
.081
.034
.038
2.9
1.5
rolled w/neat oils
furnace scrubber
- Continuous sheet
.00086
.00035
.00057
.00024
.0029
.0012
.0014
.10
.052
cast
casting lubricant
- Solution heat treat-
.90
.37
.59
.25
2.98
1.25
1.41
110
53
quenched
ment contact
cooling water
- Cleaning or etching
.079
.032
.052
.022
.262
.109
.124
9.3
4.7
cleaned or quenched
bath
- Cleaning or etching
.61
.25
.41
.17
2.03
.85
.96
73
36
cleaned or etched
rinse
- Cleaning or etching
.85
.35
.56
.23
2.82
1.18
1.34
100
50
cleaned or etched
scrubber liquor
Soiling with Emulsions
- Core
.057
.024
.038
.016
.190
.079
.090
6.8
3.4
rolled w/emulslons
- Direct chill
.59
.24
.39
.16
1.94
.81
.92
69
3.5
cast by seml-contlnuous
casting contact
methods
cooling water
- Solution heat
.90
.37
.59
.25
2.98
1.25
1.41
110
53
quenched
treatment contact
cooling water
- Cleaning or etching
.079
.032
.052
.022
.262
.109
.124
9.3
4.7
cleaned or etched
bath
- Cleaning or etching
.61
.25
.41
.17
2.03
.85
.96
73
36
cleaned or etched
rinse
- Cleaning or etching
.85
.35
.56
.23
2.83
1.18
1.34
100
50
cleaned or etched
scrubber liquor
Extrusion
- Core
.15
.061
.098
.041
.49
.21
.23
18
8.8
extruded
- Extrusion press
.65
.27
.43
.18
2.16
.90
1.02
77
39
extruded
leakage
- Direct chill
.59
.24
.39
.16
1.94
.81
.92
69
35
cast
casting contact
cooling water
- Press heat treat-
.90
.37
.59
.25
2.98
1.25
1.41
110
53
quenched
ment contact
cooling water
- Solution heat
.90
.37
.59
.25
2.98
1.25
1.41
110
53
quenched
-------
APPENDIX C-l. PRETREATMENT STANDARDS FOR EXISTING SOURCES (PSES) (Continued)
ALUMINUM FORMING CATEGORY
Pollutant Halts in mg/off-kg (pounds/raillion off-pounds)1 of Aluminum (40 CFR Part 467)
Chromium
Cyanide (t)
Zinc
TTO
Oil and Grease
Pollutant Unit Basis
O
i
to
Subcategory
Max2
3
Avg
Max
Avg
Max
Avg
Max
Avg Max
Avg
- Cleaning or etching
.079
.032
.052
.022
.26
.109
.124
9.3
4.7
cleaned or etched
bath
- Cleaning or etching
1,7
.7
1.2
.5
5.7
2,4
2.7
200
100
cleaned or etched
rinse
- Cleaning or etching
.85
,35
.56
.23
2.82
1.18
1.34
100
50
cleaned or etched
scrubber liquor
Forging
- Core
.022
.009
.015
.006
.073
.031
.035
2.6
1.3
forged
- Forging scrubber
.042
.017
.028
.011
.14
.058
.065
4.9
2.5
forged
liquor
~ Solution heat
.897
.37
.591
.25
2.98
1.24
1.41
110
53
quenched
treatment contact
cooling water
- Cleaning or etching
.079
.032
.052
.022
.26
.11
,123
9.3
4.7
cleaned or etched
bath
- Cleaning or etching
1.7
.7
1.2
.5
5.7
2.4
2.7
200
100
cleaned or etched
rinse
- Cleaning or etching
.851
.35
.561
.23
2.82
1.18
1.34
100
50
cleaned or etched
scrubber liquor
Drawing with Neat Oils
- Core
.022
.009
.015
.006
.073
.031
.035
2.6
1.3
drawn w/neat oils
- Continuous rod
.0009
.0004
.0006
.0003
.0029
.0012
.0014
.10
.052
rod cast
casting lubricant
- Continuous rod
.086
.035
.057
.023
.283
.118
.133
10
5.1
rod cast
casting contact
cooling water
- Solution heat
.896
.367
.591
.245
2.98
1.24
1.41
.— no
53
quenched
treatment contact
cooling water
- Cleaning or etching
.079
.033
.052
.022
.262
.109
.124
— 9.3
4.7
cleaned or etched
bath
- Cleaning or etching
.612
.251
.404
.17
2.03
.85
.96
73
36
cleaned or etched
rinse
- Cleaning or etching
.851
.348
.561
.232
2.82
1.18
1,34
100
50
cleaned or etched
scrubber liquor
Drawing with Eaulsions
or Soaps
drawn w/emulsions or soap
- Core
.205
.084
.135
.056
.681
.285
.32
25
12
- Continuous rod
.0009
.0004
.0006
.0003
.0029
.0012
.0014
.10
.052
rod cast
casting lubricant
rod cast
- Continuous rod
.086
.035
.056
.024
.283
.119
.134
10
5.1
casting contact
cooling water
-------
APPENDIX C-l. PRETREATMENT STANDARDS FOR EXISTING SOURCES (PSES) (Continued)
ALUMINUM FORMING CATEGORY
Pollutant limits In mg/off-kg (pounds/million off-pounds)'' of Aluminum (40 CFR Part 467)
Chromium Cyanide (T) Zinc TTO Oil and Grease4 Pollutant Unit Basis
2 3
Subpart Subcategory Max Avg Max Avg Max Avg Max Avg Max Avg
- Solution heat .896 .367 >591 >245 2.98 1.25 1.41 110 53 quenched
treatment contact
cooling water
- Cleaning or etching
.079
.032
.052
.022
.262
.11
.124
9.3
4.7
cleaned
or
etched
bath
- Cleaning or etching
.612
.251
.404
.167
2.03
.849
.96
73
36
cleaned
or
etched
rinse
- Cleaning or etching
.851
.348
.561
.232
2.82
1.18
1.34
100
50
cleaned
or
etched
scrubber liquor
^These standards are expressed In terms of mass of pollutant allowed per mass of product produced (off-kg or off-pound) In the
given process. Off-kilogram or off-pound Is defined as the mass of aluminum or aluminum alloy removed from a forming or
^ancillary operation at the end of a process cycle for transfer to a different machine or process.
2Max - Maximum pollutant discharge for any one day.
^Avg = Maximum pollutant discharge for a monthly average of all samples collected.
Oil and grease Is an alternative monitoring parameter for total toxic organlcs (TTO) under provisions of the aluminum forming
category.
-------
APPENDIX C-2. PRETBEATMENT STANDARDS FOR NEW SOURCES (PSNS)
ALUMINUM FORMING CATEGORY
Pollutant Halts In ng/off-kg (pounds/million off-pounds)'' of Aluminum (40 CFR Part 467)
O
I
-P-
Subcategory
Chromium
Cyanide
(T)
Zinc
TT0
Oil and
4
Grease
Pollutant Unit Basis
Max2
. 3
Avg
Max
Avg
Max
Avg
Max
Avg
Max
Avg
Rolling with Neat Oils
- Core with annealing
.030
.013
.017
.007
.084
.035
.057
.817
.817
rolled w/ne'at oils
furnace scrubber
- Core without annealing
.021
.009
.011
.005
.057
.024
.038
.54
.54
rolled w/neat oils
furnace scrubber
- Continuous sheet
.00073
.00029
.00039
.00016
.0020
.00082
.0014
.020
.020
cast
casting lubricant
- Solution heat treat-
.76
.31
.41
.17
2.08
.86
1.41
20.37
20.37
quenched
ment contact
cooling water
- Cleaning or etching
.067
.027
.036
.015
.183
.075
.124
1.79
1.79
cleaned or etched
bath
- Cleaning or etching
.52
.21
.28
.11
1.42
.59
.96
13.91
13.91
cleaned"or etched
rinse
- Cleaning or etching
.72
.29
.39
.16
1.97
.81
1.34
19.33
19.33
cleaned or etched
scrubber liquor
Rolling with Emulsions
- Core
.048
.020
.026
.011
.133
.055
.090
1.30
1.30
rolled w/emulslons
- Direct chill
.49
.20
.27
.11
1.36
.56
.92
13.29
13.29
cast by seml-contlnuous
casting contact
methods
cooling water
- Solution heat
.76
.31
.41
.17
2.08
.86
1.41
20.37
20.37
quenched
treatment contact
cooling water
- Cleaning or etching
.067
.027
.036
.015
.183
.075
.124
1.79
1.79
cleaned or etched
bath
- Cleaning or etching
.52
.21
.28
.11
1.42
.59
.96
13.91
13.91
cleaned or etched
rinse
- Cleaning or etching
scrubber liquor
.72
.29
.39
.16
1.97
.81
1.34
19.33
19.33
cleaned or etched
Extrusion
- Core
.13
.05
.07
.03
.35
.15
.24
3.40
3.40
extruded
- Extrusion press
.11
.05
.06
.03
.31
.13
.21
2.98
2.98
extruded
leakage
- Direct chill
.49
.20
.27
.11
1.36
.56
.92
_—
13.29
13.29
cast
casting contact
cooling water
- Press heat treat-
.76
.31
.41
.17
2.08
.86
1.41
20.37
20.37
quenched
ment contact
cooling water
- Solution heat
.76
.31
.41
.17
2.08
.86
1.41
20.37
20.37
quenched
treatment contact
cooling water
-------
APPENDIX C-2. PRETREATMENT STANDARDS FOR NEW SOURCES (PSNS) (Continued)
ALUMINUM FORMING CATEGORY
Pollutant limits In mg/off kg (pounds/million off-pounds)* of Aluminum (40 CFR Part 467)
Chromium
Cyanide (T)
Zinc
TTO
Oil and Grease
Pollutant Unit Basis
O
I
ui
Subcategory
2
Max
Avg3
Max
Avg
Max
Avg
Max
Avg
Max
Avg
- Cleaning or etching
.067
.027
.036
.015
.183
.075
.124
1.79
1.79
cleaned or etched
bath
- Cleaning or etching
.52
.21
.28
.11
1.42
.59
.96
13.91
13.91
cleaned or etched
rinse
- Cleaning or etching
.72
.29
.39
.16
1.97
.81
1.34
19.33
19.33
cleaned or etched
scrubber liquor
Forging
- Core
.019
.008
.010
.004
.051
.021
.035
.50
.50
forged
- Forging scrubber
.035
.014
.019
.008
.096
.040
.065
.95
.95
forged
liquor
- Solution heat
.76
.31
.41
.16
2.08
.86
1.41
20.37
20.37
quenched
treatment contact
cooling water
- Cleaning or etching
.067
.027
.036
.015
.183
.075
.124
1.79
1.79
cleaned or etched
bath
- Cleaning or etching
.52
.21
.28
.11
1.42
.59
.96
13.91
13.91
cleaned or etched
rinse
- Cleaning or etching
.72
.29
.39
.16
1.97
.812
1.34
19.33
19.33
cleaned or etched
scrubber liquor
Drawing with Neat Oils
- Core
.019
.008
.010
.004
.051
.021
.035
.50
.50
drawn w/neat oils
- Continuous rod
.0007
.0003
.0004
.0002
.0020
.0008
.0014
.020
.020
rod cast
casting lubricant
¦-
- Continuous rod
.072
.029
.039
.016
.198
.082
.134
1.94
1.94
rod cast
casting contact
cooling water
- Solution heat
.76
.306
.41
.163
2.08
.856
1.41
20.37
20.37
quenched
treatment contact
cooling water
- Cleaning or etching
.067
.027
.036
.015
.183
.075
.124
1.79
1.79
cleaned or etched
bath
- Cleaning or etching
.52
.21
.28
.11
1.42
.59
.96
13.91
13.91
cleaned or etched
rinse
,
- Cleaning or etching
.72
.29
.39
.16
1.97
.812
1.34
19.33
19.33
cleaned or etched
scrubber liquor
Drawing with Emulsions
or Soaps
drawn w/emulsions or soap
- Core
.173
.070
.094
.038
.48
.196
.32
4.67
4.67
- Continuous rod
.0008
.0003
.0004
.0002
.0020
.0008
.0014
.020
.020
rod cast
casting lubricant
•
- Continuous rod
.072
.029
.039
.016
.198
.082
.134
1.94
1.94
rod cast
casting contact
cooling water
-------
APPENDIX C-2. PRETREATMENT STANDARDS FOR NEW SOURCES (PSNS) (Continued)
ALUMINUM FORMING CATEGORY
Pollutant Halts in mg/off-kg (pounds/aillion off-pounds)^ of Alunimia (40 CFR Part 467)
&
Chromium Cyanide Zinc TTO Oil and Grease Pollutant Unit Basis
2 3
Subpart Subcategory Max Avg Max Avg (tax Avg Max Avg Max Avg
- Solution heat
.76
.306
.41
.163
2.08
.856
1.41
20.37
20.37
quenched
treatment contact
cooling water
- Cleaning or etching
.067
.027
.036
.015
.183
.075
.124
1.79
1.79
cleaned or
etched
bath
- Cleaning or etching
.52
.21
.28
.11
1.42
.59
.96
13.91
13.91
cleaned or
etched
rinse
- Cleaning or etching
.715
.290
.367
.155
1.97
.812
1.34
—
19.33
19.33
cleaned or
etched
scrubber liquor
*These standards are expressed In terms of mass of pollutant allowed per mass of product produced (off-kg or off-pound) in the
given process. Off-kilogram or off-pound is defined as the mass of alumlnua or aluminum alloy removed from a forming or
^ancillary operation at the end of a process cycle for transfer to a different machine or process.
.Max ¦ Maximum pollutant discharge for any one day.
,Avg « Maximum pollutant discharge for a monthly average of samples collected.
Oil and grease is an alternative monitoring parameter for total toxic organics (TTO) under provisions of the aluminum forming
category.
-------
APPENDIX C-3. PRETREATMENT STANDARDS FOR EXISTING SOURCES (PSES)
COPPER FORMING CATEGORY
Pollutant limits In mg/9ff-kg (pounds/million off-pounds)'' of Copper or Copper Alloy (40 CFR Part 468)
Chromium
Copper
Lead
Nickel
Zinc
Total Toxic
Organlcs (TTO)
Oil ang
Grease
Pollutant
Unit Basis
Process
3
Max.
A 4
Avg.
Max.
Avg.
Max.
Avg.
Max.
Avg.
Max.
Avg.
Max.
Avg.
Max.
Avg.
(a)
Hot Rolling Spent
0.045
0.018
0.195
0.103
0.015
0.013
0.197
0.130
0.150
0.062
0.066
0.035
2.060
1.236
(a)
Lubricant
(b)
Cold Rolling Spent
0.166
0.068
0.720
0.379
0.056
0.049
0.727
0.481
0.553
0.231
0.246
0.128
7.580
4.548
(b)
Lubricant
(c)
Drawing Spent Lubricant
0.037
0.015
0.161
0.085
0.012
o.ou
0.163
0.107
0.124
0.051
0.055
0.028
1.700
1.020
(c)
(d)
Solution Heat Treatment
0.284
0.116
1.227
0.646
0.096
0.083
1.240
0.820
0.943
0.394
0.419
0.219
12.920
7.752
(d)
(e)
Extrusion Heat Treatment
0.00088
0.00036
0.0030
0.0020
0.00030
0.00026
0.0030
0.0020
0.0020
0.0010
0.0010
0.00068
0.040
0.024
(eO
(f)
Annealing with Hater
0.545
0.223
2.356
1.240
0.186
0.161
2.380
1.574
1.810
0.756
0.806
0.421
24.800
14.880
(f)
(g)
Annealing with Oil
0
0
0
0
0
0
0
0
0
0
0
0
0
0
(8)
(h)
Alkaline Cleaning Rinse
1.854
0.758
8.006
4.214
0.632
0.547
8.090
5.351
6.152
2.570
2.739
1.432
84.280
50.568
(h)
(I)
Alkaline Cleaning Rinse
5.562
2.275
24.019
12.642
1.896
1.643
24.272
16.055
18.457
7.711
8.217
4.298
252.840
151.704
CD
for Forged Parts
-
(j)
Alkaline Cleaning Bath
0.020
0.0084
0.088
0.046
0.0070
0.0060
0.089
0.059
0.068
0.028
0.030
0.015
0.93
0.56
(j)
(k)
Pickling Rinse
0.574
0.235
2.481
1.306
0.195
0.169
2.507
1.658
1.906
0.796
0.848
0.444
26.120
15.672
(k)
(1)
Pickling Rinse for
1.723
0.705
7.444
3.918
0.587
0.509
7.522
4.975
5.720
2.389
2.546
1.332
78.360
47.016
(1)
Forged Parts
(m)
Pickling Bath
0.051
0.020
0.220
0.116
0.017
0.015
0.222
0.147
0.169
0.070
0.075
0.039
2.320
1.392
(m)
(n)
Pickling Fume Scrubber
0.275
0.112
1.189
0.626
0.093
0.081
1.201
0.795
0.913
0.381
0.406
0.212
12.520
7.512
(n)
(o)
Tumbling or Burnishing
0.256
0.104
1.107
0.583
0.087
0.075
1.119
0.740
0.851
0.355
0.378
0.198
11.660
6.996
(o)
(P)
Surface Coating
0.326
0.133
1.411
0.743
0.I1I
0.096
1.426
0.943
1.084
0.453
0.482
0.252
14.860
8.916
(P)
(q)
Miscellaneous Haste
Streams
0.009
0.003
0.041
0.021
0.003
0.002
0.041
0.027
0.031
0.013
0.014
0.007
0.436
0.261
(q)
These standards are expressed in terms of mass of pollutant allowed per mass of product
produced (off-kg or off-pound) In a given process. Off-kg (off-pound) means the mass
of copper or copper alloy removed from a forming or ancillary operation at the end of
2a process cycle for transfer to a different machine or process-
Oil and grease Is an alternative monitoring parameter for total toxic organlcs (TTO)
2for the copper forming category.
ax - Maximum pollutant level for any one day
jAvg - Maximum pollutant level for a monthly average of all samples taken
Miscellaneous Waste Streams - wastestreams from hydrotestlng, sawing, surface milling,
and maintenance.
Pollutant Unit Basis - see notes below.
(a) Hot rolled
(b) Cold rolled
(c) Drawn
(d) Heat treated
(e) Heat treated on an extrusion press
(f) Annealed with water
(g) Annealed with oil
(h) Alkaline cleaned
(1) Forged parts alkaline cleaned
(j) Alkaline cleaned
(k) Pickled
(1) Forged parts pickled
(m) Pickled
(n) Pickled
(o) Tumbled or burnished
(p) Surface coated
(q) Formed
-------
APPENDIX C-4. PRETREATMENT STANDARDS FOR NEW SOURCES (PSNS)
COPPER FORMING CATEGORY
Pollutant limits In mg/off-kg (pounds/million off-pounds)'' of Copper or Copper Alloy (AO CFR Part 468)
Chromium
Copper
Lead
Nickel
Zinc
Total Toxic
Organlcs (TTO)
Oil ang
Grease
Pollutant
Unit Basis
Process
Max.
Avg.
Max.
Avg.
Max.
Avg.
Max. Avg.
Max.
Avg.
Max.
Avg.
Max. Avg.
0
1
00
(a) Hot Rolling Spent
Lubricant
(b) Cold Rolling Spent
Lubricant
(c) Drawing Spent Lubricant
(d) Solution Heat Treatment
(e) Extrusion Heat Treatment
(f) Annealing with Water
(g) Annealing with Oil
(h) Alkaline Cleaning Rinse
(1) Alkaline Cleaning Rinse
for Forged Parts
(j) Alkaline Cleaning Bath
(k) Pickling Rinse
(1) Plckline Rinse for
Forged Parts
(m) Pickling Bath
(n) Pickling Fume Scrubber
(o) Tumbling or Burnishing
(p) Surface Coating
(q) Miscellaneous Waste
Streams
^These standards are expressed In terms of mass of pollutant allowed per mass of product
produced (off-kg or off-pound) In a given process. Off-kg (off-pound) means the mass
of copper or copper alloy removed from a forming or ancillary operation at the end of
2* process cycle for transfer to a different machine or process.
Oil and grease Is an alternative monitoring parameter for total toxic organlcs (TTO)
jfor the copper forming category.
^Max » Maximum pollutant level for any one day
jAvg » Maximum pollutant level for a monthly average of all samples taken
Miscellaneous Waste Streams - wastestreams from hydrotestlng, sawing, surface milling,
and maintenance.
0.038
0.015
0.131
0.062
0.010
0.0092
0.056
0.140
0.056
0.485
0.231
0.037
0.034
0.208
0.031
0.012
0.108
0,051
0.0085
0.0076
0.046
0.239
0.096
0.826
0.394
0.064
0.058
0.355
0.00074
0.00030
0.0020
0.0010
0.00020
0.00018
0.0010
0.458
0.186
1.587
0.756
0.124
0.111
0.682
0
0
0
0
0
0
0
1.559
0.632
5.393
2.570
0.421
0.379
2.317
4.677
1.896
16.181
7.711
1.264
1.137
6.953
0.017
0.0070
0.059
0.028
0.0046
0.0042
0.025
0.216
0.087
0.748
0.356
0.058
0.052
0.321
0.649
0.263
2.246
1.070
0.175
0.157
0.965
0.042
0.017
0.148
0.070
0.011
0.010
0.063
0.231
0.093
0.801
0.381
0.062
0.056
0.344
0.215
0.087
0.746
0.355
0.058
0.052
0.320
0.274
0.111
0.951
0.453
0.074
0.066
0.408
0.008
0.003
0.027
0.013
0.0021
0.0019
0.011
0.038
0.031
0.239
0.00074
0.458
0
1.559
0.017
0.216
0.649
0.042
0.231
0.215
0.274
0.008
0.105
0.043
0.035
0.035
1.030
1.030
(a)
0.386
0.159
0.128
0.128
3.790
3.790
(b)
0.086
0.035
0.028
0.028
0.850
0.850
(c)
0.658
0.271
0.219
0.219
6.460
6.460
(d)
0.0020
0.00084
0.00068
0.00068
0.020
0.020
(e)
1.264
0.520
0.421
0.421
12.400
12.400
(f)
0
0
0
0
0
0
(8)
4.298
1.769
1.432
1.432
42.140
42.140
(h)
12.894
5.309
4.298
4.298
126.420
126.420
(1)
0.047
0.019
0.015
0.015
0.46
0.46
(J)
0.596
0.245
0.198
0.198
5.850
5.850
(k)
1.790
0.737
0.596
0.596
17.550
17.550
(1)
0.118
0.048
0.039
0.039
1.160
1.160
(m)
0.638
0.262
0.212
0.212
6.260
6.260
(n)
0.594
0.244
0.198
0.198
5.830
5.830
(o)
0.757
0.312
0.252
0.252
7.430
7.430
(P)
0.022
0.009
0.007
0.007
0.218
0.218
(q)
Pollutant Unit Basis - see notes below.
(a) Hot rolled
(b) Cold rolled
(c) Drawn
(d) Heat-treated
(e) Head treatment on an extrusion press
(f) Annealed with water
(g) Annealed with oil
(h) Alkaline Cleaned
(1) Forged parts alkaline cleaned
(j) Alkaline cleaned
(k) Pickled
(1) Forged parts pickled
(ra) Pickled
(n) Pickled
(o) Tumbled or burnished
(p) Surface coated
(q) Formed
-------
APPENDIX C-5. PRETREATMENT STANDARDS FOR EXISTING SOURCES (PSES)
NONFERROUS METALS FORMING CATEGORY
SUBPART A - LEAD-TIN-BISMUTH FORMING SUBCATEGORY
Pollutant Limits In mg/off-kg (pounds/million off-pounds)'' of Lead-Tin-Bismuth (40 CFR Part 471)
Antimony
Lead
Pollutant Unit Basis
Process
Max2
3
Avg
Max
Avg
(a)
Rolling Spent Emulsions
0.067
0.030
0.010
0.005
rolled with emulsions
(b)
Rolling Spent Soap Solutions
0.120 ,
0.055
0.018
0.009
rolled with soap solutions
(c)
Drawing Spent Neat Oils
ND
ND
(d)
Drawing Spent Emulsions
0.076
0.034
0.011
0.005
drawn with emulsions
(e)
Drawing Spent Soap Solutions
0.022
0.010
0.003
0.002
drawn with soap solutions
(f)
Extrusion Press and Solution
0.414
0.185
0.061
0.029
heat treated
Heat Treatment Contact
Cooling Hater
(g)
Extrusion Press Hydraulic
0.158
0.071
0.023
0.011
extruded
Fluid Leakage
(h)
Continuous Strip Casting
0.003
0.001
0.0004
0.0002
cast by continuous strip
Contact Cooling Hater
method
(1)
Semi-Continuous Ingot Casting
0.009
0.004
0.001
0.0006
ingot case by semi-continuous
Contact Cooling Hater
strip method
(j)
Shot Casting Contact Cooling
0.107
0.048
0.016
0.008
shot cast
Hater
W
Shot-Forming Het Air Pollution
0.169
0.076
0.025
0.012
shot formed
Control Scrubber Blowdown
(1)
Alkaline Cleaning Spent Baths
0.345
0.154
0.051
0.024
alkaline cleaned
(m)
Alkaline Cleaning Rinse
0.678
0.302
0.099
0.047
alkaline cleaned
(n)
Swaging Spent Emulsions
0.005
0.002
0.0008
0.0004
swaged with emulsion
(o) Degreaslng Spent Solvents ND ND
*These standards are expressed In terms of mass of pollutant allowed per mass of product produced (off-kg or
off-pound) In a given process. Off-kilogram or off-pound 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.
.Max » Maximum pollutant level for any one day
4 Avg » Maximum pollutant level for a monthly average of all samples taken
ND ¦ No discharge of process wastewater pollutants
-------
APPENDIX C-6. PRETREATMENT STANDARDS FOR HEW SOURCES (PSNS)
NONFERROUS METALS FORMING CATEGORY
SUBPART A - LEAD-TIN-BISMUTH FORMING SUBCATEGORY
Pollutant Limits in rag/off-kg (pounds/million off-pounds)* of Lead-Tin-Bismuth (40 CPR Part 471)
Antimony
Lead
Pollutant Unit Basis
Process
Max2
. 3
Avg
Max
Avg
(a)
Rolling Spent Emulsions
0.067
0.030
0.010
0.005
rolled with emulsions
(b)
Rolling Spent Soap Solutions
0.120 .
0.055
0.018
0.009
rolled with soap solutions
(c)
Drawing Spent Neat Oils
ND
ND
(d)
Drawing Spent Emulsions
0.076
0.034
0.011
0.005
drawn with emulsions
(e)
Drawing Spent Soap Solutions
0.022
0.010
0.003
0.002
drawn with soap solutions
(f)
Extrusion Press and Solution
0.414
0.185
0.061
0.029
heat treated
Heat Treatment Contact
Cooling Hater
(g)
Extrusion Press Hydraulic
0.158
0.071
0.023
0.011
extruded
Fluid Leakage
(h)
Continuous Strip Casting
0.003
0.001
0.0004
0.0002
cast by continuous strip
Contact Cooling Hater
method
(i)
Semi-Continuous Ingot Casting
0.009
0.004
0.001
0.0006
Ingot case by semi-continuous
Contact Cooling Hater
strip method
U)
Shot Casting Contact Cooling
0.107
0.048
0.016
0.008
shot cast
Hater
(k)
Shot-Forming Het Air Pollution
0.169
0.076
0.025
0.012
shot formed
Control Scrubber Blowdown
(1)
Alkaline Cleaning Spent Baths
0.345
0.154
0.051
0.024
alkaline cleaned
(m)
Alkaline Cleaning Rinse
0.678
0.302
0.099
0.047
alkaline cleaned
(n)
Swaging Spent Emulsions
0.005
0.002
0.0008
0.0004
swaged with emulsion
(o) Degreasing Spent Solvents ND ND
''These standards are expressed in terms of mass of pollutant allowed per mass of product produced (off-kg or
off-pound) in a given process. Off-kilogram or off-pound 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.
..Max =* Maximum pollutant level for any one day
^Avg - Maximum pollutant level for a monthly average of all samples taken
ND = No discharge of process wastewater pollutants
-------
APPENDIX C-7. PRETREATMENT STANDARDS FOR EXISTING SOURCES (PSES)
NONFERROUS METALS FORMING CATEGORY
SUBPART B - MAGNESIUM FORMING SUBCATEGORY
Pollutant Limits In mg/off-kg (pounds/million off-pounds) of Magnesium (40 CFR Part 471)
Chromium
Zinc
Ammonia
Fluoride
Pollutant Unit Basis
Process
Max2
. 3
Avg
Max
Avg
Max
Avg
Max
Avg
(a)
Rolling Spent Emulsions
0.033
0.014
0.109
0.046
9.95
4.37
4.44
1.97
rolled with emulsions
(b)
Forging Spent Lubricants
ND
ND
ND
ND
(c)
Forging Contact Cooling Water
0.127
0.052
0.422
0.177
38.5
17.0
17.2
7.63
(forged magnesium)
cooled with water
-------
APPENDIX C-8. PRETREATMENT STANDARDS FOR NEW SOURCES (PSNS)
NONFERROUS METALS FORMING CATEGORY
SUBPART B - MAGNESIUM FORMING SUBCATEGORY
Pollutant Limits la mg/off-kg (pounds/million off-pounds)* of Magnesium (40 CFR Part 471)
Chromium Zinc Ammonia Fluoride Pollutant Unit Basis
Process
Max2
. 3
Avg
Max
Avg
Max
Avg
Max
Avg
(a)
Rolling Spent Emulsions
0.028
0.011
0.076
0.032
9.95
4.37
4.4*4
1.97
rolled with emulsions
(b)
Forging Spent Lubricants
ND
ND
ND
ND
(c)
Forging Contact Cooling Hater
0.107
0.044
0.295
0.122
38.5
17.0
17.2
7.63
(forged magnesium)
cooled with water
(d)
Forging Equipment Cleaning
Wastewater
0.002
0.0006
0.004
0.002
0.532
0.234
0.238
0.106
forged
(e)
Direct Chill Casting Contact
Cooling Water
1.46
0.593
4.03
1.66
527
232
235
105
cast with direct chill
method
(f)
Surface Treatment Spent Baths
0.173
0.070
0.476
0.196
62.1
27.3
27.8
12.3
surface treated
(g)
Surface Treatment Baths
0.700
0.284
1.93
0.794
252
111
113
49.9
surface treated
(h)
Sawlng/Grlndlng Spent
Emulsions
0.007
0.003
0.020
0.008
2.60
1.15
1.16
0.515
sawed or ground
(1)
Degreaslng Spent Solvent
ND
ND
NO
ND
-------
APPENDIX 09. PRETREATMENT STANDARDS FOR EXISTING SOURCES (PSES)
NONFERROUS METALS FORMING CATEGORY
SUBPART C - NICKEL-COBALT FORMING SUBCATEGORY
Pollutant Limits In mg/off-kg (pounds/million off-pounds)* of Nickel-Cobalt (40 CFR Part 471)
Chromium Nickel Fluoride Pollutant Unit Basis
2 3
Process Max Avg Max Avg Max Avg
(a) Rolling Spent Neat Oils
hd'
ND
ND
(b) Rolling Spent Emulsions
0.063
0.026
0.094
0.063
10.1
4.49
rolled with emulsions
(c) Rolling Contact Cooling Hater
0.028
0.011
0.042
0.028
4.49
1.99
rolled with water
(d) Tube Reducing Spent Lubricants
ND
ND
ND
(e) Drawing Spent Neat Oils
ND
ND
ND
(f) Drawing Spent Emulsions
0.036
0.014
0.053
0.036
5.68
2.52
drawn with emulsions
(g) Extrusion Spent Lubricants
ND
ND
ND
(h) Extrusion Press and Solution Heat
0.031
0.013
O.046
0.031
4.95
2.20
heat treated
Treatment Contact Cooling Hater
(1) Extrusion Press Hydraulic Fluid
0.086
0.034
0.128
0.086
13.8
6.13
extruded
Leakage
(j) Forging Equipment Cleaning
0.002
0.0006
0.002
0.002
0.238
0.106
forged
Wastewater
(k) Forging Contact Cooling Hater
0.018
0.007
0.026
0.018
2.82
1.25
(forged nickel-cobalt)
cooled with water
(1) Forging Press Hydraulic Fluid
0.069
0.028
0.103
0.069
11.2
4.94
forged
Leakage
(o) Forging Spent Lubricants
ND
ND
ND
(n) Stationary Casting Contact
0.448
0.182
0.666
0.448
72.0
32.0
cast with stationary methods
Cooling Hater
methods
(o) Vacuum Melting Steam Condensate
ND
ND
ND
(p) Hetal Powder Production
0.970
0.393
1.44
0.970
156
69.2
metal powder atomized
Atoalzatlon Wastewater
(q) Annealing Solution Heat Treat-
ND
ND
ND
ment Contact Cooling Hater
(r) Het Air Pollution Control
0.300
0.122
0.446
0.300
48.2
21.4
formed
Scrubber Slowdown
(s) Surface Treatment Spent Baths
0.346
0.141
0.514
0.346
55.7
24.7
surface treated
(t) Surface Treatment Rinse
0.873
0.354
1.30
0.873
141
62.3
surface treated
(u) Alkaline Cleaning Spent Baths
0.013
0.005
0.019
0.013
2.02
0.895
alkaline cleaned
(v) Alkaline Cleaning Rinse
0.086
0.035
0.128
0.086
13.9
6.15
alkaline cleaned
(w) Molten Salt Rinse
0.312
0.127
0.464
0.312
50.2
22.3
treated with molten salt
(x) Ammonia Rinse
0.006
0.002
0.008
0.006
0.881
0.391
treated with ammonia solution
(y) Saving/Grinding Spent Emulsions
0.015
•0.006
0.022
0.015
2.35
1.04
sawed or ground with emulsions
(z) Sawing/Grinding Rinse
0.067
0.027
0.100
0.067
10.8
4.78
(sawed or ground nickel-cobalt)
rinsed
(aa) Steam Cleaning Condensate
0.011
0.005
0.017
0.011
1.79
0.795
steam cleaned
(bb) Hydrostatic Tube Testing and
ND
ND
ND
Ultrasonic Testing Hastewater
(cc) Degreaslng Spent Solvents
ND
ND
ND
(dd) Dye Penetrant Testing Hastewater
0.079
0.032
0.117
0.079
—
—
tested with dye penetrant method
(ee) Electrocoatlng Rinse ^
1.25
0.506
1.86
1.25
201
89.0
electrocoated
(ff) Miscellaneous Hastewater
l
0.091
0.037
0.136
0.091
14.7
6.50
formed
These standards are expressed In terns of mass of pollutant allowed per mass of product produced (off-kg or off-pound) In a given process.
Off-kilogram or off-*pound 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 proces".
^Max a Maximum pollutant level for any one day
Avg ¦ Maximum pollutant level for a monthly average of all samples taken
*ND ¦ No discharge of process wastewater pollutants
Miscellaneous Wastewater - wastestreams from maintenance and clean-up
-------
APPENDIX C-10. PRETREATMENT STANDARDS FOR HEW SOURCES (PSNS)
NONFERROUS METALS FORMING CATEGORY
SUBPART C - NICKEL-COBALT FORMING SUBCATEGORY
Pollutant: Halts In mg/off-kg (pounds/million off-pounds)' of Nickel-Cobalt (40 ,CFR Part 471)
Chromium
Nickel
Fluoride
Pollutant Unit Basis
Process
2
Max
Avg3
Max
Avg
Max
Avg
(a) Rolling Spent Neat Oils
ND4
ND
ND
(b) Rolling Spent Emulsions
0.063
0.026
0.094
0.063
10.1
4.49
rolled with emulsions
(e) Rolling Contact Cooling Hater
0.028
0.012
0.042
0.028
4.49
1.99
rolled with water
(d) tube Reducing Spent Lubricants
ND
ND
ND
(e) Drawing Spent Neat Oils
ND
ND
ND
(f) Drawing Spent Emulsions
0.036
0.015
0.053
0.036
5.68
2.52
drawn with emulsions
(g) Extrusion Spent Lubricants
ND
ND
ND
(h) Extrusion Press and Solution Heat
0.031
0.013
0.046
0.031
4.95
2.20
heat treated
Treatment Contact Cooling Hater
(1) Extrusion Press Hydraulic Fluid
0.086
0.034
0.128
0.086
13.8
6.13
extruded
Leakage
(J) Forging Equipment Cleaning
0.002
0.0006
0.002
0.002
0.238
0.106
forged
Wastewater
(k) Forging Contact Cooling Hater
0.018
0.007
0.026
0.018
2.82
1.25
(forged nickel-cobalt)
cooled with water
(1) Forging Press Hydraulic Fluid
0.069
0.028
0.103
0.069
11.2
4.94
forged
Leakage
(¦) Forging Spent Lubricants
ND
ND
ND
(n) Stationary Casting Contact
0.448
0.182
0.666
0.448
72.0
32.0
cast with stationary methods
Cooling Water
methods
(o) Vacuum Melting Steam Condensate
ND
ND
ND
(p) Metal Powder Production
0.970
0.393
1.44
0.970
156
69.2
metal powder atomized
Atomlzatlon Wastewater
(q) Annealing Solution Heat Treat-
ND
ND
ND
ment Contact Cooling Water
(r) Wet Air Pollution Control
0.300
0.122
0.450
0.300
48.2
21.4
formed
Scrubber Blowdown
(s) Surface Treatment Spent Baths
0.346
0.141
0.515
0.346
55.7
24.7
surface treated
(t) Surface Treatment Rinse
0.874
0.354
1.30
0.873
141
62.3
surface treated
(u) Alkaline Cleaning Spent Baths
0.013
0.005
0.019
0.013
2.02
0.895
alkaline cleaned
(v) Alkaline Cleaning Rinse
0,086
0.035
0.128
0.086
13.9
6.15
alkaline cleaned
(w) Molten Salt Rinse
0.312
0.127
0.464
0.312
50.2
22.3
treated with molten salt
{*) Ammonia Rinae
0.006
0.002
0.008
0.006
0.881
0.391
treated with ammonia solution
(y) Sawing/Grinding Spent Emulsions
0.015
0.006
0.022
0.015
2.35
1.04
sawed or ground with emulsions
(z) Sawing/Grinding Rinse
0.067
0.027
0.100
0.067
10.8
4.78
(sawed or ground nickel-cobalt)
rinsed
(aa) Steaa Cleaning Condensate
0.011
0.005
0.017
0.011
1.79
0.795
steam cleaned
(bb) Hydrostatic Tube Testing and
ND
ND
ND
Ultrasonic Testing Wastewater
(cc) Degreasing Spent Solvents
ND
ND
ND
(dd) Dye Penetrant Testing Wastewater
0.079
0.032
0.117
0.079
—
—
tested with dye penetrant methods
(ee) Electrocoating Rinse ,
1.25
0.506
1.86
0.125
201
89.0
electrocoated
(ff) Miscellaneous Wastewater
0.091
0.037
0.136
0.091
14.7
6.50
formed
These standards are expressed In terms of mass of pollutant allowed per mass of product produced (off-kg or off-pound) in a given process.
Off-kilogram or off-pound means the mass of Metal or metal alloy removed from a fording operation at the end of a process cycle for transfer
to a different machine or process.
jMax - Maximum pollutant level for any one day
Avg - Maximum pollutant level for a monthly average of all samples taken
|nd - No discharge of process wastewater pollutants
Miscellaneous Wastewater - wastestreams from maintenance and clean-up
-------
APPENDIX C-ll. PRETREATMENT STANDARDS FOR EXISTING SOURCES (PSES)
NONFERROUS METALS FORMING CATEGORY
SUBPART D - PRECIOUS METALS FORMING SUBCATEGORY
Pollutant Limits in mg/off-kg (pounds/million off-pounds)1 of Precious Metals (40 CFR Part 471)
Cadmium Copper Cyanide Silver Pollutant Unit Basis
Process
2
Max
3
Avg
Max
Avg
Max
Avg
Max
Avg
(a)
Rolling Spent Neat Oils
ND4
ND
ND
ND
(b)
Rolling Spent Emulsions
0.026
0.012
0.147
0.077
0.023
0.010
0.032
0.013
rolled with emulsions
(c)
Drawing Spent Neat Oils
ND
ND
ND
ND
(d)
Drawing Spent Emulsions
0.016
0.007
0.091
0.048
0.014
0.006
0.020
0.008
drawn with emulsions
(e)
Drawing Spent Soap Solutions
0.001
0.0005
0.006
0.003
0.0009
0.0004
0.002
0.0006
drawn with soap solutions
(f)
Metal Powder Production
Atomization Wastewater
2.27
1.00
12.7
6.68
1.94
0.802
2.74
1.14
powder wet atomized
(g)
Heat Treatment Contact
Cooling Water
0.142
0.063
0.793
0.417
0.121
0.050
0.171
0.071
heat treated
(h)
Semi-Continuous and Continuous
Casting Contact Cooling Water
0.350
0.155
1.96
1.03
0.299
0.124
0.423
0.175
cast by semi-continuous or
continuous method
(i)
Stationary Casting Contact
Cooling Water
ND
ND
ND
ND
(j)
Direct Chill Casting Contact
Cooling Water
0.367
0.162
2.05
1.08
0.313
0.130
0.443
0.184
cast by direct chill
method
(k)
Shot Casting Contact
Cooling Water
0.125
0.055
0.698
0.367
0.107
0.044
0.151
0.063
shot cast
(1)
Wet Air Pollution Control
Scrubber Blowdown
ND
ND
ND
ND
(m)
Pressure Bonding Contact
Cooling Water
0.029
0.013
0.159
0.084
0.024
0.010
0.034
0.014
(precious aetals) and base
netal pressure bonded
(n)
Surface Treatment Spent Baths
0.033
0.015
0.183
0.097
0.028
0.012
0.040
0.017
surface treated
(o)
Surface Treatment Rinse
0.210
0.093
1.17
0.616
0.179
0.074
0.253
0.105
surface treated
(P)
Alkaline Cleaning Spent Baths
0.021
0.009
0.114
0.060
0.018
0.007
0.025
0.010
alkaline cleaned
(q)
Alkaline Cleaning Rinse
0.381
0.168
2.13
1.12
0.325
0.135
0.459
0.191
alkaline cleaned
(r)
Alkaline Cleaning Prebonding
0.400
0.174
2.21
1.16
0.337
0.139
0.476
0.197
(precious metals) and base
Wastewater
metal cleaned prior to
bonding
(8)
Tumbling or Burnishing
Wastewater
0.412
0.182
2.300
1.21
0.351
0.145
0.496
0.206
tumbled or burnished
(t)
Sawing/Grinding Spent Neat Oils
ND
ND
ND
ND
(u)
Sawing/Grinding Spent Emulsions
0.032
0.014
0.178
0.094
0.027
0.011
0.038
0.016
sawed or ground with
emulsions
(v)
Degreaslng Spent Solvents
ND
ND
ND
ND
^These standards are expressed in terms of mass of pollutant allowed per mass of product produced (off—kg or off-pound) in a given process.
Off—kilogram or off—pound 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.
.Max " Maximum pollutant level for any one day
^Avg = Maximum pollutant level for a monthly average of all samples taken
ND » No discharge of process wastewater pollutants
-------
APPENDIX C-12. PRETREATMENT STANDARDS FOR HEM SOURCES (PSNS)
NONFERROUS METALS FORMING CATEGORY
SUBPART D - PRECIOUS METALS FORMING SUBCATEGORY
Pollutant Limits In mg/off-kg (pounds/million off-pounds)'" of Precious Metals (40 CFR Part 471)
Cadmium Copper Cyanide Silver Pollutant Unit Basis
Process
Max2
Avg3
Max
Avg
Max
Avg
Max
Avg
(a)
Rolling Spent Neat Oils
ND*
ND
ND
ND
(b)
Rolling Spent Emulsions
0.026
0.012
0.147
0.077
0.023
0.010
0.032
0.013
rolled with emulsions
(c)
Drawing Spent Neat Oils
ND
ND
ND
ND
(d)
Drawing Spent Emulsions
0.016
0.007
0.091
0.048
0.014
0.006
0.020
0.008
drawn with emulsions
(e)
Drawing Spent Soap Solutions
0.001
0.0005
0.006
0.003
0.0009
0.0004
0.002
0.0006
drawn with soap solutions
(f)
Metal Powder Production
2.27
1.00
12.7
6.68
1.94
0.802
2.74
1.14
powder wet atomized
Atomlzatlon Wastewater
(g>
Heat Treatment Contact
0.142
0.063
0.793
0.417
0.121
0.050
0.171
0.071
heat treated
Cooling Hater
(h)
Serai-Con t inuous and Con t inuous
0.350
0.155
1.96
1.03
0.299
0.124
0.423
0.175
cast by semi-continuous or
Casting Contact Cooling Water
continuous method
(i)
Stationary Casting Contact
ND
ND
ND
ND
Cooling Hater
(j)
Direct Chill Casting Contact
0.367
0.162
2.05
1.08
0.313
0.130
0.443
0.184
cast by direct chill
Cooling Hater
method
(k)
Shot Casting Contact
0.125
0.055
0.698
0.367
0.107
0.044
0.151
0.063
shot cast
Cooling Hater
(1)
Het Air Pollution Control
ND
ND
ND
ND
Scrubber Blovdown
(m)
Pressure Bonding Contact
0.029
0.013
0.159
0.084
0.024
0.010
0.034
0.014
(precious metals) and base
Cooling Hater
metal pressure bonded
(n)
Surface Treatment Spent Baths
0.033
0.015
0.183
0.097
0.028
0.012
0.040
0.017
surface treated
(o)
Surface Treatment Rinse
0.210
0.093
1.17
0,616
0.179
0.074
0.253
0.105
surface treated
(P)
Alkaline Cleaning Spent Baths
0.021
0.009
0.114
0.060
0.018
0.007
0.025
0.010
alkaline cleaned
(
Alkaline Cleaning Prebonding
0.400
0.174
2.21
1.16
0.337
0.139
0.476
0.197
(precious metals) and base
Wastewater
metal cleaned prior to
bonding
(s)
Tumbling or Burnishing
0.412
0.182
2.300
1.21
0.351
0.145
0.496
0.206
tumbled or burnished
Wastewater
(t)
Sawing/Grinding Spent Neat Oils
ND
ND
ND
ND
(u)
Saw!ng/Grinding Spent Emulsions
0.032
0.014
0.178
0.094
0.027
0.011
0.038
0.016
sawed or ground with
emulsions
(*)
Degreasing Spent Solvents
ND
ND
ND
ND
*These standards are expressed In terns of mass of pollutant allowed per raasa of product produced (off-kg or off-pound) in a given process.
Off-kilogram or off-pound means the mss of aetal or metal alloy removed from a forming operation at the end of a process cycle for transfer
2to a different machine or process.
.Max ¦* Maximum pollutant level for any one day
^Avg - Maximum pollutant level for a monthly average of all samples taken
ND - No discharge of process wastewater pollutants
-------
APPENDIX C-13. PRETREATMENT STANDARDS FOR EXISTING SOURCES (PSES)
NONFERROUS METALS FORMING CATEGORY
SUBPART E - REFRACTORY METALS FORMING SUBCATEGORY
Pollutant Limits In mg/off-kg (pounds/million off-pounds)'' of Refractory Metals (40 CFR Part 471)
Copper Nickel Fluoride Molybdenum Pollutant Unit Basis
Process
Max2
. 3
Avg
Max
Avg
Max
Avg
Max
Avg
(a)
Rolling Spent Neat Oils
ND4
ND
ND
ND
and Graphite-Based Lubricants
(b)
Rolling Spent Emulsions
0.815
0.429
0.824
0.545
25.5
11.4
2.84
1.47
rolled with emulsions
(c)
Drawing Spent Lubricants
ND
ND
ND
ND
(d)
Extrusion Spent Lubricants
ND
ND
ND
ND
(e)
Extrusion Press Hydraulic
Fluid Leakage
2.26
1.19
2.29
1.51
70.8
31.4
7.87
4.07
extruded
(f)
Forging Spent Lubricants
ND
ND
ND
ND
(8)
Forging Contact Cooling Hater
0.062
0.033
0.062
0.041
1.92
0.853
0.214
0.111
(forged refractory metals)
cooled with water
(h)
Equipment Cleaning Wastewater
0.259
0.136
0.261
0.173
8.09
3.59
0.899
0.465
formed
(i)
Metal Powder Production
Wastewater
0.534
0.281
0.540
0.357
16.7
7.42
1.86
0.961
powder produced
(j)
Metal Powder Production Floor
Wash Wastewater
ND
ND
ND
ND
(k)
Metal Powder Pressing Spent
Lubricants
ND
ND
ND
ND
(1)
Surface Treatment Spent Baths
0.739
0.389
0.747
0.494
23.2
10.3
2.57
1.33
surface treated
(m)
Surface Treatment Rinse
23.0
12.1
23.3
15.4
720
320
80.0
41.4
surface treated
(n)
Alkaline Cleaning Spent Baths
0.635
0.334
0.642
0.424
19.9
8.82
2.21
1.14
alkaline cleaned
(o)
Alkaline Cleaning Rinse
15.5
8.16
15.7
10.4
486.0
216.0
54.0
27.9
alkaline cleaned
(P)
Molten Salt Rinse
1.20
0.633
1.22
0.804
37.7
16.7
4.19
2.17
treated with molten salt
(q)
Tumbling/Burnishing Wastewater
2.38
1.25
2.40
1.59
74.4
33.0
8.27
4.28
tumbled or burnished
(r)
Sawing/Grinding Spent Neat Oils
ND
ND
ND
ND
(s)
Sawing/Grinding Spent Emulsions
0.565
0.297
0.570
0.377
17.7
7.84
1.97
1.02
sawed or ground with
emulsions
(t)
Sawing/Grinding Contact
Cooling Water
4.62
2.43
4.67
3.09
145.0
64.2
16.1
8.31
sawed or ground with
contact cooling water
(u)
Sawing/Grinding Rinse
0.026
0.014
0.026
0.017
0.804
0.357
0.089
0.046
(sawed or ground refractory
metals) rinsed
(v)
Wet Air Pollution Control
Blowdown
1.50
0.787
1.51
1.00
46.9
20.8
5.20
2.69
sawed, ground, surface
coated or surface treated
(w)
Miscellaneous Wastewater Sources
0.656
0.345
0.663
0.438
20.6
9.11
2.28
1.18
formed
(x)
Dye Penetrant Testing Wastewater
0.148
0.078
0.149
0.099
4.62
2.05
0.513
0.266
product tested
(y)
Degreaslng Spent Solvents
ND
ND
ND
ND
These standards are expressed in terms of mass of pollutant allowed per mass of product produced (off-kg or off-pound) in a given process.
Off-kilogram or off-pound 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.
^Max » Maximum pollutant level for any one day
^Avg = Maximum pollutant level for a monthly average of all samples taken
ND - No discharge of process wastewater pollutants
-------
APPENDIX C-14. PRETREATMENT STANDARDS FOR NEW SOURCES (PSNS)
NONFERROUS METALS FORMING CATEGORY
SUBPART E - REFRACTORY METALS FORMING SUBCATEGORY
Pollutant: Limits In mg/off-kg (pounds/million off-pounds)'' of Refractory Metals (40 CFR Part 471)
Copper Nickel Fluoride Molybdenum Pollutant Unit Basis
Process
Max2
Avg3
Max
Avg
Max
Avg
Max
Avg
(a)
Rolling Spent Neat Oils
m1
ND
ND
ND
and Graphite-Based Lubricants
(b)
Rolling Spent Emulsions
0.549
0.262
0.236
0.159
25.5
11.3
2.16
0.957
rolled with emulsions
(c)
Drawing Spent Lubricants
ND
ND
ND
ND
(d)
Extrusion Spent Lubricants
ND
ND
ND
ND
(e)
Extrusion Press Hydraulic
1.53
0.726
0.655
0.441
70.8
31.4
5.99
2.66
extruded
Fluid Leakage
(f)
Forging Spent Lubricants
ND
ND
ND
ND
(g)
Forging Contact Cooling Mater
0.041
0.320
0.018
0.21
1.92
0.853
0.163
0.072
(forged refractory metals)
cooled with water
(h)
Equipment Cleaning Wastewater
0.174
0.063
0.075
0.051
8.09
3.59
0.684
0.303
formed
(1)
Metal Powder Production
0.360
0.172
0.155
0.104
16.7
7.42
1.42
0.627
powder produced
Wastewater
(J)
Metal Powder Production Floor
ND
ND
ND
ND
Wash Wastewater
(k)
Metal Powder Pressing Spent
ND
ND
ND
ND
Lubricants
(1)
Surface Treatment Spent Baths
0.496
0.237
0.214
0.144
23.2
10.3
1.96
0.868
surface treated
(m)
Surface Treatment Rinse
15.5
7.36
6.66
4.48
720
320
60.9
27.0
surface treated
(n)
Alkaline Cleaning Spent Baths
0.428
0.204
0.184
0.124
19.9
8.82
1.68
0.745
alkaline cleaned
(o)
Alkaline Cleaning Rinse
10.5
4.96
4.49
3.02
48.6
216.0
41.1
18.2
alkaline cleaned
(P)
Molten Salt Rinse
0.810
0.386
0.348
0.234
37.7
16.7
3.19
1.41
treated with molten salt
(q)
Tumbling/Burnishing Wastewater
1.60
0.763
0.688
0.463
74.4
33.0
6.29
2.79
tumbled or burnished
(r)
Sawlng/Grlndlng Spent Neat Oils
ND
ND
ND
ND
(a)
Sawlng/Grlndlng Spent Emulsions
0.380
0.181
0.164
0.110
17.7
7.84
1.50
0.663
sawed or ground with
emulsions
(t)
Sawing/Grinding Contact
3.11
1.48
1.34
0.899
145.0
64.2
12.2
5.42
sawed or ground with
Cooling Water
contact cooling water
(u)
Sawlng/Grlndlng Rinse
0.018
0.009
0.008
0.005
0.803
0.357
0.068
0.030
(sawed or ground refractory
metals) rinsed
(v)
Wet Air Pollution Control
1.01
0.480
0.433
0.291
46.8
20.8
3.96
1.76
sawed, ground, surface
Blowdown
coated or surface treated
(w)
Miscellaneous Wastewater Sources
0.442
0.211
0.192
0.128
—
—
1.74
0.770
formed
(x)
Dye Penetrant Testing Wastewater
0.100
0.048
0.043
0.029
4.62
2.05
0.391
0.173
product tested
(y)
Degreaslng Spent Solvents
ND
ND
ND
ND
^These standards are expressed In terms of mass of pollutant allowed per mass of product produced (off-kg or off-
-pound) In a given process.
Off-kilogram or off-pound means the mass of metal or metal alloy removed from a forming operation at the end of a process cycle for transfer
2to a different machine or process•
^Max » Maximum pollutant level for any one day
^Avg " Maximum pollutant level for a monthly average of all samples taken
ND « No discharge of process wastewater pollutants
-------
APPENDIX C-15. PRF.TREATMF.NT STANDARDS FOR EXISTING SOURCES (PSES)
NONFERROUS METALS FORMING CATEGORY
SUBPART F - TITANIUM FORMING SUBCATEGORY
Pollutant Limits In mg/off-kg (pounds/million off-pounds)' of Titanium (40 CFR Part 471)
Cyanide
Lead
Zinc
Ammonia
Fluoride
Pollutant Unit Basis
Process
Max2
Avg3
Max
Avg
Max
Avg
Max
Avg
Max
Avg
(a)
Rolling Spent Neat Oils
ND4
ND
ND
ND
ND
(b)
Rolling Contact Cooling Water
0.142
0.059
0.205
0.098
0.713
0.298
65.1
28.6
29.1
12.9
rolled with contact
cooling water
(c)
Drawing Spent Neat Oils
ND
ND
ND
ND
ND
(d)
Extrusion Spent Neat Oils
ND
ND
ND
ND
ND
(e)
Extrusion Spent Emulsions
0.021
0.009
0.030
0.015
0.105
0.044
9.59
4.22
4.28
1.90
extruded
(f)
Extrusion Press Hydraulic
Fluid Leakage
0.052
0.022
0.75
0.036
0.260
0.109
23.7
10.5
10.6
4.70
extruded
(e)
Forging Spent Lubricants
ND
ND
ND
ND
ND
(h)
Forging Contact Cooling Hater
0.029
0.012
0.042
0.020
0.146
0.061
13.3
5.86
5.95
2.64
(forged titanium) cooled
with water
(i)
Forging Equipment Cleaning
Wastewater
0.012
0.005
0.017
0.008
0.059
0.025
5.33
2.35
2.38
1.06
forged
(J)
Forging Press Hydraulic Fluid
Leakage
0.293
0.121
0.424
0.202
1.48
0.616
135
59.2
60.1
26.7
forged
(k)
Tube Reducing Spent Lubricants
ND
ND
ND
ND
ND
(1)
Heat Treatment Contact Cooling
Water
ND
ND
ND
ND
ND
(m)
Surface Treatment Spent Baths
0.061
0.025
0.088
0.042
0.304
0.127
27.7
12.2
12.4
5.49
surface treated
(n)
Surface Treatment Rinse
0.847
0.351
1.23
0.584
4.27
1.78
389
171
174
77.1
surface treated
(o)
Wet Air Pollution Control
Scrubber Blowdown
0.062
0.026
0.090
0.043
0.313
0.131
28.5
12.6
12.8
5.65
surface treated or
forged
(P)
Alkaline Cleaning Spent Baths
0.070
0.029
0.101
0.048
0.351
0.147
32.0
14.1
14.3
6.34
alkaline cleaned
(q)
Alkaline Cleaning Rinse
0.080
0.033
0.116
0.055
0.403
0.169
36.8
16.2
16.4
7.29
alkaline cleaned
(r)
Molten Salt Rinse
0.277
0.115
0.401
0.191
1.40
0.583
128
56.0
56.8
25.2
treated with molten salt
(s)
Tumbling Wastewater
0.023
0.010
0.033
0.016
0.116
0.048
10.6
4.63
4.70
2.09
tumbled
(t)
Sawing/Grinding Spent Neat Oils
ND
ND
ND
ND
ND
(u)
Sawlng/Grlndlng Spent Emulsions
0.053
0.022
0.077
0.037
0.267
0.112
24.4
10.7
10.9
4.83
sawed or ground with
emulsions
(v)
Sawing/Grinding Contact Cooling
Water
0.138
0.057
0.200
0.095
0.695
0.291
63.5
27.9
28.3
12.6
sawed or ground with
contact cooling water
(w)
Dye Penetrant Testing
Wastewater
0.325
0.135
0.471
0.224
1.64
0.638
149
65.7
66.7
29.6
treated using dye
penetrant method
(x)
Miscellaneous Wastewater Sources
0.010
0.004
0.014
0.007
0.048
0.020
4.32
1.90
1.93
0.858
formed
(y)
Degreasing Spent Solvents
ND
ND
ND
ND
ND
These standards are expressed in terms of mass of pollutant allowed per mass of product produced (off-kg or off-pound) In a given process.
Off-kilogram or off-pound 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.
^Max » Maximum pollutant level for any one day
.Avg = Maximum pollutant level for a monthly average of all samples taken
ND
No discharge of process wastewater pollutants
-------
APPENDIX C-16. PRETREATMENT STANDARDS FOR NEW SOURCES (PSNS)
NONFERROUS METALS FORHING SUBCATEGORY
SUBPART F - TITANIUM FORMING SUBCATEGORY
Pollutant Limits in mg/off-kg (pounds/million off-pounds)'' of Titanium (40 CFR Part 471)
Cyanide
Lead
Zinc
Ammonia
Fluoride
Pollutant Unit Basis
O
t
to
O
Process
Max2
. 3
Avg
Max
Avg
Max
Avg
Max
Avg
Max
Avg
(a)
Rolling Spent Neat Oils
ND«
ND
ND
ND
ND
(b)
Rolling Contact Cooling Hater
0.142
0.059
0.205
0.098
0.713
0.298
65.1
28.6
29.1
12.9
rolled with contact
cooling water
(c)
Drawing Spent Neat Oils
ND
ND
ND
ND
ND
(d)
Extrusion Spent Neat Oils
ND
ND
ND
ND
ND
(e)
Extrusion Spent Emulsions
0.021
0.009
0.030
0.015
0.105
0.044
9.59
4.22
4.28
1.90
extruded
(f)
Extrusion Press Hydraulic
Fluid Leakage
0.052
0.022
0.75
0.036
0.260
0.109
23.7
10.5
10.6
4.70
extruded
(g)
Forging Spent Lubricants
ND
ND
ND
ND
ND
(h)
Forging Contact Cooling Hater
0.029
0.012
0.042
0.020
0.146
0.061
13.3
5.86
5.95
2.64
(forged titanium) cooled
with water
(i)
Forging Equipment Cleaning
Hastewater
0.012
0.005
0.017
0.008
0.059
0.025
5.33
2.35
2.38
1.06
forged
(J)
Forging Press Hydraulic Fluid
Leakage
0.293
0.121
0.424
0.202
1.48
0.616
135
59.2
60.1
26.7
forged
(k)
Tube Reducing Spent Lubricants
ND
ND
ND
ND
ND
(1)
Heat Treatment Contact Cooling
Uater
ND
ND
ND
ND
ND
(m)
Surface Treatment Spent Baths
0.061
0.025
0.088
0.042
0.304
0.127
27.7
12.2
12.4
5.49
surface treated
(n)
Surface Treatment Rinse
0.847
0.351
1.23
0.584
4.27
1.78
389
171
174
77.1
surface treated
(o)
Wet Air Pollution Control
Scrubber Blowdown
0.062
0.026
0.090
0.043
0.313
0.131
28.5
12.6
12.8
5.65
surface Created or
forged
(P)
Alkaline Cleaning Spent Baths
0.070
0.029
0.101
0.048
0.351
0.147
32.0
14.1
14.3
6.34
alkaline cleaned
(q)
Alkaline Cleaning Rinse
0.080
0.033
0.116
0.055
0.403
0.169
36.8
16.2
16.4
7.29
alkaline cleaned
(r)
Molten Salt Rinse
0.277
0.115
0.401
0.191
1.40
0.583
128
56.0
56.8
25.2
treated with molten salt
(s)
Tumbling Wastewater
0.023
0.010
0.033
0.016
0.116
0.048
10.6
4.63
4.70
2.09
tumbled
(t)
Sawing/Grinding Spent Neat Oils
ND
ND
ND
ND
ND
(u)
Sawing/Grinding Spent Emulsions
0.053
0.022
0.077
0.037
0.267
0.112
24.4
10.7
10.9
4.83
sawed or ground with
emulsions
(v)
Sawing/Grinding Contact Cooling
Water
0.138
0.057
0.200
0.095
0.695
0.291
63.5
27.9
28.3
12.6
sawed or ground with
contact cooling water
(w)
Dye Penetrant Testing
Wastewater
0.325
0.135
0.47L
0.224
1.64
0.638
149
65.7
66.7
29.6
treated using dye
penetrant method
(*)
Miscellaneous Wastewater Sources
0.010
0.004
0.014
0.007
0.048
0.020
4.32
1.90
1.93
0.858
formed
(y)
Degreaaing Spent Solvents
ND
ND
ND
ND
ND
These standards are expressed in terms of mass of pollutant allowed per mass of product produced (off-kg or off-pound) in
Off-kllogram or off-pound means the mass of metal or metal alloy removed from a forming operation at the end of a process
2to a different machine or process.
jMax = Maximum pollutant level for any one day
.Avg = Maximum pollutant level for a monthly average of all samples taken
a given process*
cycle for transfer
ND
No discharge of process wastewater pollutants
-------
APPENDIX C-17. PRETREATMENT STANDARDS FOR EXISTING SOURCES (PSES)
NONFERROUS METALS FORMING CATEGORY
SUBPART G - URANIUM FORMING SUBCATEGORY
RESERVED
PRETREATMENT STANDARDS FOR NEW SOURCES (PSNS)
NONFERROUS METALS FORMING CATEGORY
SUBPART G - URANIUM FORMING SUBCATEGORY
Pollutant Limits in mg/off-kg (pounds/million off-pounds)^ of Uranium (AO CFR Part 471)
Cadmium Chromium Copper Lead Nickel Fluoride Molybdenum Pollutant Unit Basis
Process
Max2
Avg
Max
Avg
Max
Avg
Max
Avg
Max
Avg
Max
Avg
Max
Avg
(a)
Extrusion Spent Lubricants
nda
ND
ND
ND
ND
ND
ND
(b)
Extrusion Tool Contact
0.007
0.003
0.013
0.005
0.044
0.021
0.010
0.005
0.019
0.013
2.05
0.908
0.173
0.077
extruded
Cooling Hater
(c)
Heat Treatment Contact
0.006
0.003
0.012
0.005
0.040
0.019
0.009
0.004
0.017
0.012
1.86
0.827
0.158
0.070
(extruded or forged
Cooling Hater
uranium) heat treated
(d)
Forging Spent Lubricants
ND
ND
ND
ND
ND
ND
ND
(e)
Surface Treatment Spent
0.006
0.002
0.010
0.004
0.035
0.017
0.008
0.004
0.015
0.010
1.62
0.718
0.137
0.061
surface treated
Baths
(f)
Surface Treatment Rinse
0.068
0.027
0.125
0.051
0.432
0.206
0.095
0.044
0.186
0.125
20.1
8.90
1.70
0.752
surface treated
(g)
Het Air Pollution Control
0.0007
0.0003
0.001
0.0005
0.005
0.002
0.001
0.0005
0.002
0.001
0.208
0.092
0.018
0.008
surface treated
Scrubber Blowdown
(h)
Sawlng/Grlndlng Spent
0.001
0.0005
0.002
0.0009
0.007
0.004
0.002
0.0008
0.003
0.002
0.338
0.150
0.029
0.013
sawed or ground with
Emulsions
emulsions
(1)
Sawlng/Grlndlng Contact
0.033
0.013
0.061
0.025
0.211
0.101
0.046
0.022
0.091
0.061
9.82
4.36
0.830
0.368
sawed or ground with
Cooling Water
contact cooling water
(J)
Sawlng/Grlndlng Rinse
0.001
0.0004
0.002
0.0007
0.006
0.003
0.002
0.0006
0.003
0.002
0.277
0.123
0.024
0.011
(sawed or ground
titanium) rinsed
(k)
Area Cleaning Rinse
0.009
0.004
0.016
0.007
0.055
0.026
0.012
0.006
0.024
0.016
2.56
1.14
0.216
0.096
formed
(1)
Drum Hashwater
0.009
0.004
0.017
0.007
0.057
0.027
0.013
0.006
0.025
0.017
2.64
1.17
0.223
0.099
formed
(m)
Laundry Hashwater**
5.24
2.10
9.70
3.93 33.6
16.0
7.34
3.41 :
14.4
9.70 1
,560
692. 132.
58.4
**mg/employee day
(n)
Degreaslng Spent Solvents
ND
ND
ND
ND
ND
ND
ND
^These standards are expressed In terms of mass of pollutant allowed per mass of
product
produced (off
-kg or
off-pound) In
a given
process.
Off-kilogram or off-pound 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.
^Max " Maximum pollutant level for any one day
^Avg - Maximum pollutant level for a monthly average of all samples taken
ND ¦ No discharge of process wastewater pollutants
-------
APPENDIX C-18.
PRETREATMENT STANDARDS FOR EXISTING SOURCES (PSBS)
NONFERROUS METALS FORMING CATEGORY
SUBPART H - ZINC FORMING SUBCATEGORY
RESERVED
PRBTREATMENT STANDARDS FOR NEW SOURCES (PSNS)
NONFERROUS METALS FORMING CATEGORY
SUBPART H - ZINC FORMING SUBCATEGORY
Pollutant Units In ag/off-kg (pounds/million off-pounds)* of Zinc (40 CPR Part 471)
Chromium Copper Cyanide Zinc Pollutant Unit Basis
Process
Ma*2
» 3
Avg
Max
Avg
Max
Avg
Max
Avg
(a)
Rolling Spent Neat Oils
4
ND
ND
ND
ND
Alkaline Cleaning Rinse
0.626
0.254
2.17
1.03
0.338
0.134
1.73
0.710
alkaline cleaned
(15
Sawing/Grinding Spent Emulsions
0.009
0.004
0.031
0.015
0.005
0.002
0.025
0.010
sawed or ground with
Elietrocoating Rinse
emulsions
(»)
0.085
0.035
0.293
0.140
0.046
0.019
0.234
0.096
electrocoated
(n)
Degreaslng Spent Solvents
ND
ND
ND
ND
''These standards are expressed In terms
of mass
of
pollutant allowed
per
mass of
product produced (off-kg
or off-
¦pound) in a giv
en process.
Off-ktlogran or off-pound 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.
,Max ~ Maximum pollutant level for any one day
^Avg - Maximum pollutant level for a monthly average of all samples taken
ND = No discharge of process wastewater pollutants
-------
APPENDIX'C-19. PRETREATMENT STANDARDS FOR EXISTING SOURCES (PSES)
NONFERROOS METALS FORMING CATEGORY
SUBPART I - ZIRCONIUM/HAFNIUM FORMING SUBCATEGORY
Pollutant Limits In mg/off-kg (pounds/ml111ton off-pounds)1 of Zirconium-Hafnium (40 CFR Part 471)
Chromium
Cyanide
Nickel
Ammonia
Fluoride
Pollutant Unit Basis
O
I
to
LO
Process
Max2
Avg3
Max
Avg
Max
Avg
Max
Avg
Max
Avg
(a)
Rolling Spent Neat Oils
4
ND
ND
ND
ND
ND
(b)
Drawing Spent Lubricants
ND
ND
ND
ND
ND
(c)
Extrusion Spent Emulsions
ND
ND
ND
ND
ND
(d)
Extrusion Press Hydraulic
Fluid Leakage
0.104
0.043
0.069
0.029
0.455
0.301
31.6
13.9
14.1
6.26
extruded
(e)
Swaging Spent Neat Oils
ND
ND
ND
ND
ND
(f)
Heat Treatment Contact
Cooling Water
0.015
0.006
0.010
0.004
0.066
0.044
4.57
2.01
2.04
0.906
heat treated
(g)
Tube Reducing Spent Lubricants
ND
ND
ND
ND
ND
(10
Surface Treatment Spent Baths
0.150
0.061
0.099
0.041
0.653
0.432
45.3
20.0
20.0
8.98
surface treated
(i)
Surface Treatment Rinse
0.391
0.160
0.258
0.107
1.71
1.13
119
52.1
52.9
23.5
surface treated
(j)
Alkaline Cleaning Spent Baths
0.704
0.288
0.464
0.192
3.07
2.03
214
93.8
95.2
42.3
alkaline cleaned
(k)
Alkaline Cleaning Rinse
1.38
0.565
0.911
0.377
6.03
3.99
419
184
187
82.9
alkaline cleaned
(1)
Sawlng/Grlndlng Spent Emulsions
0.124
0.051
0.082
0.034
0.540
0.357
37.5
16.50
16.7
7.42
sawed or ground with
C
emulsions
(m)
Wet Air Pollution Control
Scrubber Blowdown
NA
NA
NA
NA
NA
(n)
Degreaslng Spent Solvents
ND
ND
ND
ND
ND
(o)
Degreasing Rinse
ND
ND
ND
ND
ND
(P)
Molten Salt Rinse
0.333
0.136
0.220
0.091
1.45
0.960
101
44.3
45
20
treated with molten salt
(q)
Sawlng/Grlndlng Contact
Cooling Water
0.142
0.058
0.093
0.039
0.617
0.408
42.8
18.8
19.1
8.48
sawed or ground with
contact cooling water
(r)
Sawing/Grinding Rinse
0.079
0.033
0.052
0.022
0.346
0.229
24.0
10.6
10.7
4.75
(sawed or ground zirconium
hafnium) rinsed
(s)
Sawlng/Grlndlng Spent
Neat Oils
ND
ND
ND
ND
ND
(t)
Inspection and Testing
0.007
0.003
0.005
0.002
0.030
0.020
2.06
0.903
0.917
0.407
tested
Wastewater
^These standards are expressed In terms of mass of pollutant allowed per mass of product produced (off-kg or off-pound) In a given process.
Off-kilogram or off-pound 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.
^Max ~ Maximum pollutant level for any one day
Avg = Maximum pollutant level for a monthly average of all samples taken
ZND
NA
No discharge of process wastewater pollutants
No allowance for the discharge of process wastewater pollutants
-------
APENDIX C-20. PRETREATMENT STANDARDS FOR NEW SOURCES (PSNS)
NONFERROUS METALS FORMING CATEGORY
SUBPART I - ZIRCONIUM/HAFNIUM FORMING SUBCATEGORY
Pollutant Limit a In ag/kg (pounds/million off-pounds)'' of Zirconium-Hafnium (40 CFR Part 471)
Chromium Cyanide Nickel Ammonia Fluoride Pollutant Unit Basis
Process
Max2
A 3
Avg
Max
Avg
Max
Avg
Max
Avg
Max
Avg
(a)
Rolling Spent Neat Oils
nda
ND
ND
ND
ND
(b)
Drawing Spent Lubricants
ND
ND
ND
ND
ND
(c)
Extrusion Spent Emulsions
ND
ND
ND
ND
ND
(d)
Extrusion Press Hydraulic
Fluid Leakage
0.104
0.043
0.069
0.029
0.455
0.301
31.6
13.9
14.1
6.26
extruded
(e)
Swaging Spent Neat Oils
ND
ND
ND
ND
ND
(f)
Heat Treatment Contact
Cooling Uater
0.015
0.006
0.010
0.004
0.066
0.044
4.57
2.01
2.04
0.906
heat treated
(g)
Tube Reducing Spent Lubricants
ND
ND
ND
ND
ND
(h)
Surface Treatment Spent Baths
0.150
0.061
0.099
0.041
0.653
0.432
45.3
20.0
20.0
8.98
surface treated
(i)
Surface Treatment Rinse
0.391
0.160
0.258
0.107
1.71
1.-13
119
52.1
52.9
23.5
surface treated
(J)
Alkaline Cleaning Spent Baths
0.704
0.288
0.464
0.192
3.07
2.03
214
93.8
95.2
42.3
alkaline cleaned
(k)
Alkaline Cleaning Rinse
1.38
0.565
0.911
0.377
6.03
3.99
419
184
187
82.9
alkaline cleaned
(1)
Sawing/Grinding Spent Emulsions
0.124
0.051
s
0.082
0.034
0.540
0.357
37.5
16.50
16.7
7.42
sawed or ground with
emulsions
(¦)
Uet Air Pollution Control
Scrubber Blowdown
NA
NA
NA
NA
NA
(n)
Degreasing Spent Solvents
ND
ND
ND
ND
ND
(o)
Degreaslng Rinse
ND
ND
ND
ND
ND
(p)
Molten Salt Rinse
0.333
0.136
0.220
0.091
1.45
0.960
101
44.3
45.0
20.0
treated with molten salt
(q)
Sawing/Grinding Contact
Cooling Uater
0.142
0.058
0.093
0.039
0.617
0.408
42.8
18.8
19.1
8.48
sawed or ground with
contact cooling water
(r)
Sawing/Grinding Rinse
0.079
0.033
0.052
0.022
0.346
0.229
24.0
10.6
10.7
4.75
(sawed or ground zirconium
hafnium) rinsed
(s)
Sawing/Grinding Spent
Neat Oils
ND
ND
ND
ND
ND
(t)
Inspection and Testing
Uastewater
. 0.007
0.003
0.005
0.002
0.030
0.020
2.06
0.903
0.917
0.407
tested
These standards are expressed in terms of mass of pollutant allowed per mass of product produced (off-kg or off-pound) In a given process.
Off-kilogram or off-pound 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.
^Max « Maximum pollutant level for any one day
^Avg =* Maximum pollutant level for a monthly average of all samples taken
,-ND - No discharge of process wastewater pollutants
NA " No allowance for the discharge of process wastewater pollutants
-------
APPENDIX C-21. PRETREATMENT STANDARDS FOR EXISTING SOURCES (PSES)
NONFERROUS METALS FORMING CATEGORY
SUBPART J - METAL POWDERS SUBCATEGORY
Pollutant Limits in tug/kg (pounds/million off-pounds)'' of Powder (40 CFR Part 471)
Copper Cyanide Lead Pollutant Unit Basis
2 3
Process Max Avg Max Avg Max Avg
(a)
Metal Powder Production
Atomlzation Wastewater
9.58
5.040
1.46
0.605
2.12
1.01
wet atomized
(b)
Sizing Spent Emulsions
0.028
0.015
ND
0.004
0.002
0.006
0.003
sized
(c)
Oil-Resin Impregnation Wastewater
ND
ND
(d)
Steam Treatment Wet Air Pollution Control
Scrubber Blowdown
1.51
0.792
0.230
0.095
0.333
0.159
metallurgy part steam treated
(e)
Tumbling, Burnishing and Cleaning Wastewater
8.36
4.40
1.28
0.528
1.85
0.880
metallurgy part tumbled,
burnished or cleaned
(f)
Sawing/Grinding Spent Neat Oils
ND
ND
ND
(g)
Sawing/Grinding Spent Emulsions
0.035
0.018
0.005
0.002
0.008
0.004
sawed or ground with emulsions
(h)
Sawing/Grinding Contact Cooling Water
3.08
1.62
0.470
0.195
0.681
0.324
sawed or ground with contact
cooling water
(i)
Hot Press Contact Cooling Water
16.7
8.80
2.55
1.06
3.70
1.76
cooled after pressing
(j)
Mixing Wet Air Pollution Control Scrubber
15.0
7.90
2.29
0.948
3.32
1.58
mixed
0
1
to
Ul
W
l,
Blowdown
Degreasing Spent Solvents
ND
ND
These standards are expressed in terras of mass of pollutant allowed per mass of product produced (off-kg
Off-kilogram or off-pound means the mass of metal or metal alloy removed from a forming operation at the
£to a different machine or process.
jMax » Maximum pollutant level for any one day
^Avg " Maximum pollutant level for a monthly average of all samples taken
ND » No discharge of process wastewater pollutants
ND
or off-pound) In a given process,
end of a process cycle for transfer
-------
APPENDIX C-22. PRETREATMENT STANDARDS FOR NEW SOURCES (PSNS)
HOHFERROUS METALS FORMING CATEGORIC
SUBPART J - METAL POWDERS SUBCATEGORY
Pollutant Limits In og/off-kg (pounds/million off-pounds)1 of Ponder (40 CFR Part 471)
Copper Cyanide Lead Pollutant Unit Basis
Process
Max2
3
Avg
Max
Avg
Max
Avg
(a)
Metal Powder Production
Atomizatlon Wastewater
9.58
5.04
1.46
0.605
2.12
1.01
wet atomized
-------
APPENDIX D
PRETREATHENT COORDINATORS
-------
(MARCH 1989)
APPENDIX D
PRETREATMENT COORDINATORS
U.S. EPA Headquarters and Regional Contacts - 1989
Region
Address
Contact
Phone
1
U.S. Environmental Protection Agency
Region 1
Water Division
Permits Compliance Section
Room 2103
John F. Kennedy Federal Building
Boston, MA 02203
Mr. John (Jack.) Stoecker
Environmental Engineer
Pretreatment Engineer
Ms. Joan Serra
Environmental Engineer
General Regional Information
(617) 565-3492
(617) 565-3490
(617) 565-3400
CM
D-l
U.S. Environmental Protection Agency
Region 2
26 Federal Plaza
Room 845A
New York, NY 10278
Mr. Phil Sweeney
Chief, Permits Management Section
Mr. John S. Kushwara
Pretreatment Compliance Coordinator
General Regional Information
(212) 264-2676
(212) 264-9826
(212) 264-2525
3
U.S. Environmental Protection Agency
; Region 3 , .
841 Ches tnut Building ..¦>
Philadelphia, PA 19107
Mr. John Lovell (3WM-52)
Pretreatment Coordinator
General Regional Information
(215) 597-6279
(215) 597-9800
4
Water Management Division
Facilities Performance Branch
U.S. Environmental Protection Agency
Region 4
345 Courtland Street, N.E.
Atlanta, GA 30365
Mr. Albert Herndon
Chief, Pretreatment (0&M Unit)
General Regional Information
(404) 347-2211
(404) 881-4727
-------
(MARCH 1989)
PRETREATMENT COORDINATORS (Continued)
Region Address
5 U.S. Environmental Protection Agency
Region 5
230 S. Dearborn Street
Chicago, IL 60604
ALL FEDERAL EXPRESS
111 tf. Jackson St.
. 8th Floor
Chicago, IL 60604
Contact
Mr. Dave Rankin (VQP-TUB-8)
Pretreatment Coordinator
Mr. Don Schregardus (VQC-TUB-8) (E)
Section Chief, Enforcement
General Regional Information
Phone
(312) 886-6111
(312) 353-2105
(312) 353-2000
U.S. Environmental Protection Agency
Region 6
1445 Ross Avenue
Dallas, TX 75202
Mr. Lee Bohme (6W-PM)
Regional Pretreatment Coordinator
Mr. Bob Goodfellov (6W-E0)
Enforcement Coordinator
General Regional Information
(214) 655-7175
(214) 655-6470
(214) 767-2600
U.S. Environmental Protection Agency Mr. Lee Duvall (VACM) (913) 236-2817
Region 7 Pretreatment Coordinator
726 Minnesota Avenue
Kansas City, KS 66101 Mr. Paul Marshall (VACM) (913) 236-2817
Environmental Engineer
General Regional Information (913) 236-2800
-------
(MARCH 1989)
PRETREATMENT COORDINATORS (Continued)
Region Address
8 U.S. Environmental Protection Agency
Region 8
1 Denver Place
999 18th Street, Suite 500
Denver, CO 80202-2405
Contact
Hr. Marshall Fischer (8VM-C)
Industrial Pretreatment Program
Cooordinator
Ms. Dana Allen (8WM-C)
Associate Industrial Pretreatment
Program Coordinator
General Regional Information
Phone
(303) 293-1592
(303) 293-1593
(303) 293-1603
U.S. Environmental Protection Agency
Region 9
215 Fremont Street
San Francisco, CA 94105
Mr. Frank Laguna (W-5-2)
Pretreatment Coordinator
Ms. Juliet Hannafin (W-4-1)
Pretreatment Compliance Coordinator
General Regional Information
(415) 974-8268
(415) 974-7271
(415) 974-8071
10
U.S. Environmental Protection Agency
Region 10
Permits Branch
1200 Sixth Avenue
Seattle, WA 98101
Mr. Robert Robichaud (M/S 521)
Pretreatment Coordinator
Mr. Don Dossett (Idaho Compliance)
Ms. Florence Carroll (Alaska Compliance)
(206) 442-1448
General Regional Information
(206) 442-5810
-------
(MARCH 1989)
PRETREATMENT COORDINATORS (Continued)
Headquarters Address
OFFICE OF U.S. Environmental Protection Agency
VATER 401 M Street, S.V.
ENFORCEMENT Washington, DC 20460
AND PERMITS
PERMITS Permits Division
DIVISION U.S. Environmental Protection Agency
401 M Street, S.V.
Washington, DC 20460
Contact Phone
Mr. James R. Elder (EN-335) (202) 475-8488
Director, Office of Water Enforcement
and Permits
Room 220, N.E. Mall
Mr. Rick Brandes (EN-336) (202) 475-9537
Chief
Program Development Branch
Room 214, N.E. Mall
Mr. Gene Chou (EN-336) (202) 382-6960
Environmental Engineer
Technical Support Branch
Room 202, N.E. Mall
Ms. Debra Clovis (202) 475-7052
Attorney
Sludge Task Force Program
Development Branch
Room 2702, Mall
Mr. Paul Connor (EN-336) (202) 475-7718
Attorney - Advisor
Program Development Branch
Room 211, N.E. Mall
Ms. Desiree DiMauro (EN-336) (202) 245-3715
Environmental Protection Specialist
Program Implementation Branch
Room 220
Ms. Cynthia Dougherty (EN-336) (202) 475-9545
Director
Permi ts Division
Room 214, N.E. Mall
-------
(MARCH 1989)
PRETREATMENT COORDINATORS (Continued)
Headquarters Address
PERMITS Permits Division
DIVISION U.S. Environmental Protection Agency
(Continued) 401 H Street, S.V.
Washington, DC 20460
Contact Phone
Mr. Tim Dvyer (EN-336) (202) 475-7056
Environmental Engineer
Technical Support Branch
Room 2840, Mall
Mr. Louis Eby (EN-336) (202) 475-9553
Attorney - Advisor
Program Implementation Branch
Room 2702, Mall
Dr. James Gallup (EN-336) (202) 475-9541
Chief, Technical Support Branch
Room 208, N.E. Mall
Mr. Robert Goo (EN-336) (202) 382-6961
Environmental Protection Specialist
Program Development Branch
Room 202, N.E. Mall
Ms. Marilyn Goode (EN-336) (202) 475-9526
Attorney - Advisor
Program Development Branch
Room 208, N.E. Mall
Mr. Prank Hall (EN-336) (202) 475-9545
Deputy Director
Permits Division
Room 214, N.E. Mall
Mr. John Hopkins (EN-336) (202) 475-9527
Environmental Protection Specialist
Program Implementation Branch
Room 214, N.E. Mall
-------
PRETREATMENT COORDINATORS (Continued)
(MARCH 1989>
Headquarters Address Contact Phone
PERMITS Permits Division Mr. Ephraim King (EN-336) (202) 475-9539
DIVISION U.S. Environmental Protection Agency Chief, Program Implementation Branch
(Continued) 401 M Street, S.ff. Room 211, N.E. Mall
Washington, DC 20460
Ms. Martha Kirkpatrick (EN-336) (202) 475-9529
Project Manager, Sludge Task Force
Program Development Branch
Room 208, N.E. Mall
Mr. Jeffrey Lape (EN-336) (202) 475-9525
Chief, NPDES and Pretreatment
Program Section
Program Implementation Branch
Room 212, N.E. Mall
Ms. Christina Morrison (EN-336) (202) 475-9535
Environmental Engineer
Sludge Task Force
Program Development Branch
Room 208, N.E. Mall
Mr. William Svietlik (EN-336) (202) 382-6284
Environmental Protection Specialist
Program Implementation Branch
Room 202, N.E. Mall
Mr. Jim Taft (EN-336) (202) 475-9536
Chief, Multi-Media Section
Program Development Branch
Room 208, N.E. Mall
Mr. George Utting (EN-336) (202) 475-9533
Attorney
Program Implementation Branch
Room 208, N.E. Mall
-------
(MARCH 1989)
PRETREATHENT COORDINATORS (Continued)
Headquarters
PERMITS
DIVISION
Address
Permits Division
U.S. Environmental Protection Agency
401 M Street, S.W.
Washington, DC 20460
Contact
Mr. Tom Wall (EN-336)
Environmental Scientist
Program Implementation Branch
Room 214, N.E. Mall
Ms. Katharine Wilson (EN-336)
Environmental Protection Specialist
Program Development Branch
Room 2702, Mall
Phone
(202) 475-9515
(202) 475-7050
u
I
ENFORCEMENT Enforcement Division
DIVISION U.S. Environmental Protection Agency
401 M Street, S.W.
Washington, D.C. 20460
Dr. Edward Bender (EN-338)
Biologist
Policy Development Branch
Room 216-F, N.E. Mall
Ms. Karen Gray (EN-338)
Environmental Protection Specialist
Policy Development Branch
Room 216, N.E. Mall
Mr. Andy Hudock (EN-338)
Environmental Engineer
Policy Development Branch
Room 216, N.E. Mall
Mr. William Jordan (EN-338)
Director, Enforcement Division
Room 216, N.E. Mall
Mr. Richard Kinch (EN-338)
Environmental Engineer
Policy Development Branch
Room 216,-N.E. Mall
(202) 475-8331
(202) 382-4373
(202) 382-7745
(202) 475-8304
(202) 475-8319
-------
(MARCH 1989)
PRETREATMENT COORDINATORS (Continued)
Headquarters ' Address
ENFORCEMENT Enforcement Division
DIVISION U.S. Environmental Protection Agency
(Continued)
Contact Phone
Ms. Anne Lassiter (EN-338) (202) 475-8307
Chief, Policy Development Branch
Room 216, N.E. Mall
Ms. Virginia Lathrop (EN-338) (202) 475-8299
Environmental Scientist
Enforcement Support Branch
Room 216, N.E. Mall
Mr. Brian Maas (EN-338) (202) 475-8330
Environmental Engineer
Room 216, N.E. Mall
Mr. Lee Okster (EN-338) (202) 475-9511
a Environmental Engineer
Policy Development Branch
Room 217, N.E. Mall
Mr. Gary Polvi (EN-338) (202) 475-8316
Supervisor, Enforcement Support Branch
Room 216, N.E. Mall
INDUSTRIAL Industrial Technology Division Mr. Thomas P. O'Farrell (VH-552) (202) 382-7120
TECHNOLOGY U.S. Environmental Protection Agency Director, ITD
DIVISION 401 M Street, S.V. Room E911C
Washington, DC 20460
Mr. Ernst P. Hall (VH-552) (202) 382-7126
Chief, Metals Industry Branch
Room E905C
-------
PRETREATHENT COORDINATORS (Continued)
Headquarters Address
INDUSTRIAL Industrial Technology Division
TECHNOLOGY U.S. Environmental Protection Agency
DIVISION 401 M Street, S.V.
(Continued) Washington, DC 20460
Contact Phone
Mr. George H. Jett (VH-552) (202) 382-7151
Project Officer, Metals Forming
Manufacturing
Room E905A
Mr. Marvin Rubin (VH-552) (202) 382-7124
Chief, Chemicals Branch
Room E901C
OFFICE OP Office of General Counsel
GENERAL U.S. Environmental Protection Agency
COUNSEL 401 M Street, S.V.
Washington, DC 20460
o
VO
Ms. Ruth G. Bell (LE-132V) (202) 382-7706
Asst. General Counsel
Office of General Counsel -
Vater Division
Room V503
Mr. Dave Gravallese (LE-132V)
Attorney, Metal Forming Industry
Office of General Counsel
-------
(MARCH 1989)
State
REGION 1
CT
RI
t)
¦
i-*
o
MA
STATE PRETREATHENT CONTACTS
Address
Contact
Phone
CT Department o£ Environmental
Protection Division of Water Compliance
122 Washington Street
Hartford, CT 06106
Rhode Island Department of
Environmental Management
Vater Resources Division
Permits and Planning Section
291 Promenade Street
Providence, RI 02908
MA Department of Environmental
Quality and Engineering
Division of Water Pollution Control
1 Winter Street
Boston, MA 02108
ME Department of Environmental
Protection
21 Vocational Drive
South Portland, ME 04106
Mr. Mike Harder
Assistant Director
Mr. James Grier
Principal Sanitary Engineer
Mr. Simon Mobarek
Principal Sanitary Engineer
Ms. Christine Volkay-Hilditch
Sanitary Engineer
Ms. Eileen Gleber
Senior Environmental Scientist
Ms. Gina Natale-Friedman
Jr. Environmental Engineer
Mr. Joe Dorant
Environmental Engineer
Mr. James Jones
Environmental Specialist
(203) 566-3245
(203) 566-2719
(203) 566-3282
(401) 277-6519
(401) 277-6519
(401) 277-6519
(617) 292-5645
(207) 767-4761
-------
(MARCH 1989)
STATE PRETREATHENT CONTACTS (Continued)
State
Address
Contact
Phone
REGION 1 (Continued)
NH NH Department of Environmental
Services
Water Supply and Pollution Control
Division
P.O. Box 95
Concord, NH 03301
VT Agency of Natural Resources
Department of Environmental Conservation
103 S. Maine Street
Waterbury, VT 05676
Mr. Dan H. Allen
Supervisor, Industrial Pretreatment
Program
Mr. Gary Shokes
Environmental Engineer
(603) 271-2052
(802) 244-5674
REGION 2
NJ
NY
NJ Department of Environmental
Protection
Division of Water Resources
Office of Sludge Management and
Industrial Pretreatment
401 E. State Street (CN-029)
Trenton, NJ 08625
NY State Department of Environmental
Conservation
50 Wolf Road
Albany, NY 12233-0001
Ms. Mary Joe Aiello
Acting Chief - Industrial Pretreatment
Section
Mr. Paul Kurisko
Chief - Bureau Industrial Waste
Management
Mr. Robert Cronin
Chief, Compliance Section
Room 320
Mr. Angus Eaton
Senior Sanitary Engineer
Room 318
(609) 292-4860
(609) 292-4860
(518) 457-3790
(518) 457-6716
-------
(MARCH 1989)
STATE PRETREATMENT CONTACTS (Continued)
State
Address
Contact
Phone
REGION 2 (Continued)
Hr. Robert E. Tovnsend
Senior Sanitary Engineer
Room 320
(518) 457-3790
PR
Puerto Rico Aquieduct and Sewer
Authority
P.O. Box 7066
Barrio Obrero Station
Santurce, PR 00916
Mr. Carl-Axel P. Soderberg
Director, Pretreatment Area
(809) 765-9113
a
I
N)
REGION 3
DC
DE
MD
Water Resources Management
Administration
5010 Overlook Avenue, S.W.
Washington, DC 20032
Dept. o£ Natural Resources and
Environmental Control
Edward Tatnell Building
89 Kings Highway
P.O. Box 1401
Dover, DE 19901
Maryland Department o£ the Environment
Pretreatment Division
State o£ Maryland
2500 Broening Highway
Baltimore, MD 21224
Mr. Jean Levesque
Administrator
Mr. Paul Janiga
Environmental Engineer
Water Resources Section
Mr. Frank Henshaw
Environmental Engineer
Point Source Control Program
Ms. Karen Irons
Chief, Pretreatment and Envorcement
Division
Mr. Gary Kelman
Section Head, Pretreatment Division
(202) 767-7651
(302) 736-5731
(302) 736-3829
(301) 225-6228
(301) 333-7480
-------
(MARCH 1989)
STATE PRETREATHENT CONTACTS (Continued)
State
REGION 3 (Continued)
Address
PA
VA
0
1
W
Bureau of Water Quality Management
Pennsylvania Department of
Environmental Resources
P.O. Box 2063
Harrisburg, PA 17120
VA State Water Control Board
Office of Engineering Application
P.O. Box 11143
2111 N. Hamilton Street
Richmond, VA 23230
Vest Virginia Dept. of Natural
Resources
1201 Greenbrier Street
Charleston, WV 25311
Contact
Mr. Tim Carpenter
Chief, Operation Section
Division of Sewerage and Grants
Mr. Peter Slack.
Chief, Permits Section
Ms. LaVern Corkran
Pretreatment Program Director
Mr. Donald Richvine
Program Manager
Mr. Pravin Sangani
Engineer
Mr. Dave Montali
Engineer
Phone
(717) 787-8184
(717) 787-8184
('804) 367-6313
(804) 367-6389
(304) 348-4086
(304) 348-4086
REGION 4
AL
Alabama Department of Environmental
Management
Water Division
State Office Building
1751 Federal Drive
Montgomery, AL 36130
Mr. John Pool
Chief, Industrial Branch
Mr. Curt Johnson
Environmental Engineer II
(205) 271-7700
(205) 271-7700
-------
(MARCH 1989)
STATE PRETREATMENT CONTACTS (Continued)
State Address Contact Phone
REGION 4 (Continued)
GA Water Quality Control Mr. Alan Hallum (404) 656-7400
Environmental Protection Division Manager Municipal Permitting Program
Georgia Department of Natural Resources
205 Butler Street E. Tower
Atlanta, GA 30334
KY
a
i
FL
MS
NC
Permit Review Branch
Division of Water
Natural Resources and Environmental
Protection Cabinet
18 Reilly Road
Frankfort, KY 40601
Facilities Planning Section
FL Department of Environmental
Regulation
Twin Towers Office Building
2600 Blair Stone Road
Tallahassee, FL 32301
Mississippi Department of Natural
Resources
Bureau of Pollution Control
P.O. Box 10385
Jackson, MS 39209
North Carolina Dept. of Natural
Resources & Community Develop.
P.O. Box 27687
512 North Salisbury Street
Raleigh, NC 27611-7687
Mr. Michael Welch
Pretreatment Coordinator
(502) 564-3410
Noel Jack
(904) 488-8163
Mr. Louis LaVallee
Chief, Pretreatment Section
Mr. William S. Spengler
Assistant Coordinator, Industrial
Wastewater Control Section
Mr. Doug Finan
Supervisor
Pretreatment Unit
Ms. Dana Folley
Environmental Scientist
(601) 961-5171
(601) 961-5171
(919) 733-5083
(919) 733-5083
-------
(MARCH 1989)
STATE PRETREATHENT CONTACTS (Continued)
State
BEGION 4 (Continued)
NC (Continued)
Address
SC
u
i
H-*
TN
South Carolina Department of
Health and Environmental Control
2600 Bull Street
Columbia, SC 29201
Tennessee Dept. of Health and
Environment
150 9th Avenue North
Terra Building, 4th Floor
Nashville, TN 37219-5405
Contact
Ms. Suzanne Hoover
Environmental Scientist
Nr. Nile Testerman
Environmenal Engineer
Mr. Russ Sherer
Domestic Wastewater Division
Mr. Brian Rivers
Pretreatment Coordinator
Mr. Michael Montebello
Section Manager, Municipal Wastewater
Mr. Roger Leemasters
Pretreatment Coordinator
Mr. Robert Slayden
Mr. Scott Crabtree
Phone
(919) 733-5083
(919) 733-5083
(803) 734-5296
(803) 734-5319
(803) 734-5262
(615) 741-0633
(615) 741-0633
(615) 741-0633
REGION 5
IL
Division of Water Pollution Control
Illinois Environmental Protection
Agency
2200 Churchhill Road
Springfield, IL 62706
Mr. Tim Kluge
Supervisor, Permits Section
Candy Morin
Pretreatment Coordinator
(217) 782-0610
-------
(MARCH 1989)
STATE PRETREATMENT CONTACTS (Continued)
State
REGION 5 (Continued)
Address
IN
MI
o
i-1
OH
WI
Indiana Dept. of Environmental
Management
Office of Water Management
105 South Meridian
Indianapolis, IN 46225
Dept. of Natural Resources
P.O. Box 30028
Lansing, MI 48909
Minnesota Pollution Control Agency
Water Quality Division
520 Lafayette Road, North
St. Paul, MN 55155
Ohio Environmental Protection Agency
1800 Watermark Drive
P.O. Box 1049
Columbus, OH 43266-0149
Wisconsin Dept. of Natural Resources
P.O. Box 7921
Madison, WI 53707
Contact
Mr, Phil Preston
Indiana Pretreatment Coordinator
Mr. Paul Blakeslee
Pretreatment Coordinator
Industrial Pretreatment Program
Mr. Randy Dunnette
Pretreatment Coordinator
Mr. John Sadcevicz
Manager, Public Wastewater Section
John Albrecht
Supervisor, Pretreatment Unit
Ms. Heidi Sorin
Group Leader, Compliance and
Enforcement
Mr. Stan Kleinert
Environmental Specialist
Mr. Randy Case
Pretreatment Unit Leader
Phone
(317) 232-8728
(517) 373-4624
(517) 373-4625
(612) 296-8006
(614) 466-3791
(614) 644-2028
(614) 644-2027
(608) 267-7635
(608) 267-7639
-------
STATE PRETREATMENT CONTACTS (Continued)
(MARCH 1989)
State
REGION 6
AR
LA
NM
a
(H1
OK
Address Contact Phone
Arkansas Department of Pollution
Control and Ecology
8001 National Drive
Little Rock, AR 72009
LA Department of Environmental
Quality
Office of Water Resources
P.O. Box 44091
Baton Ruoge, LA 70804-4091
NM Environmental Improvement Division
Surface tfater Quality Bureau
P.O. Box 968
Santa Fe, NM 87504-0968
OK State Department of Health
1000 N.E. 10th Street
Oklahoma City, OK 73152
TX Water Commission
1700 N. Congress
P.O. Box 13087
Capital Station
Austin, TX 78711-3087
Ms. Donna Parks
Pretreatment Coordinator
Enforcement Division
Ms. Barbara Romanowsky
Regulations Unit Coordinator
Ms. Ann Young
Environmental Scientist
Mr. Ted Williamson
Pretreatment Engineer
Ms. Ann McGinley
Chief, Wastewater Permits Section
Mr. Randy Palachek
Environmental Scientist
(501) 562-7444
(504) 342-6363
(505) 827-2796
(405) 271-7335
(512) 463-7788
(512) 463-8420
-------
(MARCH 1989)
STATE PRETREATHENT CONTACTS (Continued)
State
REGION 7
IA
KS
u
i
OQ
MO
Address
lova Department of Natural
Resources
Henry A. Wallace Building
900 East Grand
Des Moines, IA 50319
Kansas Department of Health and
Environment
Water Pollution Control Section
6700 S. Topeka Boulevard
Building 740 - Forbes Field
Topeka, KS 66620
Missouri Dept. of Natural Resources
Division of Environmental Quality
P.O. Box 176
Jefferson City, MO 65101
Contact
Mr. Steve Williams
Environmental Specialist
Wastewater Permits Branch
Mr. Don Carlson
Chief, Industrial Unit
Mr. Steve Casper
Environmental Technician
Mr. Elborn Mendenhall
Chief, Pretreatment Unit
Mr. Richard Kuntz
Environmental Engineer
Phone
(515) 281-8884
(913) 296-1500
(913) 296-5551
(913) 296-5552
(314) 751-6996
NE Nebraska Dept. of Environmental Control Mr. Jay Ringenberg (402) 471-2186
Water Pollution Control Division Environmental Specialist
Box 94877, Statehouse Station
301 Centennial Mall, South Mr. Jim leggy (402) 471-4239
Lincoln, NE 68509 Pretreatment Coordinator
Environmental Specialist
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(MARCH 1989)
STATE PRETREATMENT CONTACTS (Continued)
State
REGION 8
CO
MT
a
VO
SD
UT
WY
Address
Colorado Dept. of Health
Water Quality Control Division
4210 E. 11th Avenue
Denver, CO 80220
Montana Department of Health
Water Quality Bureau
Capitol Station
Helena, MT 59601
North Dakota State Department of Health
1200 Missouri Avenue
Bismarck, ND 58505
SD Department of Water and Natural
Resources
Foss Building, Room 416
Pierre, SD 57501
Utah Department of Health
Division of Environmental Health
Bureau of Water Pollution Control
P.O. Box 16690
Salt Lake City, UT 84116-0690
Wyoming Dept. of Environmental Quality
Hathaway Office Building
122 West 25th Street
Cheyenne, WY 82002
Contact
Mr. Phil Hegeman
Industrial Pretreatment Coordinator
Mr. Fred Shewnan
Sanitary Engineer
Ms. Sheila McClenathen
Permits
Mr. Brad Archibald
Natural Resource Engineer
Mr. Donald Hilden
Environmental Health Specialist
Mr. John Wagner
Technical Supervisor
Water Quality Division
Phone
(303) 331-4564
(406) 444-2406
(701) 224-4578
(605) 773-3351
(801) 538-6146
(307) 777-7781
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(MARCH 1989)
STATE PRETREATHENT CONTACTS (Continued)
State
REGION 9
AZ
CA
e
I
N3
O
HI
NV
Address
AZ Department of Environmental Quality
Office of Water Quality
2655 E. Hagnolia
Phoenix, AZ 85034
CA State Water Resource Control Board
Division of Water Quality
901 P Street
P.O. Box 100
Sacramento, CA 95801
Hawaii State Department of- Health
P.O. Box 3378
Honolulu, HI 96801
Department of Environmental
Protection
201 S. Fall Street
Capi tol Complex
Carson City, NV 89710
Contact
Hr. Charles E. Ohr
Quality Assurance Officer
Mr. Scott McFarland
Water Resources Control Engineer
(Acting Contact)
Mr. Charley Oumi
Chief of NPDES Section
Mr. Joe Livak.
Pretreatment Coordinator
Phone
(602) 392-4003
(916) 323-1033
(808) 548-6410
(702) 885-4670
REGION 10
OR Oregon Department of Environmental Mr. John Harrison (503) 229-5371
Quality Supervisor, Source Control
Executive Building
811 Southwest 6th Avenue
Portland, OR 97204 ,
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(MARCH 1989)
STATE PRETREATMENT CONTACTS (Continued)
State
REGION 10 (Continued)
Address
WA
Washington Department of Ecology
Mail Stop PV-11
Olympia, WA 98504
Contact
Ms. Nancy Winters
Pretreatment Coordinator
General Information
Phone
(206) 438-7036
(206) 459-6000
e
I
ro
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