DEVELOPMENT DOCUMENT               «nf) 3

                                                  for
j                                    EFFLUENT LIMITATIONS  GUIDELINES        CU»:

                                    NEW SOURCE PERFORMANCE STANDARDS

                                                    and

                                         PRETREATMENT STANDARDS

                                                 for the
!
)  :                                    IRON AND STEEL MANUFACTURING
I                                          POINT SOURCE  CATEGORY

                                             Anne M. Gorsuch
                                              Administrator

,s                                             Steven Schatzow
|                                                 Director
1                                Office of Water Regulations and Standards
                                      Jeffery Denit,  Acting Director-
                                       Effluent Guidelines Division

                                           Ernst P. Hall,  P.E.
                                     Chief,  Metals  & Machinery Branch

                                         Edward L. Dulaney, P.E.
                                          Senior Project Officer
                                                May,  1982
                                       Effluent Guidelines Division
                                 Office  of Water Regulations  and Standards
                                   U.S. Environmental Protection Agency
                                          Washington, D.C. 20460
I.

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 I                                         VOLUME  I

 I                                    TABLE OF CONTENTS

 \ .         SECTION                         SUBJECT                        PAGE
 I '',
 I                          PREFACE                                             1

 ! .]        I               CONCLUSIONS        '                                 3

 I .'•        II              INTRODUCTION                                       69

 \ ]                        Legal  Authority                                    69
 I 'I                        Background                                         69
 I 'i                        The  Clean Water Act                                69
 I )                        Prior  EPA Regulations                              71
 I                          Overview of the  Industry                           72
 '                          Summary of EPA Guidelines  Development              79
 ;  •                            Methodology and Overview
 ;  i                        Regulated Pollutants                               82
 ;  I                        Control and Treatment Technology                   84
 :  •'                        Capital and Annual Cost Estimates                  86
 :                          Basis  for Effluent Limitations and Standards      87
-*,                         Suggested Monitoring Program                       88
                           Economic Impact  on the  Industry                   89
                           Energy and Non-water Quality  Impacts              89
\\
 ||          III             REMAND ISSUES  ON  PRIOR REGULATIONS                125

 i                          Introduction                                      125
                           Site  Specific  Costs                               125
 1                          Impact of  Age  on  Costs                           132
                           Consumptive Water Loss                           136

            IV             INDUSTRY SUBCATEGORIZATION                       155

            V              SELECTION  OF REGULATED POLLUTANTS                165

                           Introduction                                      165
                           Development of Regulated Pollutants              165
                           Regulated  Pollutants                             166

            VI             WATER POLLUTION CONTROL AND TREATMENT            177
                           TECHNOLOGY

                           Introduction                                      177
                           End-of-Pipe Treatment                            177
                           In-Piant Treatment and Controls                  214

            VII             DEVELOPMENT OF COST ESTIMATE                     217

                           Introduction                                      217
                           Basis of Cost  Estimates                          217


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 SECTION
VIII
IX
X

XI
XII
XIII

XIV
                VOLUME I

     TABLE OF CONTENTS (Continued)


                  SUBJECT                        PAGE

Assumptions Underlying Capital Recovery          218
     Factors
Calculation of Capital Recovery Factors          219
Basis for Direct Costs                           219
Basis for Indirect Costs                         221
BPT, BAT, NSPS, PSES and PSNS Cost Estimates     222

EFFLUENT QUALITY ATTAINABLE THROUGH TKE          223
APPLICATION OF THE BEST PRACTICABLE CONTROL
TECHNOLOGY CURRENTLY AVAILABLE

Introduction                                     223
Identification of BPT                            224
Development of BPT Limitations                   227

EFFLUENT QUALITY ATTAINABLE THROUGH THE          235
APPLICATION OF THE BEST AVAILABLE TECHNOLOGY
ECONOMICALLY ACHIEVABLE

Introduction                                     235
Development of BAT Effluent Limitations          236

BEST CONVENTIONAL POLLUTANT CONTROL TECHNOLOGY   245

EFFLUENT QUALITY ATTAINABLE THROUGH THE APPLI-   247
CATION OF NEW SOURCE PERFORMANCE STANDARDS

Introduction                                     247
Identification of NSPS                           247
NSPS Costs                                       247

PRETREATMENT STANDARDS FOR PLANTS DISCHARGING    249
TO  PUBLICLY OWNED TREATMENT WORKS
                                                   •
Introduction                                     249
National Pretreatment Standards                  249
Categorical Pretreatment Standards               249

ACKNOWLEDGEMENTS                                 257

REFERENCES                                       259

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f                                       VOLUME I
i
I                            TABLE OF CONTENTS (Continued)
|
I         APPENDIX                        SUBJECT                        PAGE
j           A            STATISTICAL  METHODOLOGY AND  DATA ANALYSIS        273
i
I           B            IRON AND  STEEL  PLANT  INVENTORY                   341
^
I           C            SUBCATEGORY  SUMMARIES                           389
I           D            STEEL  INDUSTRY  WASTEWATER  POLLUTANTS            547
                                          m

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                               VOLUME I
                                TABLES
NUMBER                          TITLE                          PAGE
1-1            BPT Concentration and Flow Summary                 13
1-2            BPT Effluent Limitations Comparison                18
1-3            BAT Concentration and Flow Summary                 27
1-4            BAT Effluent Limitations Summary                   31
1-5            PSNS/NSPS Concentration and Flow                   34
                    Summary
1-6            PSNS/NSPS Summary                                  40       |
1-7            PSES Concentration and Flow                        46       j
                    Summary                                               j
1-8            PSES Summary                                       51
1-9            BCT Concentration and Flow Summary                 55
1-10           BCT Effluent Limitations Summary                   59
1-11           Effluent Load Summary - Direct                     63
                    and Indirect Dischargers
1-12           Effluent Load Summary - Direct                     64
                    Dischargers
1-13           Effluent Load Summary - Indirect                   66
                    Dischargers
1-14           Cost Summary                                       67
1-15           Control and Treatment Technology                   68
                    Summary
II-l           Standard Industrial  Classification                 91
                    Listing
I1-2           Subcategory Inventory                              97
II-3           Summary of Sampled Plants                         100
I1-4           Data Base Summary                                 109
I1-5           Revised Iron and Steel Subcategories             110
                                                  Preceding page blank
                                                                          i,

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                                                    n
     VOLUME I
TABLES (Continued)
NUMBER
II-6
II-7
II-8
III- 1
III-2
III-3
III-4
III-5
III-6
III-7
V- 1
V-2
V-3
V-4
VI-1
VIII-1
IX-1
TITLE
Cross Reference of Subcateforization Scheme
Solid Waste Generation. Due to Water
Pollution Control
Energy Requirements Due to Water
Pollution Control
Capital Cost Comparison - Youngstown
Sheet and Tube
Capital Cost Comparison - U.S. Steel
Corporation
Capital Cost Comparison - Republic Steel
Corporation
Age of Plants in the Steel Industry -
By Subcategory
Examples of Plants with Retrofitted
Treatment
Water Usage Summary - Iron and Steel
Industry
Water Consumption Summary
Development of Regulated Pollutant
List
Development of Regulated Pollutant
List - By Subcategory
Regulated Pollutant List - Iron and Steel
Industry
Regulated Pollutant List - By Subcategory
Toxic Organic Concentrations Achievable
By Treatment
BPT Cost Summary
BAT Cost Summary
PAGE
113
116
118
142
143
144
145
147
152
153
167
171
173
174
216
230
242
       VI

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 NUMBER
IX-2

XII-1

XII-2
A-l
A-2 to
A-5
A-6 to
A-8
A-9 to
A-50
A-51
                VOLUME I
           TABLES (Continued)

                  TITLE
Advanced Treatment Systems Considered
     for BAT
List of Plants with Indirect Discharges
     to POTW Systems
Pretreatment Cost Summary
Key to Long-Term Data Summaries
Long-Term Data Analysis - Filtration
     Systems
Long-Term Data Analysis - Clarification/
     Sedimentation Systems
Long-Term Data Analysis - By Plant
Standard Deviation of the  30-Day Averages
PAGE
243

251

253
280
281

287

291

336
                                vn

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                               VOLUME I
                               FIGURES
 NUMBER

II-l

II-2

II-3

VIII-1
A-1 to
A-4
                 TITLE
Product Flow Diagram - Steelaaking
     Segment
Product Flow Diagram - Steel Forming
     Segment
Product Flow Diagram - Steel Finishing
     Segment
Potential Means to Achieve BPT Effluent
     Limitations
Long-Term Data Plots
PAGE

121

122

123

233

337
                                 ix
                                                 Preceding page blank

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                              VOLUME I
                              PREFACE
            conains   «   n   i»     -  or
                                      v.   -
                                                 performance
(NSPS).
This  Development  Document  "ighlights the technical
^?yaiSnrtretneinfnI^ry,Thihile0lUtSe  regaining  volu.es contain
specific subcategory reports.

The Agency's •con-lc^^^.^jSEJli'S? Effluent
separate  document entitled Economic. ^tYdp- ^nt  is  available  from
                          iii£^aluS?on?0pS-!20, US.PA. Washington,
D.C.,  20460.

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                                            VOLUME I

                                           SECTION I

                                          CONCLUSIONS
             1.   Total  process  water  usage  in  the  steel  industry  is  about
                  5,740,000,000  (5740 MGD) gallons per day.  The untreated process
                  wastewaters contain  about  43,600  tons/year  of  toxic  organic
                  pollutants,  121,900 tons/year of toxic inorganic pollutants, and
                  14,500,000  tons/year   of   conventional   and   nonconventional
                  pollutants.   Steel industry process wastewaters are treatable by
                  currently  available,  practicable  and  economically  achievable
                  control and treatment technologies.

             2.   The Regulation contains limitations  and  standards  for  process
                  wastewaters    generated    in   the   different   subcategories,
                  subdivisions and segments of the industry.  The subcategorization
                  is based primarily upon differences in  wastewater  quantity  and
                  quality   related   to   differences  in  industry  manufacturing
                  processes.  The Agency has adopted a revised subcategorization of
                  the  industry  from  that  used  in  prior  regulations  to  more
                  accurately  effect production operations in the industry, and, to
                  simplify the use of the regulation.  The subcategorization of the
                  industry  in  this  fashion  does  not  affect  the   substantive
                  requirements of the regulation.  The Regulation applies to the 12
                  subcategories  of  the  steel  industry,  their subdivisions, and
                  segments as shown below:
             Subpart/Subcategory

             A.  Cokemaking



             B.  Sintering

             C.  Ironmaking



             D.  Steelmaking
   Subdivision

By-Product

Beehive
Iron Blast Furnace
Ferromanganese
Blast Furnace

Basic Oxygen Furnace
   Segment

Iron and Steel
Merchant
                                        Open Hearth Furnace

                                        Electric Arc Furnace
Semi-Wet
Wet-Suppressed
  Combustion
Wet-Open
  Combustion

Wet

Semi-Wet
L
                                                                 Preceding page blank

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                                                            Wet
      E.  Vacuum Degassing

      F.  Continuous Casting

      G.  Hot Forming
Primary
                                 Section


                                 Flat
                                 Pipe & Tube Mills

      H.  Salt Bath Descaling    Oxidizing
      I.  Acid Pickling
                                 Reducing
Sulfuric Acid
                                 Hydrochloric Acid
                                 Combination Acid
Carbon and
  Specialty Mills
  without Scarfers
Carbon and
  Specialty Mills
  with Scarfers

Carbon Mills
Specialty Mills

Hot Strip and
  Sheet Mills
Carbon Plate Mills
Specialty Plate
  Mills
Batch: Sheet, Plate
Batch: Rod, Wire, Bar
Batch: Pipe, Tube
Continuous

Batch  .
Continuous

Rod, Wire, Coil
Bar, Billet, Bloom
Strip, Sheet, Plate
Pipe, Tube, Other
Fume Scrubber

Rod, Wire, Coil
Strip, Sheet, Plate
Pipe, Tube, Other
Fume Scrubber
Acid Regeneration

Rod, Wire, Coil
Bar, Billet, Bloom
Strip, Sheet, Plate-
  Continuous
Strip, Sheet, Plate-
  Batch
Pipe, Tube, Other
Fume Scrubber
i.  :

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           J.   Cold Forming
Cold Rolling
           K.   Alkaline Cleaning
           L.   Hot Coating
                                      Cold Worked Pipe & Tube
Batch
Continuous

Galvanizing, Terne
 and Other Metal
 Coatings
                                     Fume Scrubbers
Recirculation:
  Single Stand
  Multi-Stand
Combination
Direct Application:
  Single-Stand
  Multi-Stand

  Water Solutions
  Oil Solutions
Strip, Sheet, and
  Miscellaneous
  Products
Wire Products
  and Fasteners
                Best Practicable Control Technology Currently Available (BFT)

                For the most part, the BPT limitations for the basic  steelmaking
                operations   (cokemaking,   sintering,  ironmaking,   steelmaking,
                vacuum degassing, and continuous casting) are the same  as  those
                contained  in the prior regulations and those proposed in January
                1981,  (46 FR 1858).  Where the  BPT  limitations  for  the  basic
                steelmaking  operations  are  different  than those proposed, the
                changes are the result of the Agency's evaluation and response to
                comments received  during  the  public  comment  period  for  the
                proposed regulation.   The major changes are summarized below:

                A.    Cokemaking

                     The total  suspended  solids  limitations  were  relaxed  to
                     reflect  actual   operations  of biological treatment systems
                     used to treat cokemaking wastewaters.  Separate  limitations
                     are promulgated  for merchant cokemaking operations.
                B.    Sintering

                     The limitations were  relaxed  to  reflect
                     treatment system effluent flow rate.

                C.    Ironmaking

                     None

                D.    Steelmaking
                           a  higher  model
L

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     The limitations for the EOF wet-open combustion and  EAF-Wet
     segments  were  relaxed  to  reflect  higher model treatment
     system  effluent  flow  rates.   The  Open  Hearth  semi-wet
     segment was deleted.

E.   Vacuum Degassing

     None

F.   Continuous lasting

     None

Many  of  the  BPT  effluent  limitations  for  the  forming  and
finishing  operations (hot forming, descaling, cold rolling, acid
pickling, alkaline cleaning, and hot coating) were changed.  Some
of the final limitations are more stringent than  those  proposed
and  some  are  less stringent.  These changes result partly from
revised segmentation and subdivision of certain subcategories and
partly from the Agency's re-assessment of its existing data  base
and additional data received during the public comment period for
the  proposed  regulation.   In  all  cases,  however,  the basic
technologies underlying the BPT. limitations  have  remained  the
same.  The model treatment system flow rates and effluent quality
were  changed  to  reflect  actual,  flows in the industry and the
performance of properly designed and operated treatment  systems.
In  all cases, the Agency believes the changes made have resulted
in  more  appropriate,  technically  sound  limitations.    These
changes are summarized below:

G.   Hot Forming

     The model treatment system flow rates and  effluent  quality
     were  revised  to  reflect  actual  performance of the model
     treatment systems.

H.   Salt Bath Descaling

     The subcategory was resegmented to provide more  appropriate
     rinsewater  flows  by  product  and  by  type  of operation.
     Limitations were promulgated for suspended solids, chromium,
     nickel, and pH.

I.   Acid Pickling

     The subcategory was resegmented to provide more  appropriate
     rinsewater   flows   by   product.    Separate   daily  mass
     limitations were promulgated  for  fume  scrubbers  and  for
     regeneration  system absorber vent scrubbers.  Lead and zinc
     are limited for  sulfuric  and  hydrochloric  acid  pickling
     operations   and   chromium   and  nickel  are  limited  for
     combination acid pickling operations.

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              J.   Cold Forming

                   Separate   limitations  were  promulgated  for  single  stand
                   recirculation  and  direct  application  cold rolling mills.
                   Lead and   zinc  are  limited   for   cold  rolling  operations
                   processing carbon steels and chromium and nickel are limited
                   for  cold   rolling  operations processing specialty steels.
                   Limitations for  naphthalene   and   tetrachloroethylene  are
                   provided   for  all  cold  rolling   operations.  There are no
                   changes to the BPT limitations for  cold worked pipe and tube
                   operations.

              K.   Alkaline Cleaning

                   The  limitations  were  relaxed to reflect  higher   model
                   treatment  system effluent flow rates.

              L.   Hot Coating

                   Separate daily mass limitations were promulgated  for  fume
                   scrubbers.   Limitations  were promulgated for lead and zinc
                   for all hot coating operations.   Chromium  limitations  are
                   promulgated for  those hot coating operations with chromate
                   rinse operations.

 |             The model treatment system flow rates and effluent  quality  used
 i             to  develop  the BPT  limitations   are   presented  in Table 1-1.
 I             Comparisons of  the BPT limitations  contained in prior regulations
 I             with the promulgated BPT limitations are presented in Table 1-2.

 f        4.   Best Available  Technology Economically Achievable  (BAT)

 I    '         The BAT limitations for  the  basic steelmaking  operations  are
 1             generally  based upon  the  same   treatment  technologies as the
 j             proposed limitations.  However, in  several cases, the limitations
 |             were changed based upon comments and data received as a result of
 $             the public  comment  period.   In   some   cases,  different  model
 I             treatment technologies were used to develop the limitations.  The
 I             more significant changes are summarized  below:
 &
 I             A.   Cokemaking

|                  The limitations for ammonia-N,  cyanide, and  phenols  (4AAP)
|                  were  relaxed  to  a  minor  extent based  upon a review of
                   extensive  data for the model treatment system.   Only  daily
                   maximum    limitations   for    benzene,  benzo(a)pyrene,  and
                   naphthalene are  promulgated.   Separate  limitations   are
                   promulgated for merchant cokemaking operations.

              B.   Sintering

                   The model  treatment system effluent flow rate was relaxed to
                   reflect achievable wastewater  recycle  rates  for  sintering

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     operations  with  wet  air  pollution control systems on all
     parts  of  the  process.   The  selected   model   treatment
     technology    is   filtration   as   opposed   to   alkaline
     chlorination.  However,  limitations  for  ammonia-N,  total
     cyanide,  and  phenols  (4AAP)  were  promulgated  for those
     sintering  operations  with  wastewaters   co-treated   with
     ironmaking wastewaters.

C.   Ironmaking

     The ammonia-N limitation was significantly relaxed  to  take
     into  account  full  scale  operation  of the selected model
     treatment technology.

D.   Steelmaking

     The model treatment system was changed by deleting the final
     effluent  filter   and   the   limitations   were   adjusted
     accordingly.   Only  limitations  for  lead  and  zinc  were
    •promulgated.  Limitations for chromium were proposed.

E.,F. Vacuum Degassing, Continuous Casting

     The model treatment systems were changed from filtration  to
     lime precipitation and sedimentation to address treatment of
     dissolved  toxic  metals.   The  promulgated limitations for
     lead and zinc are  consistent  with  those  for  Steelmaking
     operations.

G.   Hot Forming

     BAT  limitations  are  not  promulgated  for   hot   forming
     operations.   The  Agency  has determined that the BPT model
     treatment  system  provides  sufficient  control  of   toxic
     metals.
H.,I.,J. Salt Bath  Descaling, Acid Pickling, Cold Forming

     BAT limitations more  stringent  than  the  promulgated  BPT
     limitations   were   not  promulgated  for  descaling,  acid
     pickling, and cold forming operations.

K.   Alkaline Cleaning

     None

L.   Hot Coating

     For those operations with fume  scrubbers,  BAT  limitations
     based  upon recycle of fume scrubber wastewaters and the BPT
     model  treatment  system  were   promulgated.    For   those

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                  operations  without  fume  scrubbers,  BAT   limitations more
                  stringent than  the  respective  BPT  limitations  were  not
                  promulgated.

             The  model  treatment  system  effluent  flow  rates and effluent
             quality used to develop the  BAT  limitations  are  presented   in
|             Table  1-3.  The BAT limitations are presented  in  Table  1-4.

         5.   -New Source Performance Standards  (NSPS)

             In all cases, the promulgated NSPS are based upon the same  basic
             technologies  used  to  develop   the BPT and BAT  limitations.   In
j             several instances, NSPS more stringent than  the  respective  BPT
I             and  BAT  limitations  were promulgated based  upon more stringent
i             model  treatment system discharge  flow rates demonstrated  in  the
«             industry.  The development of NSPS is set out  in  each subcategory
f             report.   The  model  treatment   system  effluent flow rates and
{             effluent quality used to develop  NSPS are presented in  Table 1-5.
f             The NSPS are presented in Table 1-6.
i
'         6.   Pretreatment Standards (PSES and  PSNS)

}             The promulgated pretreatment standards are designed  to minimize
;             pass   through  of toxic pollutants discharged  to  POTWs  from steel
i             industry  operations.   Except  for  cokemaking   operations,  the
I             promulgated  PSES  and  PSNS  are' the same as the respective BAT
j             limitations and NSPS.  For cokemaking operations, PSES  and  PSNS
;             are  based  upon  the same pretreatment the industry provides for
             on-site biological  treatment  of  cokemaking  wastewaters.   The
5             model  treatment  system  effluent  flow  rates   and the effluent
i             quality used to develop the PSES  are presented in Table 1-7.  The
             PSES are presented in Table 1-8.  The same information  for  PSNS
t             and the PSNS are presented in Tables 1-5 and 1-6, respectively.

         7.   Best Conventional Technology {BCT)

I             As a result of the remand of the  Agency's BCT  costing methodology
I             in API vs EPA [660 F.2d 954  (4th  Cir.  1981)]   the  Agency  has
(             reserved  BCT  limitations in those subcategories where the model
y             BAT treatment technologies  provide  for  conventional  pollutant
i             removal  beyond  that  provided   by  the  model   BPT technologies
i'             (sintering, ironmaking, steelmaking, vacuum degassing,  continuous
:             casting).   For  the  remaining   subcategories,   the  Agency  has
'.             promulgated  BCT  limitations that are the same as the  respective
;             BPT limitations.
                                                                          *
             The model treatment system flow rates and effluent  quality  used
             to  develop  the BCT limitations  are presented in Table 1-9.  The
             BCT limitations are presented in  Table 1-10.

         8.   The  Agency  concludes  that  the  effluent  reduction   benefits
             associated  with  compliance  with  the regulation will result  in
             significant removals ot toxic, conventional and other pollutants.

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     Table 1-11  presents a summary of the effluent reduction  benefits
     associated with this regulation on an industry-wide basis.  Table
     1-12   and   1-13  present  summaries  for  direct  and  indirect
     dischargers,  respectively.

     The  Agency  concludes  that  the  effluent  reduction   benefits
     associated  with  compliance  with  both  existing and new source
     limitations and standards outweigh the minor adverse  energy  and
     non-water quality environmental impacts.

9.    The Agency estimates that based  upon  production  and  treatment
     facilities  in  place as of July 1, 1981, the industry will incur
     the following costs to comply with the  regulation.   The  Agency
     has  determined  that  the effluent reduction benefits associated
     with compliance with the limitations and standards  outweigh  the
     costs of compliance.

               Costs (Millions of July 1, 1979 Dollars)
              	Capital Costs	Total
              Total     In-place     Required     Annual

     BPT
     EAT
     PSES

     TOTAL     1971      1647 -         324         259

     Table  1-14  presents these costs by subcategory.  The Agency has
     also determined that the effluent reduction  benefits  associated
     with  compliance  with  new source standards (NSPS, PSNS) justify
     the associated costs.

     The industry production  capacity  profile  used  in  this  study
     differs  slightly  from  that used in the preparation of Economic
     Analysis of Proposed Effluent Guidelines -  Integrated  Iron  and
     Steel  Industry  which  reviews  in detail the potential economic
     impact of this regulation.  The capacity  profile  used  in  that
     analysis  is  based  upon  information  obtained  from  AISI  and
     includes predictions of future  retirements,  modernization,  and
     reworks  over  the  next  ten  years,  whereas  this  development
     document has focused on the industry as it  now  exists  and  the
     extent to which pollution control technologies are demonstrated.


10.  With respect to the general issues remanded by the United  States
     Court of Appeals for the Third Circuit, the Agency concluded:

     a.    The "age" of facilities has no  significant  impact  on  the
          "cost  or  feasibility  of retrofitting" pollution controls.
          First, "age" is a relatively meaningless term in  the  steel
          industry.   It is extremely difficult to define because many
          plants are continually rebuilt and modernized.
                                 10

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     Whether "first year of  production"  or  "years  since  last
     rebuild"  is  taken  as  an indicia of plant "age", the data
     show  that  "age"  has  no   significant   impact   on   the
     "feasibility"  of  retrofitting.   Many "old" facilities are
     served  by  modern  and  efficient   retrofitted   treatment
     systems.   With  regard  to the impact of plant "age" on the
     cost of retrofitting, most respondents to EPA questionnaires
     were  unable  to  estimate  "retrofit"  costs,   reported  no
     retrofit  costs,  or reported retrofit costs of less than 5%
     of pollution control costs.  The Agency compared  its  model
     based  cost estimates with actual industry costs for over 90
     installed  treatment  facilities,   many   of   which   were
     retrofitted  to  older  production  facilities.   The Agency
     found that the model based cost estimates  are  sufficiently
     generous  to  account  for  retrofit costs at both older and
     newer  plants.   Also,  detailed  engineering  studies   and
     industry  cost estimates for three of the "oldest" plants in
     the country produced cost estimates similar to  EPA's  model
     plant estimates.

     The Agency found that both old and newer facilities generate
     similar  raw  wastewater  pollutant loadings; that pollution
     control facilities can be and have been retrofitted to  both
     old  and  newer  production  facilities  without substantial
     retrofit costs; that these pollution control facilities  can
     and  are  achieving  the  same  effluent  quality; and, that
     further subcategorization  or  further  segmentation  within
     each subcategory on the basis of age is not appropriate.

     However,  even  assuming  that  plant  "age" does affect the
     "cost or feasibility of  retrofitting,"  EPA  believes  that
     separate   subcategorization   or  relaxed  limitations  for
     "older" plants are not justifiable.   "Older"  plants  cause
     similar  pollution  problems as "newer" plants, and the need
     to control these problems would justify the  expenditure  of
     reasonable,  if any, additional "retrofit" costs.  Therefore
     the regulation does  not  differentiate  between  "old"  and
     "new" facilities.

b.   The Agency's cost estimates  are  sufficiently  generous  to
     reflect  all costs to be incurred when installing wastewater
     treatment systems,  including  "site-specific  costs".   The
     Agency's  cost  models  now  include  several "site-specific
     cost" items not included in prior cost models (See  Sections
     III   and   VII)   and   incorporate   several  conservative
     assumptions.  As noted above, the Agency also  compared  its
     model plant cost estimates with actual costs reported by the
     industry including "site-specific costs."  Finally, detailed
     plant-by-plant   engineering   estimates   (cost   estimates
     provided by the industry) for eight plants reveal  estimated
     costs  (including  "site-specific  costs")  similar to EPA's
     model plant cost estimates.
                           ll
                                                                      I '


                                                                 -•-_»*-iSai

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              c.   The BPT and BAT limitations and the PSES, PSNS, and NSPS  in
                   seven  subcategories  are based upon model treatment systems
                   including  recycle  systems  and  mechanical  draft  cooling
                   towers.   The  installation  of  these systems may result in
                   evaporative water losses of  about  4.2  MGD  above  current
                   losses  (16.0  MGD).  However, the environmental benefits of
                   these treatment systems justify the  additional  evaporative
                   water  losses.   Recycle and cooling systems are extensively
                   used at steel plants in water-scarce areas  and  the  Agency
                   concludes  that the incremental impacts of the regulation on
                   these plants is either minimal or nonexistent.

         11.  Table 1-15 presents a  summary,  by  subcategory,  of  the  water
              pollution  control  and  treatment technologies considered by the
              Agency in developing the limitations and standards.


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-------
'  1
                                                             TABLE  1-9

                                                 BCT CONCENTRATION AND FLOW SUMMARY
                                                       IRON & STEEL INDUSTRY
Subcategory
Cokemaking
Iron & Steel-Biological

Iron & Steel-Physical Chemical

Merchant-Biological

Merchant-Physical Chemical

Beehive

Sintering

Ironmaking
Iron

Ferromanganese

Steelmaking
BOF: Semi-vet

BOF: Wet-Open Combustion

BOF: Wet-Suppressed Combustion

Open Hearth: Wet

Electric Arc Furnace! Semi-vet

Electric Arc Furnace: Wet

Vacuum Degassing

Continuous Casting

Hot Forming
Primary: Carbon * Spec, v/o Scarfers

Primary: Carbon 4 Spec. v/Scarfers

Section: Carbon

Section: Specialty



Avg
Max
Avg
Max
Avg
Max
Avg
Max
Avg
Max
Avg
Max

Avg
Max
Avg
Max

Avg
Max
Avg
Max
Avg
Max
Avg
Max
Avg
Max
Avg
Max
Avg
Max
Avg
Max

Avg
Max
Avg
Max
Avg
Max
Avg
Max
Discharge
Flow (CPT)

225

175

240

190

BPT

Reserved


Reserved

Reserved


BPT

Reserved

Reserved

Reserved

BPT

Reserved

Reserved

Reserved


897

1326

2142

1344

BCT
Cone
TSS

140
270
179
346
».40
270
177
341



























15
40
15
40
15
40
15
40
Effluent
. (mg/l)
O&G

11.6
34.8
14.9
44.8
11.6
34.8
14.6
43.9



























-
10
-
10
-
10
-
10
                                                            55

-------
TABLE 1-9
BCT CONCENTRATION AND FLOW SOMHAtT
IRON 4 STEEL INDUSTRY
PACE 2
Subcateeory
Hot Forcing
Flat: Hot Strip 4 Sh**t (Car boa 4 Spec.)

Flat: Plate-Carbon

Flat: Plate-Specialty

Pip* i Tub*

Salt Bath Dctcaling
Oxidizing: Batch, Sheet 4 Plat*

Oxidising: Batch, Rod 4 Wire

Oxidizing: Batch, Pip* 4 Tub*

Oxirtiiingi Continuous

Reducing: Batch

Reducing: Continuous

Sulfuric Acid Pickling
Rod, Uir* 4 Coil

Bar, Billet i Bloo*

Strip, Sheet 4 Plat*

Pip*, Tub* 4 Other
FUM Scrubber*2*

Hydrochloric Acid Pickling
Rod, Wire 4 Coil

Strip, Sheet 4 Plata

Pipe, Tube 4 Other
(j)
FUM Scrubber



Avg
Max
Avg
Max
Avg
Max
Avg
Max

Avg
Max
Avg
Max
Avg
Max
Avg

Avg
Max
Avg
Max

Avg
Max
Avg
Max
Avg
Max
Avg
Max
Avg
Max

Avg
Max
Avg
Max
Avg
Max
Avg
Max
Diacharg*
Flo* (CPT)

2560

1360

600

1270


700

420

1700

330

325

1820


280

90

180

500
IS CPM


490

280

1020

15 CPM

BCT Effluent
Cone. (BC/!>
TSS

15
40
15
40
15
40
15
40

30
70
30
70
30
70
30
70
30
70
30
70

30
70
30
70
30
70
30
70
30
70

30
70
30
70
30
70
30
70
04C

-
1C
-
10
-
10
-
10

-
—
-
—
-
—
-
-
-
_
-
_

10: *|
30)j(
ioj* J
30
lof *J
30
l°m
30
10 '
I* 1 \
30(1)

IV
30
100>
30 *'
io;jj
30J}J
10.. .
30° >
                                         56

-------
TAtlZ I-«
BCT COHCEKTRATIO* AHD FLOW SUMMARY
IBiffl 4 STEEL INDUSTRY
PACE 3




1
BCT Effluent

Subcategory
Hydrochloric Acid Pickling
Acid Regeneration

Combination Acid Pickling
Bod, Wire 4 Coil

Bar, Billet 4 Bloom

Continuous! Strip, Sheet 4 Plat*

Batcbt Strip, Sheet 4 Plat*

Pip*, Tub* 4 Other

Pume Scrubbed 2)

Cold forming
Cold Rolling: Reeir. -Single Stand

Cold Boilings Recir. -Multi Stand

Cold Rolling! Combination

Cold Rolling! Direct Appl. -Single Stand

Cold Rolling! Direct Appl. -Multi Stand

Pip* 4 Tub*

Alkaline Cleaning
Batch

Continuous

Hot Coating-Call coating operation*)
Strip, Sheet 4 Misc. wo/Scrubber*

Wire 4 Fastener* wo/Scrubbers
/ •% \
Pume Scrubbers^'




Avg
Max

Avg
Max
Avg
Max
Avg
Max
Avg
Max
Avg
MJX
Avg
Max

Avg
Max
Avg
Max
Avg
Max
Avg
Max
Avg
Max
Avg
Max

Avg
Max
Avg
Max

Avg
Max
Avg
Max
Avg
Max
Discharge
Plo« (CPT)

100 CPM


510

230

1500

460

770

15 CPM


5

25

300

90

400

BPT


250

350


600

2400

100 CPM

Cone.
TSS

30
70

30
70
30
70
30
70
30
70
30
7f)
/ V
30
70

30
60
30
60
30
60
30
60
30
60



30
70
30
70

30
70
30
70
30
70
(ms/1)
04C
1
1 1 \ «
10 m
30(1)
* .
/ t \ J
10 f . » i
30 , ^
*o/{\
30 \ i
10
30
I0(l)
30
'°f \\
1A
10(l)
*w* * »
30(1)

10
25
10
25
10
25
10
25 i
10
25


{
10 !
30
10
30

10
30
10
30
10
30
                                      57

-------
TABLE 1-9
BCT COHCEOTRATIOH AMD FLOW SUMMARY
IRON & STEEL INDUSTRY
PACE 4	       	
Holt I  pH it tiro regulated in all subcategories and  is  lisuted  to  6.0  to  9.0  standard
       units.

(1) This pollutant •pplict only wh«n lh<(« w**ce* art tr««ted  in combination with  cold
    rolling mill uatia*.
(2) The fvwe icrubber allowance shall b« applied to each  fuo*  scrubber  associated  with
    a pickling or hot coating operation.
                                        58
                                                                                     .i JL._ .  :=,---r- r-

-------
           TABLE 1-10

BCT F.FFLUE8T LIMITATIONS SUMMARY
      IRON  &  STEEL  INDUSTRY
BCT Effluent
Discharge Limitations (kg/kkg)
Subcalesorv
Cokemaking
Iron & Steel-Biological

Iron & Steel-Physical Chemical

Merchant-Biological

Merchant-Physical Cheaical

Beehive

Sintering

Ironmaking
Iron

Ferromanganese

Steelmaking
EOF: Semi -wet

BOF: Wet-Open Combustion

BOF: Wet-Suppressed Combustion

Open Hearth: W«t

Electric Arc Furnace: Seoi-Wet

Electric Arc Furnace: Wet

Vacuum Degassing

Continuous Casting



Avg
Max
Avg
Max
Avg
Max
Avg
Max
Avg
Max
Avg
Max

Avg
Max
Avg
Max

Avg
Max
Avg
Max
Avg
Max
Avg
Max
Avg
Max
Avg
Max
Avg
Max
Avg
Max
Flow (CPT) TSS

225 0.131
0.253
175 0.131
0.253
240 0.140
0.270
190 0.140
0.270
BPT

Reserved


Reserved

Reserved


BPT

Reserved

Reserved

Reserved

BPT

Reserved

Reserved

Reserved

OAG

0.0109
0.0327
0.0109
0.0327
0.0116
0.0348
0.0116
0.0348



























-------
r
                   TABLE 1-10
                   BCT EFFLrENT LIMITATIONS SUMMARY
                   IRON & STEEL INDUSTRY
                   PACE 2
Subcategory
HoC Forming
Primary: Carbon & Spec, via Scarfera

Primary: Carbon & Spec. w/Scarfers

Section: Carbon

Section: Specialty

Flat: Hot Strip & Sheet (Carbon & Spec.)

Flat: Plate-Ccrbon

Flat: Plate-Specialty

Pipe & Tube

Salt Bath Descaling
Oxidizing: Batch, Sheet & Plate

Oxidizing: Batch, Rod & Wire

Oxidizing: Batch, Pipe & Tube

Oxidizing: Continuous

Reducing: Batch

Reducing: Continuous

Sult'uric Acid Pickling
Rod, Wire & Coil

Bar, Billet & Bloom

Strip, Sheet & Plate

Pipe, Tube & Other

BCT Effluent
Discharge Limitations (kg/kkg)
Flow (CPT) TSS OiC

Avg
Max
Avg
Max
Avg
Max
Avg
Max
Avg
Max
Avg
Max
Avg.
Max
Avg
Max

Avg
Max
Avg
Max
Avg
Max
Avg
Mix
Avg
Max
Avg
Max

Avg
Max
Avg
Max
Avg
Max
Avg
Max

897

1326

2142

1344

2560

1360

600

1270


700

420

1700

330

325

1820


280

90

180

500


0.0561
0.150
0.0830
0.221
0.134
0.357
0.0841
0.224
0.160
0.427
0.0851
0.227
0.0375
0.100
0.0795
0.212

0.0876
0.204
0.0526
0.123
0.213
0.496
0.0413
0.0964
0.0407
0.0949
0.228
0.532

0.0350
0.0818
0.0113
0.0263
0.0225
0.0526
-0.0626
0.146

-
0.0374
-
0.0553
-
0.0894
-
0.0561
-
0.107
-
0.0567
-
0.0250
-
0.0530

-
—
-
—
-
—
-
-
-
-
-
-
t \\
o.om;;(
0.03501;;
0.00375J,
o.om1;;
0.0075lJJ;
0.0225;!'
0.0209;*;
0.0626tu
                                                           60

-------
                    TABLE I-10
                    BCT EFFLUENT LIMITATIONS SUMMARY
                    IRON & STEEL INDUSTRY
                    PAGE 3	
                                                                                       BCT Effluent
Subcategory
Sulfuric Acid Pickling
Fume Scrubber

Hydrochloric Acid Pickling
Rod Wire & Coil

Strip, Sheet & Plate

Pipe, Tube & Other
(2)
Fume Scrubber

*Acid Regeneration

Combination Acid Pickling
Rod Wire & Coil
Bar, Billet & Bloom
Continuous-Strip, Sheet & Plate

Batch-Strip, Sheet & Plate

Pipe, Tube & Other
Fume Scrubber (2)

Cold Forming
Cold Rolling: Recirc. -Single Stand

Cold Rolling: Recirc. -Multi Stand

Cold Rolling: Combination

Cold Rolling: Direct Appl. -Single Stand



Avg
Max

Avg
Max
Avg

Avg
Max
Avg
Max
Avg
Max
Avg
Max
Avg
Max
Avg
Max
Avg
Max
Avg
Max
Avg
Max

Avg
Max
Avg
Max
Avg
Max
Avg
Max
Discharge
Flow (GPT)

15 GPM


490

280

1020

15 GPM

100 GPM

510

230
1500

460

770
15 GPM


5

25

300

90

Limitations (kg/kkg)
TSS O&G

2.45
5.72

0.0613
0.143
0.0350
0.0818
0.128
0.298
2.45
5.72
16.3
36.1
0.0638
0.149
0.0288
0.0672
0.188
0.438
0.0576
0.134
0.0964
0.225
2.45
5.72

0.000626
0.00125
0.00313
0.00626
0.0375
0.0751
0.0113
0.0225

0.819 :
2.45(1)
/ 1 \
0.0204,}'
0.0613
0.0117$}}
0.0350;}'
0.0426}}'
0.128(J'
0.0819;1'
2.45;1'
5.45
2.45U)

0.000209
0.000522
0.00104
0.00261
0.0125
0.0313
0.00375
0.00939
                                                         61
L.

-------
TABLE 10
BCT EFFLUENT LIMITATIONS SUIWARY
IRON & STEEL INDUSTRY
PACT 4            	
	Subcategory	

Cold Forming Cont.
   Cold Rolling:  Direct Appl.-Multi Stand

   Pipe & Tube

Alkaline Cleaning.
   Batch

   Continuous

Rot Coating-includes all coating operitions
   Strip, Sheet & Misc. wo/ScrubUers

   Wire & Fasteners wo/Scrubbers

   Fume Scrubbers<2)
                                                                       BCT Effluent



Max
Avg
Max
Avg
Max
Avg
Max
Avg
Max
Avg
Max
Avg
Max
Discharge
Flow (GPT)
400

BPT

250

350

600

2400

100 CPM

Limitations
TSS
0.0501
0.100


0.0313
0.0730
0.0438
0.102
0.0751
0.175
0.300
0.701
16.3
38.1
(kg/kkg )
O&G
0.0167
0.0417


0.0104
0.0313
0.0146
0.0438
0.0250
0.0751
0.100
0.300
5.45
16.3
Note:  pH is also regulated in all subcategories and is limited to 6.0 to 9.0 standard
       units.

(1) This load applies only when these wastes are treated in combination with cold rolling
    ni'l wastes.
(2) The fuae scrubber allowauce shall be applied to each fine scrubber associated with a
    pickling or hot coating operation.
    Load is expressed in kg/day x 10
                                          62

-------
                                   EFFLUENT LOAD SUHHARY
                              DIRECT AND INDIRECT DISCHARGERS
Effluent Loadings (tons/year)

A.

B.

C.

D.

B.

F.

6.

H.

I.

J.

K.

L.

Subcatecory
Cokemaking

Sintering

Ironmaking

Steelmaking

Vacuum Degassing

Continuous Catting

Hot Forming

Salt Bath Descaling

Acid Pickling

Cold Forming

Alkaline Cleaning

Rot Coating

Totals


Treatment
Level
Raw
BAT/PSES
Raw
BAT/PSES
Raw
BAT/PSES
Raw
BAT/PSES
Raw
BAT/PSES
Raw
BAT/PSES
Raw
BPT/PSES
Raw
BPT/PSES
Raw
BPT/PSES
Raw
BPT/PSES
Raw
BPT
Raw
BAT/PSES
Raw
Treated
Discharge
Flow (KGD)
32
27
99
7
864
17
273
20
55
0
233
1
3,974
1,543
1
1
86
69
76
28
17
17
30
23
5,744
1,758
.5
.5
.2
.7
.0
.2
.3
.5
.4
.9
.2
.1
.4
.2
.1
.1
.7
.1
.5
.3
.5
.5
.4
.9
.2
.0
Toxic
Organic* (1)
23,200
704
78
6
19,948
5
12
1
_
-
_
-
_
-
-
-
_
-
?65
4
1
1
_
—
43,606
722
.8
.8
.8
.0
.2
.4
.3
.2










.0
.3
.2
.2


.3
.6
Toxic
Metals
128
35
317
5
34,935
12
22,220
32
667
1
575
2
52,964
123
191
0
7,438
56
332
21
6
5
2,098
12
121,875
308
.8
.0
.5
.1
.5
.0
.4
.5
.0
.3
.4
.2
.9
.1
.2
.9
.4
.5
.0
.7
.7
.3
.1
.8
.9
.4
Other
67
5
960

2,546
1
1,231
1
5

30

6,510
19


358
2
2,792



4

14,507
34
,088
,974
,420
462
,149
,260
,042
,300
,488
33
,193
45
,673
,852
503
26
,422
,955
,058
945
425
492
,992
755
,453
,099
(1) Includes total cyanide and phenolic compounds (4AAP).
                                           63
                                                                                                      ^M--iiMJS

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                                         TABLE 1-12

                                   EFFLUENT LOAD SUMMARY
                        IRON ANC STEEL INDUSTRY - DIRECT DISCHARGES
Subcategory

A. Cokenaking



B. Sintering



C. Ironmaking



D. Steelmaking



E. Vacuum Degassing



F. Continuous Casting



C. Hot Forcing



H. Salt Bath Descaling



I. Acid Pickling



J. Cold Forming

Treataent
Level
Raw
BPT
BAT-1
Raw
BPT
BAT-1
Raw
BPT
BAT-4
Raw
BPT (2)
BAT-2 VZ;
Raw
BPT
BAT-2
Raw
BPT
BAT-2
Raw
B"(3)
BATV '
Raw
B"(3)
BAT1 '
Raw
BVT(3)
BATIJ'
Raw
BPT,-.
BAT

Discharge
Flow (MOD)
25.1
33.3
22.7
93.4
7.2
7.2
825.6
29.2
16.4
252.1
18.9
18.9
55.4
0.9
0.9
199.9
4.4
0.9
3,679.9
1,418.5
1,418.5
1.0
1.0
1.0
72.5
58.4
58.4
73.3
28.1
26.1
Effluent
Toxic fn
Organ ics '
17,922.0
416.1
120.3
74.1
5.7
5.7
19,061.6
287.8
5.1
11.3
1.1
1.1
-
-
-
_
-
-
_
-
_
-
—
_
-
-
356.9
4.1
4.1
Loadings (Tons /Year)
Toxic
Metals
99.5
35.4
24.2
298.8
14.0
4.8
33,382.8
77.1
11.4
20,887.2
116.0
29.7
667.0
8.4
1.3
493.2
10.8
1.7
49,460.4
113.9
. 113.9
161.2
0.8
0.8
6,384.5
48.4
48.4
320.6
21.4
21.4
Others
51,824
8,200
3,042
903,925
844
433
2,432,967
6,548
1,199
1,138,622
2,250
1,202
5,488
55
33
25,880
33J
35
6,052,741
18,159
18,159
432
22
22
306,145
2,524
2,524
2,787,508
939
939
                                        64

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TABLE 1-12
EFFLUENT LOAD SUMMARY
IRON AMD STEEL INDUSTRY - DIRECT DISCHARGES
PAGE 2        	
Subcategory

K. Alkaline Cleaning



L. Hot Coating



Total*
                         Treatment
                           Level
Rav
BPT
BAT
(4)
Rav
BPT
BAT-1
                         Ra«
                         BPT
                         BAT
  (5)
Discharge
Flov (MOD)

12.4
12.4
12.4

22.9
22.8
18.3

5,313.5
1,635.1
1,603.7
                            Effluent  Loadings  (Toot/Year)
                          Toxic   ,,i    Toxic
Organics

0.9
0.9
0.9
                          37,426.8
                          715.7
                          137.2
                                  (1)
Metals

4.8
3.4
3.4

1,829.3
12.2
9.8

113,989.3
461.8
270.8
Others

302
369
369

4,082
724
580

13,709,936
40,967
28,537
(1) Includes total cyanide and phenolic compounds (4AAP).
(2) BPT for seai-vet steelaaking operation*.
(3) BAT is being promulgated at a level equal to HPT in this subcategory.
(4) BAT is not being promulgated in this aubcategory.
(5) BAT is being proBulgated only for those operation* with fine scrubber*.

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                                        TABLE 1-13

                                  EFFLUENT LOAD SUMMARY
                      IROH AND STEEL IHDUSTT.Y - IKDIRECT DISCHARGES
Effluent Loading! (Tons/Year)
Subcategory
A. Cokeaaking
B.
C.
P.
E.
F.
C.
B.
I.
J.
K.
L.
Sintering
Ironaaking
Ste* lacking
Vacuum Degassing
Continuous C«*ting
Hot Forming
Salt Bath Descaling
Acid Pickling
Cold Forming
Alkaline Cleaning
Hot Coating
Total
Treatment
Level
Raw
PSES-1
Raw
PSES-2
Raw
PSES-5
**" (2)
PSES-3 U'
Raw
PSES-3
Raw
PSES-3
**" (3)
PSES^3'
Raw
PSEb-KBPT)
Raw
PSES-1 (BPT)
**" (4)
PSES-l(BPT)
**" (3)
PSES13'
*** (5)
PSES-213'
Raw
PSES
Oiicharge Toxic ...
Flow (MOD) Organic*"'
7.4
4.8
5.8
0.5
38.4
0.8
21.2
1.6
*
*
33.3
0.2
294.5
12'».7
0.1
0.1
16.2
10.7
3.2
0.2
5.1
5.1
7.5
5.6
430.7
154.3
5,278.8
584.5
4.7
0.3
886.6
0.3
1.0
0.1
*
*
-
-
-
-
8.1
0.2
0.3
0.3
-
6,179.5
585.4
Toxic
Metal*
29.3
10.8
18.7
0.3
1,552.7
0.6
1,333.2
2.8
*
*
82.2
O.S
3,504.5
9.2
30.0
0.1
1,053.9
8.1
11.4
0.3
1.9
1.9
268. 8
3.0
7,886.6
37.6
Other*
15,264
2,932
56, '495
29
113,162
61
92,420
98
*
*
4,313
10
457,932
1,693
71
4
52,277
431
4,550
6
123
123
910
175
797,517
5,562
*There are no indirect discharger* in thil Subcategory.
(1) Include* total cyanide and phenolic compound* (4AAP).
(2) PSES-1 for *emi-vet iteelouking operation*.
(3) Only general pretreatmen: standard* are being promulgated in this (ubcategory.
(4) Only general pretreataent standard* are being promulgated for cold worked
    pipe and tube operations using water.
(5) PSES-1 for those operation* without fume scrubber*.
                                      66

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-------
                               VOLUME I

                              SECTION II

                             INTRODUCTION
I.   Legal Authority

     The regulation which this Development Document supports has  been
     promulgated  by  the Agency under authority of Sections 301, 304,
     306, 307 and 501 of  the  Clean  Water  Act  (the  Federal  Water
     Pollution  Control  Act  Amendments  of 1972, 33 U.S.C «$ 1251 et
     seq., as amended by the Clean Water Act of 1977, P.L. 95-217)(the
     *Act").   This regulation has also been promulgated in response to
     the "Settlement Agreement" in Natural Resources Defense  Council,
     Inc., et al. v Train, 8 ERC 2120 (D.D.C~!  1976), modified. 12 ERC
     1833 (D.D.C. 1979).

II.  Background

A.   The Clean Water Act

     The Federal  Water  Pollution  Control  Act  Amendments  of  1972
     established  a comprehensive program to "restore and maintain the
     chemical, physical, and  biological  integrity  of  the  Nation's
     waters,"  Section  101(a).   By July 1, 1977, existing industrial
     dischargers  were  required  to  achieve  "effluent   limitations
     requiring   the  application  of  the  best  practicable  control
     technology currently available" (BPT), Section 301(b)(1)(A); and,
     by July 1, 1983,  these  dischargers  were  required  to  achieve
     "effluent  limitations  requiring  the  application  of  the best
     available technology economically achievable...which will  result
     in  reasonable  further  progress  toward  the  national  goal of
     eliminating the  discharge  of  all  pollutants"  (BAT),  Section
     301(b)(2)(A).   New industrial direct dischargers were required to
     comply  with  Section 306 new source performance standards (NSPS)
     based upon best available demonstrated technology;  and  new  and
     existing  dischargers  to  publicly owned treatment works (POTWs)
     were subject to pretreatment standards under Sections 307(b)  and
     (c)  of   the  Act.  While the requirements for direct dischargers
     were  to  be  incorporated  into  National  Poilutant   Discharge
     Elimination  System  (NPDES)  permits issued ur.der Section 402 of
     the Act, pretreatment standards were  made  enforceable  directly
     against  dischargers to POTWs (indirect dischargers).

     Although Section 402(a)(l) of the 1972 Act authorized the setting
     of  requirements  for direct dischargers on a case-by-case basis,
     Congress intended that,  for the most part,  control  requirements
     would  be based upon regulations promulgated by the Administrator
     of EPA.   Section 304(b)  of the Act required the Administrator  to
     promulgate   regulations   providing   guidelines   for  effluent

-------
limitations  setting  forth  the  degree  of  effluent  reduction
attainable  through  the  application  Of BPT and 3AT.  Moreover,
Sections 304(c) and 306  of  the  Act  required  promulgation  of
regulations  for  NSPS,  and  Sections 304(f), 307(b), and 307(c)
required promulgation of regulations for pretreatment  standards.
In   addition   to  these  regulations  for  designated  industry
categories, Section 307(a) of the Act required the  Administrator
to promulgate effluent standards applicable to all dischargers of
toxic  pollutants.  Finally, Section 50Ua) of the Act authorized
the  Administrator  to  prescribe  any   additional   regulations
"necessary to carry out his functions" under the Act.

The  Agency was unable to promulgate many of these regulations by
the dates contained in the Act.  In 1976, the Agency was sued  by
several  environmental groups, and in settlement of this lawsuit,
the Agency and the plaintiffs executed a  "Settlement  Agreement"
which  was  approved  by  the Court.  This Agreement required the
Agency to  develop  a  program  and  adhere  to  a  schedule  for
promulgating  BAT  effluent  limitations guidelines, pretreatment
standards, and new source performance standards for 65 "priority"
pollutants and classes of pollutants  for  21  major  industries.
See  Natural Resources Defense Council^ Inc. v. Train, 8 ERC 2120
(D.D.C. 1976), as modified 12 ERC 1833 (D.D.C. 1979).

On December 27, 1977, the President signed  into  law  the  Clean
Watfr  Ace  of 1977.  This law make» several important changes in
the Federal water pollution control program including several  of
the  basic elements of the Settlement Agreement program for toxic
pollution control.  Sections 301(b)(2)(A) and 301(b)(2)(C) of the
Act now require the achievement  by  July  1,  1984  of  effluent
limitations  requiring application of BAT for "toxic" pollutants,
including the 65 "priority" pollutants and classes of  pollutants
whirh  Congress declared "toxic" under Section 307(a) of the Act.
Likewise,   the  Agency's  programs  for  new  source  performance
standards and pretreatment standards are now aimed principally at
toxic  pollutant  controls.   Moreover,   to strengthen the toxics
control  program,  Section  304(e)  of  the  Act  authorizes  the
Administrator  to prescribe "best management practices" (BMPs) to
prevent the release of toxic and hazardous pollutants from  plant
site  runoff,  spillage  or  leaks, sludge or waste disposal, and
drainage from raw material storage associated with, or  ancillary
to, the manufacturing or treatment process.

In keeping with its emphasis on toxic pollutants, the Clean Water
Act  of  1977  also  revises  the  control  program  for nontoxic
pollutants.  . Instead  of  BAT  for   "conventional"   pollutants
identified  under Section 304(a)(4) (including biochemical oxygen
demand, oil and grease, suspended solids, fecal coliform and pH),
the new Section 301(b)(2)(E)  requires  achievement  by  July  1,
1984,  of  "effluent limitations requiring the application of the
best  conventional  pollutant  control  technology"  (BCT).   The
factors  considered  in assessing BCT for an industry include the
costs of attaining a reduction  in  effluents  and  the  effluent
                           7 )

-------
     reduction  benefits  derived  compared  to the costs and effluent
     reduction benefits from the discharge of publicly owned treatment
     works  (Section  304(b;<4)(B)).    For  nontoxic,  nonconventional
     pollutants,   Sections   301(b)(2)(A)   and   (b)(2)(F)   require
     achievement of BAT effluent limitations within three years  after
     their  establishment or July 1,  1984, whichever is later, but not
     later than July 1, 1987,

     This regulation includes effluent limitations for  »PT,  BAT  and
     BCT,   performahce   standards   for   new  sources  (NSPS),  and
     pretreatment standards for new and  existing  sources  (PSNS  and
     PSES)  which  were promulgated under Sections 301,304,306,307 and
     501 of the Clean Water Act.

B.   Prior EPA Regulations

     On June 28, 1974, EPA promulgated effluent  limitations  for  BPT
     and  BAT,  new  source  performance  standards,  and pretreatment
     standards for new sources for basic steelmaking operations  (Phase
     I) of the integrated steel industry, 39 FR  24114-24133,  40  CFR
     Part 420, Subparts A-L.  That regulation covered 12 subcategories
     of  the  industry:   By-Product  Cokemaking,  Beehive Cokemaking,
     Sintering, Blast Furnace (Iron),  Blast Furnace  (Ferromanganese),
     Basic  Oxygen  Furnace  (Semi-Wet Air Pollution Control Methods),
     Basic Oxygen Furnace (Wet Air Pollution  Control  Methods),  Open
     Hearth,  Electric  Arc  Furnace  (Semi-Wet  Air Pollution Control
     Methods),  Electric  Arc  Furnace  (Wet  Air  Pollution   Control
     Methods),  Vacuum  Degassing, and Continuous Casting and Pressure
     Slab Molding.

     In response to several petitions for review,  the  United  States
     Court  of  Appeals for the Third Circuit remanded that regulation
     on November 7, 1975,  American I_ron and Steel Insti tute, et al A  y_
     EPA, 526 F.2d 1027 (3rd Cir. 1975)".   While the Court rejected all
     technical challenges to the BPT limitations, it held that the BAT
     effluent limitations and NSPS for certain subcategories were "not
     demonstrated."   In  addition,  the  court  questioned the entire
     regulation on  the  grounds  that  EPA  had  failed  to  consider
     adequately  the impact of plant age on the cost or feasibility of
     retrofitting pollution controls,  had failed to assess the   impact
     of  the  regulations  on  water  scarcity  in  arid and semi-arid
     regions  of  the  country,  and  had  failed  to  make   adequate
     "net/gross"  provisions  for  pollutants  found  in  intake water
     supplles.*
*The court also held that the "form" of the regulations was  improper,
because they did not provide "ranges" of limitations to be selected by
permit  issuers.  This holding,  however, wa? recalled in American Iron
and Steel Institute, et al.  v EPA,  (3d Cir.1977).

-------
     On March 29, 1976, EPA promulgated BPT effluent  limitations  and
     proposed  BAT  limitations, NSPS standards and PSNS standards for
     steel forming and finishing  operations  (Phase  II)  within  the
     steel industry, 39 FR 12990-13030, 40 CFR Part 420, Subparts M-Z.
     That  regulation  covered  14 subcategories of the industry:  Hot
     Forming- Primary; Hot Forming-Section; Hot Forming-Flat;  Pipe  &
     Tube;      Pickling-Sulfuric     Acid-Batch     fc     Continuous;
     Pickling-Hydrochloric Acid-Batch & Continuous; Cold Rolling;  Hot
     Coating-Galvanizing;     Hot     Coatings-Terne;    Miscellaneous
     Runoffs-Storage Piles, Casting, and  Slagging;  Combination  Acid
     Pickling-Batch  and Continuous; Scale Removal-Kolene and Hydride;
     Wire Pickling and Coating, and Continuous Alkaline Cleaning.

     The U.S. Court of Appeals for the  Third  Circuit  remanded  that
     regulation  on  September  14,  1977,  American  Iron  and  Steel
     Institute, et al. v EPA, 568 F.2d 284 (3d Cir. 1977).  While  the
     court   again  rejected  all  technical  challenges  to  the  BPT
     limitations, it again questioned the regulation in regard to  the
     age/retrofit  and  water scarcity issues.  In addition, the court
     invalidated the regulation for  lack  of  proper  notice  to  the
     specialty steel industry, and directed EPA to reevaluate its cost
     estimates  in light of "site-specific costs" and to reexamine its
     economic impact analysis.2

     On January 28, 1981 the Agency promulgated  General  Pretreatment
     Regulations  applicable  to existing and new indirect dischargers
     within the steel industry and other major industries, 46 FR  9404
     et seq, 40 CFR Part 403.  See also 47 FR 4518 (February 1, 1982).

C.   Overview of the Industry

     The manufacture of steel involves many  processes  which  require
     large  quantities  of  raw  materials ancJ other resources.  Steel
     facilities range from comparatively small plants engaging in  one
     or  more  production  processes  to  extremely  large  integrated
     complexes engaging in several or all production processes.   Even
     the  smallest  steel  plant,  however,  represents a fairly large
     industrial facility.  Because of the wide variety of products and
     processes, operations vary from plant to plant.  Table II-) lists
     the various products classified by the Bureau of the Census under
     Major Group 33 - Primary Metal Industries.

     The steel industry can be segregated into two major components  -
     raw steelmaking and forming and finishing operations.  The Agency
     estimates  that  there  are  about 680 plant locations containing
     over  2000  individual  steelmaking  and  forming  and  finishing
     operations.   A  listing of these plants is presented in Appendix
'The court also held that the Agency had  no  statutory  authority  to
exempt  plants  in  the  Mahoning  Valley  region of Eastern Ohio from
compliance with the BPT limitations.

-------
r'
            B.  Table  I1-2   is  an  inventory  of  production  operations  by
            subcateqory.

            In  the  first   major process, coal  is converted to coke which is
            then combined with  iron ore and  limestone  in  blast  furnaces  to
            produce  iron.   The  iron is then converted  into steel in either
            open hearth, basic  oxygen, or electric  arc   furnaces.   Finally,
            the  steel can be further refined by vacuum degassing.  Following
            these steelmaking operations, the steel is subjected to a variety
            of  hot  and  cold  forming  and  finishing   operations.    These
            operations  produce products  of  various  shapes and sizes, and
            impart desired mechanical and  surface  characteristics.   Figure
            II-l  is a process  flow diagram of the steelmaking segment of the
            industry.

            Coke plants are  operated at integrated facilities to supply  coke
            for  the  production  of iron in blast furnaces or as stand alone
            facilities to supply coke to other users.  Nearly all active coke
            plants are by-product plants which produce, in addition to  coke,
            such  usable  by-products  as  coke  oven gas, coal tar, crude or
            refined light oils, ammonium sulfate or  anhydrous  ammonia,  and
            naphthalene.   A by-product coke plant consists of ovens in which
            bituminuous coal is heated in the absence of  air  to  drive  off
            volatile  components.   The  coke  is supplied to blast furnaces,
            while the volatile  components are recovered   and  processed  into
            materials  of potential value.  Less than one percent of domestic
            coke is produced in beehive cokemaking processes.

            The coke from by-product cokemaking  and  beehive  cokemaking  is
            then  supplied   to  blast   jrnace processes  where molten iron is
            produced for subsequent steelmaking.   In  blast  furnaces,  iron
            ore,  limestone  and  coke are placed into the top of the furnace
            and heated air is blown into the bottom.  Combustion of the  coke
            provides   heat   and   a   reducing   atmosphere  which  produce
   ,         metallurgical reactions in the furnace.  The  limestone  forms   a
   !         fluid  slag  which  combines with unwanted impurities in the ore.
   !         Two kkg (2.2 tons)  of ore, 0.54 kkg  (0.6 tons) of coke, 0.45  kkg
   |         (0.5  tons)  of  limestone, and 3.2  kkg (3.5  tons) of air produce
            approximately 0.9 kkg (1 ton) of iron, 0.45   kkg  (0.5  tons)  of
            slag,  and  4.5  kkg (5 tons) of blast furnace gas containing the
            fines (flue dust) carried out by  the  blast.   Molten  iron  and
            molten  slag,  which  floats on top of the iron, are periodically
            withdrawn from the  bottom of the  furnace.    Blast  furnace  flue
            gas,  which  has heating  value,  is  cleaned and then burned in
            stoves to preheat the incoming air to the furnace.

            Steel is an alloy of iron containing less than 1.0% carbon.   The
            basic  raw  materials for steelmaking are hot metal, pig iron, or
            steel scrap, limestone, burned lime,  dolomite,  fluorspar,  iron
            ores,  and  iron-bearing materials such as pellets or mill scale.
            In steelmaking operations,  the  furnace  charge  is  melted  and
            refined by oxidizing certain constituents, particularly carbon in
I                                       73

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the  molten  bath,  to  specified  low  levels.  Various alloying
elements are added to produce different grades of steel.

The principal steelmaking processes in use today  are  the  Basic
Oxygen  Furnace  (BOP  or  BOP), the Open Hearth Furnace, and the
Electric Arc Furnace.  These processes refine the product of  the
blast  furnace (hot metal or, if cooled, pig iron) which contains
approximately 6% carbon.  About  fifteen  percent  of  the  steel
produced  in  this  country  is  made  in  open  hearth furnaces.
However, the trend has been towards less steel production in open
hearth furnaces because of inefficiencies in the process compared
to BOF and electric furnace steelmaking.   Open  hearth  furnaces
are similar in design, but may vary widely in capacity.  Furnaces
in  this  country  range in capacity from 9 to 545 kkg (10 to 600
tons) per heat.  The steelmaking ingredients are charged into the
front of the furnace through movable doors; while  the  flame  to
refine the steel is supplied by liquid or gaseous fuel ignited by
hot air.

In  the standard open hearth furnace, molten steel is tapped from
the furnace eight to ten hours  after  the  first  charge.   Many
furnaces  use  oxygen  lances  which  create more intense heat to
reduce  tap-to-tap   time.    The   tap-to-tap   time   for   the
oxygen-lanced  open  hearth  averages  about  eight  hours.   The
average is about ten hours when oxygen is  not  used.   The  open
hearth  furnace  allows  the  operator,  in effect, to "cook" the
steel to required specifications.   The  nature  of  the  furnace
permits  the operator to continually sample the contents and make
necessary additions.  The major drawback of the  process  is  the
long time required to produce a "heat."

Since   the  introduction  in  the  United  States  of  the  more
productive basic  oxygen  process,  open  hearth  production  has
declined from a peak of 93 million kkg (102 million tons) in 1956
to  19  million kkg (21 million tons) in 1978.  Most basic oxygen
furnaces can produce eight times the amount of steel produced  by
a comparable open hearth furnace during the same production time.
The  annual  domestic  production  of  steel  by the basic oxygen
process has increased from about 545,000 kkg  (600,000  tons)  in
1957 to 75 million kkg (83 million tons) in 1978.

Vessels  for  the  basic  oxygen  process  generally are vertical
cylinders surmounted by a truncated cone.  Scrap and molten  iron
are   placed   in   the  vessel  and  oxygen  is  then  admitted.
High-purity  oxygen  is  supplied  at  high  pressure  through  a
water-cooled  tube  mounted  above  the  center of the vessel.  A
violent reaction occurs immediately, bringing  the  molten  metal
and  hot  gases  into intimate contact causing impurities to burn
off quickly.  An oxygen blow of  18  to  22  minutes  is  usually
sufficient  to  refine  the metal.  Finally, alloys are added and
the steel is then tapped.  A basic oxygen furnace can produce 180
to 270 kkg (200 to 300 tons) of steel per hour and  permits  very
close  control  of steel quality.  Another major advantage of the
                          - -    ,.,,.  ~~-

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process is the ability to process a wide range of raw  materials.
Scrap  may  be  light  or heavy, and the oxide charge may be iron
ore, sinter, pellets, or mill scale.

The third process for making steel is the electric  arc  furnace.
This  process  is  uniquely  adapted  to  the  production of high
quality steels and practically all stainless steel is produced in
electric arc furnaces.  Electric furnaces range up to.nine meters
(30 feet) in diameter and produce from 1.8 to 365 kkg (2  to  400
tons) per cycle in 1.5 to 5 hours.

The  cycle  in  electric  furnace steelmaking consists of a scrap
charge, meltdown, a hot metal  charge,  a  molten  metal  period,
boil,  a refining period, and the pour.  The electric arc furnace
generates heat by passing an electric current between  electrodes
through  the  charge  in  the  furnace.   The refining process is
similar to that of the open  hearth  furnace,  but  more  precise
control  is  possible  in the electric furnace.  Use of oxygen in
the electric furnace steelmaking process has been common practice
for many years.

At many plants, only electric furnaces are operated with scrap as
the raw material.  In most "cold shops" the electric arc  furnace
is   the  sole  steelmaking  process.   They  are  the  principal
steelmaking process employed by the so-called mini  steel  plants
which  have been built since World War II.  The annual production
of steel in electric arc furnace has  increased  from  about  7.2
million  kkg  (8  million  tons)  in  1957  to 29 million kkg (32
million tons)  in  1978.   Although  electric  arc  furnaces  are
usually  smaller  in  capacity  than  open hearth or basic oxygen
furnaces, the  trend  is  toward  furnaces  with  larger  heating
capacities.

The hot forming (including continuous casting) and cold finishing
operations   follow  the  basic  steelmaking  operations.   These
operations  are  so  varied  that   simple   classification   and
description  is difficult.  In general, hot forming primary mills
reduce ingots to slabs or blooms and secondary hot forming  mills
reduce  slabs  or  blooms  to billets, plates, shapes, strip, and
other  forms.   Continuous   casting   of   molten   steel   into
semi-finished  shapes  is  used to bypass the primary hot forming
operations.  Steel finishing operations involve a number of other
processes that are not used to substantially alter the dimensions
of the hot rolled product,  but  are  used  to  impart  desirable
surface  or  mechanical  properties.   The  product flow of these
operations is illustrated in Figures II-2 and II-3.

It is possible, and often economical,  to  roll  ingots  directly
through  the  bloom,   slab, or billet stages into more refined or
finished  steel  products  in  one  continuous  mill,  frequently
without  reheating.  Large tonnages of standard rails, beams, and
plates are produced by this practice.  Most of the ingot tonnage,
however, is rolled into bloom, slabs, or  billets  in  one  mill,

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           then  cooled,  stored} and  eventually  reheated  and  rolled in other
           mills or  forged.

i           The basic operation  in  a primary mill  is  the gradual   compression
j           of   the  steel ingot between  two rotating rolls.   Multiple passes
           through the rolls, ususally in  a reversing mill, are  required  to
        .  reshape  the  ingot   into  a slab,  bloom,  or billet.   As the ingot
           begins to pass through  the rolls,  high pressure water jets remove
           surface scale. The  ingot  is  passed back  and   forth   between  the
           horizontal  and vertical rolls  while  manipulators  turn the ingot.
           When the  desired  shape  is  achieved in the rolling  operation,   the
           end  pieces  (or   crops)   are  removed by electric  or hydraulic
           shears.  The semi-finished pieces  are stored or sent  to reheating
           furnaces  for subsequent rolling operations.

           As   the  demand  for higher    quality   steel  increases,    the
           conditioning of semi-finished products has become  more important.
           This  conditioning  involves  the  removal of surface  defects from
           blooms, billets,  and slabs prior to   shaping.   Defects  such  as
           rolled seams, light  scabs,   and checks generally  retain their
           identity   during   subsequent  forming  processes   and  result  in
           inferior   products.   Surface  defects may be removed by manual
           chipping,  machine chipping, scarfing,  grinding, milling,  and  hot
           steel  scarfing.     The   various  mechanical  means   of  surface
           preparation are common  in  all   metal   working  and machine  shop
           operations.    Scarfing  is a process of  supplying jet streams of
           oxygen to the surface of the  steel   product,  while   maintaining
           high  surface  temperatures,  resulting  in rapid oxidation and
           localized melting of a  thin  layer   of  the   metal.    While  the
           process  may be manual  (consisting of  the continuous  motion of an
           oxyacetylene torch along   the  length   of  the piece  undergoing
           treatment),   in  recent years  the hot scarfing machine has come
           into wide use. This machine  is designed  to remove a   thin  layer
           (1/8  in.   or  less)  of   metal from  the  steel passed through the
!           machine in a manner   analogous  to the .motion  through  roiling
           mills.

           Merchant-bar.,  rod, and  wire mills  are continuous operations which
;           produce  a wide variety of products,  ranging from  shapes of  small
           size through bars and rods.   The  designations  of   the  various
           mills  as .well  as   the classification of their products are not
           very  well  defined   within   industry.    In general,   the  small
           cross-sectional area and long lengths  distinguish  the products of
j           these  mills.   The   raw   materials   for  these mills  are reheated
I           billets.   Some older mills include hand   looping  operations  in
I           which  the  material  is   manually passed from mill stand to mill
j           stand.  Newer   mills include   mechanical   methods for  material
           transfer.    As with other   rolling   operations,  the  billet is
           progressively  compressed and  shaped to the desired dimensions  in
           a   series  of   rolls.   Water   sprays   are used   throughout   the
           operation to remove  scale.
                                     76


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 5         The  continuous hot strip mill  is used  to process slabs which  are
 j         brought  to  rolling temperatures in  continuous reheating  furnaces.
          The  slabs   then  are  passed  through scale  breakers  and high
 J         pressure water sprays which dislodge loosened scale.  A  series of
 J         roughing stands and a rotary crop shear are  used   to  produce   a
 |         section  that can be finished into a coil of  the proper weight and
 i         gauge.   A   second  scale  breaker  and high  pressure water sprays
 ;         precede  the finishing stands   where final   size   reductions  are
 i         made.    Cooling  water  is applied  by  sprays on the runout table,
 j         and  the  fir.ished strip is coiled.   On  hot strip mills a  six  inch
 i         thick  slab  of  steel can be  formed into a  thin strip or sheet  a
 i         quarter  of  a mile long in three minutes or   less.   Strip  up  to
 |         ni-nty  six   inches in width can be  produced  with hot strip mills,
 j         although the most common width in newer mills is 80 in.  Products
 i         of the hot  strip mill  are  sold  as   produced,  or are further
 j         processed in cold reduction mills.  Cold rolled products are sold
 !         as produced or are used in producing plated  or coated products.

 !         Welded   tubular  products  are made   from   hot-rolled skelp with
 !         square or slightly beveled edges.   The width and thickness of the
 |         skelp are selected to suit the desired size  and wall thicknesses.
 I         The  coiled  skelp is uncoiled,  heated,  and fed through forming and
 !         welding  rolls where  the  edges  are   pressed  together  at  high
 I         temperatures to  form  a  weld.  Welded pipe or tube can also be
 i         made by  the electric weld processes, where the weld is  made  by
          either   fusion  or resistance  welding.  Seamless tubular products
          are  made by rotary piercing of a   solid  round  bar  or billet,
          followed by various  forming operations to produce the required
 i         size and wall thickness.
 t
 1         Correct  surface preparation is the  most important  requirement for
 '         satisfactory application of protective and decorative coatings to
 i         steel.   Without  a  properly  cleaned surface,   even   the  most
 I         expensive   coatings will fail  to adhere or prevent rusting of the
 :         steel base.   A variety of cleaning  methods   are  used  to  insure
          -proper   surface  preparation   for   subsequent coating.   The steel
          surface  must also be cleaned   at  various  production  stages  to
 j         insure   that the oxides which form on the surface are not worked
 i         into the finished product causing   marring,  staining,   or  other
 i         surface  imperfections.

 I         The  pickling process chemically removes oxides and scale from the
 I         surface  of   the  steel  by  the  action  of water solutions of
 I         inorganic acids.  While pickling is only one of  several  methods
 :         of   removing undesirable  surface  oxides,  this   method is most
 j         widely used  because of comparatively low operating costs and ease
 ;         of operation.

 !         Some products such  as  tubes  and  wire  are  pickled   in  batch
 !         operations.   The  product  is immersed in an acid solution until
,         the  scale or oxide film is removed.  The material  is lifted  from
|         the  bath,   allowed  to  drain,  and   then   rinsed by sequential
i         immersion in rinse tanks.
                                      77

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Pickling lines for hot-rolled strip operate continuously on coils
that are welded together.  The steel passes through  the  pickler
countercurrent  to  the  flow  of  the acid solution, and is th?n
sheared and recoiled.  Most carbon steel is pickled with sulfuric
or  hydrochloric  acid;  stainless  steels   are   pickled   with
hydrochloric,  nitric,  and  hydrofluoric acids.  Various organic
chemicals are used in the pickling process to inhibit acid attack
on the base metal, while permitting preferential  attack  on  the
oxides.  Wetting agents are used to improve the effective contact
of  the  acid  solution  with the metal surface.  As in the batch
operation, the steel passes from  the  pickling  bath  through  a
series of rinse tanks.

Alkaline  cleaners  are used, where necesssary, to remove mineral
and animal fats and oils from the steel surface.   Caustic  soda,
soda  ash, alkaline silicates, and phosphates are common alkaline
cleaning agents.  Merely dipping the steel in alkaline  solutions
of  various  compositions,  concentrations,  and  temperatures is
often satisfactory.  The use  of  electrolytic  cleaning  may  be
employed  for  large scale production, or where a cleaner product
is desired.  Sometimes the addition  of  wetting  agents  to  the
cleaning bauh facilitates cleaning.

Blast  cleaning  is  a process which uses abrasives such as sand,
steel, iron grit, or shot to clean the steel.  The abrasives come
into contact with the steel by  either  a  compressed  air  blast
cleaning  apparatus or by rotary type blasting cleaning machines.
However, these methods usually result  in  a  roughened  surface.
The  degree  of  roughness  must  be regulated to insure that the
product is satisfactory for its intended use.  Newer  methods  of
blast  cleaning  produce  smooth finishes and, consequently, have
potential as substitutes for some types of pickling.

Steel finishing also includes operations such  as  cold  rolling,
cold  reduction,  cold drawing, tin plating, galvanizing, coating
with other metals, coating with  organic  as  well  as  inorganic
compounds, and tempering.

Cold  reduced  flat  rolled  products  are  made  by cold rolling
pickled strip steel.  The thickness of the steel is  reduced   by
25%  to 99% in this operation to produce a smooth, dense surface.
The product may be sold as cold  reduced,  but  is  usually  heat
treated.

The  cold  reduction process generates heat that is dissipated by
flooded lubrication systems.   These  systems  use  palm  oil  or
synthetic oils which are emulsified in water and directed in jets
against the rolls and the steel surface; during rolling.  The cold
reduced  strip  is then cleaned with alkaline detergent solutions
to remove the rolling oils prior to coating operations.

Tin plate is made from cleaned and pickled cold reduced strip  by
either  the electrolytic or hot dip process.  The hot dip process

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     consists of passing the steel through a light pickling  solution;
     a  tin  pot  containing  a flux and the molten tin; and a bath of
     palm  oil.   Effluent  limitations  for   discharges   from   the
     electrolytic  processes  are  not included in this regulation but
     are addressed in the Development Document for .the  Electroplating
     Point Source Category (40 CFR 413).

     Hot  dipped  galvanized  sheets  are  produced on either batch or
     continuous lines.  The process consists of a  light  pickling  in
     hydrochloric  acid  and  the  application  of the zinc coating by
     dipping  in  a  pot  containing  molten  zinc.    Variations   in
     continuous   hot   dip   operations  include  alkaline  cleaning,
     continuous annealing in controlled  atmosphere  furnaces,  and  a
     variety of fluxing techniques.

     In  recent  years,  steel  products which are coated with various
     synthetic resins have become commercially important.  Other steel
     products are being produced with coatings of various  metals  and
     inorganic  materials.   Several major tin plate manufacturers are
     substituting chromium  plating  for  tin  plating  for  container
     products.   Finishing  operations  for  stainless  steel products
     requiring a bright finish include  rolling  on  temper  mills  or
     mechanical polishing.

     A  more  detailed description of steel industry operations can be
     found in the individual subcategory reports of  this  Development
     Document, and in the references cited in Section XIV.

D.   Summary of EPA Guidelines Development Methodology and Overview
                                                *
     Approach to the Study

     In order to develop the'effluent limitations and  standards,  the
     Agency  first  studied  the  steel  industry to determine whether
     differences  in  raw  materials,  final  products,  manufacturing
     processes,  equipment,   age  and  size  of  plants,  water usage,
     wastewater  constituents,  or   other   factors   justified   the
     development  of  separate  effluent limitations and standards for
     different segments of the  industry.   This  study  included  the
     identification  of  untreated  wastewater  and  treated  effluent
     characteristics including:  (1) the sources and volume  of  water
     used,  the  processes employed, and the sources of pollutants and
     wastewaters  in  the  plant,   and   (2)   the   constituents   of
     wastewaters,   including   toxic  pollutants.   The  Agency  then
     identified the wastewater pollutants which  were  considered  for
     effluent limitations and standards.

     Next,   the   Agency  identified  several  distinct  control  and
     treatment   technologies,    including    both    in-plant    and
     end-of-process technologies,  which are in use or capable of being
     used  in  the  ste^l  industry.  The Agency compiled and analyzed
     historical data  and  recently  obtained  effluent  quality  data
     resulting  from the application of these technologies.  Long term
                                79

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performance, operating limitations, and the reliability  of  each
control  and  treatment  technology  were  also  identified.   In
addition,   the   Agency   considered   the   non-water   quality
environmental impacts of those technologies, including impacts on
air  quality,  solid  waste  generation,  water  consumption, and
energy requirements.

The Agency then developed the costs of each control and treatment
technology by using standard engineering cost analyses as applied
to steel industry wastewaters.  Unit process costs  were  derived
from  model plant characteristics  (production, flow and pollutant
loads) applied to each  treatment  process  unit  (e.g.,  primary
coagulation-sedimentation,    activated    sludge,    multi-media
filtration).  These unit process costs were added to yield  total
costs   of  the  model  treatment  facility  developed  for  each
treatment level.  After confirming  the  reasonableness  of  this
methodology  by  comparing EPA cost estimates to actual treatment
system costs supplied by the industry and other data, the  Agency
evaluated  the  economic  impacts  of  these  costs.   Costs  are
discussed in detail in each subcategory report and  the  economic
impact  on  the  industry  is  reviewed  in  the  economic impact
analysis done for this study.

Upon consideration of these  factors,  as  more  fully  described
below,  the  Agency  identified-  various  control  and  treatment
technologies as models for the BPT, BCT, and BAT limitations  and
for  the  PSES,  PSNS, and NSPS.   The regulation Does not require
the  installation  of  any  particular  technology.   Rather,  it
requires  the  achievement  of effluent limitations and standards
representative of the proper operation of the model technologies,
equivalent technologies, or operating practices.

Nearly all of the BPT, BCT and  BAT  limitations  and  the  PSES,
PSNS,  and  NSPS are expressed as mass limits (kg/kkg of product)
and were calculated by multiplying three  values:   (1)  effluent
concentrations  determined  from  analysis  of control technology
performance data, (2) model wastewater flow  (gal/ton)  for  each
subcategory,  and  (3)  an  appropriate  conversion  factor.  The
effluent limitations and standards for  scrubbers  used  at  acid
pickling  and hot coating operations are established on the basis
of mass load per day (kg/day), and were calculated by multiplying
the same three factors, except that the model flows are expressed
in gal/minute.  The Agency performed the  basic  calculation  for
each limited pollutant for each subcategory of the industry.

Data and Information Gathering Program
       ^^

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     Upon   initiating  this  study,  the  Agency  reviewed  the  data
     underlying its previous studies  of  the  steel  industry.'   The
     Agency concluded that additional data were required to respond to
     the  Third  Circuit's  remands  and  to  develop  limitations and
     standards in accordance with the  Settlement  Agreement  and  the
     Clean Water Act of 1977.

     The  Agency  sent  Data Collection Portfolios (DGPs) to owners or
     operators of all basic steelmaking operations and operators of at
     least 85% of the steel forming  and  finishing  operations.   The
     DCPs   requested  information  concerning  production  processes,
     production capacity and rates, process  water  usage,  wastewater
     generation  rates,  wastewater  treatment  and  disposal methods,
     treatment  costs,  location,  age  of  production  and  treatment
     facilities,  as  well  as  general  analytical  information.  The
     Agency received responses from  391  steelmaking  operations  and
     from 1632 steel forming and finishing operations.

     The   Agency   also  sent  Detailed  Data  Collection  Portfolios
     (D-DCPs), under the authority of  Section  308  of  the  Act,  to
     owners  or  operators  of 50 basic steelmaking facilities and 128
     forming and finishing facilities.  The D-DCPs requested  detailed
     information  concerning  the  cost  of installing water pollution
     control equipment including capital, annual, and retrofit  costs.
     The  D-DCPs also requested long-term effluent monitoring data and
     data regarding specific production operations.

     The Agency determined the  presence  and  magnitude  of  the  129
     specific  toxic  pollutants  in  steel  industry wastewaters in a
     two-part sampling and analysis program  that  included  31  basic
     steelmaking  facilities  and 83 forming and finishing operations.
     Table II-3 is a listing of  those  facilities  sampled  for  this
     study.   Table  I1-4 is a summary of the number of sampled plants
     and the number  of  facilities  for  which  the  Agency  received
     questionnaire responses.

     The primary objective of the field sampling program was to obtain
     composite   samples  of  wastewaters  and  flow  measurements  to
     determine  the  concentrations  and  discharge  rates  of   toxic      I
     pollutants.   Sampling  visits  were  made  during  two  or three      i
     consecutive days of plant operation, with raw wastewater  samples
     taken  either  before  treatment  or  after  minimal  preliminary
•See EPA 440/1-74-024a;  Development Document for  Effluent  Limitation
Guidelines  and  New Source Performance Standards for the Steel Making
Segment of the Iron and  Steel  Manufacturing  Point  Source  Category,
June  1974;  and  EPA 440/1-76/048-d;  Development Document for Interim
Final  Effluent  Limitations  Guidelines  and  Proposed   New   Source
Performance  Standards  for the Forming, Finishing and Specialty Steel
Segments of the Iron and Steel Manufacturing  Point  Source  Category;
March,  1976.

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     treatment.   Treated  effluent  samples  were   taken   following
     application  cf in-place treatment technologies.  The Agency also
     sampled  intake  waters  to  determine  the  presence  of   toxic
     pollutants prior to contamination by steel industry processes.

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

     The Agency used the analytical techniques described  in  Sampling
     and Analysis Procedures for Screening of Industrial Effluents for
     Priority  Pollutants,  revised  April, 1977.  Analyses for metals
     were performed by AA spectrophotometry.   However,  the  standard
     cold  vapor  method was used for mercury.  This 304(h) method was
     modified in order to avoid  excessive  matrix  interference  that
     causes  hiqh limits of detection.  Analyses for total cyanide and
     cyanide amenable to chlorination were also performed using 304(h)
     methods.

     Analyses  for  asbestos   fibers   used   transmission   electron
     microscopy  with selected area diffraction; results were reported
     as chrysotile fiber count.

     Analyses for conventional pollutants (BODJ5, TSS, pH,  and oil  and
     grease)  and nonconventional pollutants (total residual chlorine,
     iron, ammonia, fluoride, and COD)  were  performed  using  304(h)
     methods.

     Industry Subcateqorization

     The  Agency  has adopted a revised subcategorization of the steel
     industry to more accurately reflect production operations in  the
     industry  and  to  simplify the implementation of the regulation.
     The modified subcategorization is displayed in Table II-5.  Table
     11-6  cross  references  the  modified   subcategorization   with
     subparts of the previous regulations.   Industry subcategorization
     is reviewed in detail in Section IV of this report and in Section
     IV of each subcategory report in the Development Document.

Regulated Pollutants

The  basis  upon which the Agency selected the pollutants specifically
Hrcited, as well as the general nature and  environmental   effects  of
these pollutants is set out in Section V.
                                82

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A.   BPT

     The pollutants limited by this regulation include, for  the  most
     part,   the   same   pollutants   limited  by  the  remanded  BPT
     regulations.  Some pollutants have been deleted from the list  of
     limited  pollutants  because the sampling conducted subsequent to
     the promulgation of the prior regulations showed that  only  very
     low  levels  of  these  pollutants  are  present  in  the process
     wastewaters.  For the finishing  subcategories,  BPT  limitations
     for  additional  pollutants  were  promulgated  to facilitate the
     co-treatment of compatible  wastewaters  and  to  regulate  toxic
     pollutants  where  more stringent BAT limitations based upon more
     advanced  wastewater  treatment  were   not   promulgated.    The
     discharge  of  BPT  limited  pollutants  is  controlled by 30 day
     average and maximum daily mass effluent limitations in  kilograms
     per  1000  kilograms  (lbs/1000 Ibs) of product, and in kilograms
     per day for fume scrubbers associated with acid pickling and  hot
     coating operations.

B.   BCT

     The conventional pollutants controlled by this regulation include
     TSS,  oil  and  grease,   and  pH.   BCT  limitations  have   been
     promulgated  in  seven  steel  industry  subcategories and in all
     seven of those subcategories BCT is set equal to BPT.  Therefore,
     no additional costs beyond BPT will be incurred  to  comply  with
     the  BCT  limitations.   In the remaining five subcategories, BCT
     has been reserved for further consideration.

C.   BAT and NSPS

     1.   Nontoxic,  Nonconventional Pollutants

          Ammonia-N is a nontoxic, nonconventional  pollutant  limited
          by BAT and NSPS.

     2.   Toxic Pollutants

          Forty-eight toxic pollutants were  found  at   -
-------
     3.   Indicator Pollutants

          The cost of analyses for the many toxic-pollutants found  in
          steel  industry wastewaters has prompted the Agency to adopt
          alternative methods of regulating certain toxic  pollutants.
          Instead  of  promulgating  specific effluent limitations for
          each of the forty-eight  toxic  pollutants  found  in  steel
          industry  wastewaters  at significant levels, the Agency has
          promulgated effluent  limitations  for  certain  "indicator"
          pollutants.   These  include  chromium,  lead, nickel, zinc,
          phenols (4AAP) and certain toxic  organic  pollutants.   The
          data available to the Agency generally show that the control
          of  the  "indicator"  pollutants  will  result in comparable
          control of toxic pollutants not  specifically  limited.   By
          establishing  specific  limitations for only the "indicator"
          pollutants, the Agency has reduced the high cost and  delays
          of   monitoring   and   analyses   that  would  result  from
          limitations for each  toxic  pollutant.   The  total  annual
          monitoring  cost  to  the  industry is estimated to be about
          $3.8 million (including $3.2 million for current  monitoring
          programs).   The  pollutants  found and those that have been
          specifically limited at the BAT and NSPS levels of treatment
          are listed  in  Section  V.   The  bases  for  selection  of
          "indicator"  pollutants  is  presented  in Section X of each
          subcategory report.

D.   PSES and PSNS

     The pollutants for which PSES and PSNS have been promulgated  are
     identical to those limited at BAT and NSPS, with the exception of
     the  conventional  pollutants.   Limitations were promulgated for
     certain toxic pollutants, and  other  "indicator"  pollutants  to
     insure  against  POTW  upsets,  to  prevent accumulation of toxic
     pollutants  in  POTW   sludges,    and   primarily   to   minimize
     pass-through  of certain toxic pollutants.   The PSES and PSNS are
     expressed as 30 day average and maximum daily mass limitations in
     kilograms per 1000 kilograms (lbs/1000 Ibs)  of  product  and  in
     kilograms per day.

Control and Treatment'Technology

A.   Status of In-Place Technology

     There are several treatment technologies currently  used  by  the
     steel  industry.  Generally, primary wastewater treatment systems
     rely upon  physical/chemical  methods  including  neutralization,
     sedimentation..   floccuJation and filtration.  Treatment for toxic
     pollutants includes  advanced  technologies  such  as  biological
     oxidation  and  carbon  adsorption.    Technologies  such  as  ion
     exchange, ultrafiltration, multiple-effect  evaporation,  reverse
     osmosis,  and more sophisticated chemical techniques are generally
     not  currently  used  in  the  industry  for wastewater treatment
     applications.
                                64


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                                                                              n
     Within the cokemaking subcategory, treatment  systems  include  a
     component  to  remove  organic  wastes.   Organic  removal  steps
     include biological methods  such  as  bio-oxidation  lagoons  and
     activated  sludge plants, and physical/chemical methods including
     ammonia  stills,  dephenolizers  and  activated  carbon  systems.
     Sedimentation and filtration techniques are also used.

     Treatment  facilities at plf.nts in the sintering, ironmaking, and
     steelmaking subcategories include sedimentation and  flocculation
     systems  followed by recycle of treated wastewaters.  Wastewaters
     from nearly all hot forming operations are treated in scale  pits
     followed   by   lagoons,  clarifiers,  filters,  or  combinations        |  |
     thereof,  with  recycle   of   treated   or   partially   treated        j  <
     wastewaters.   Coagulants  aids  such  as  lime,  alum, polymeric        j  ]
     flocculants, and ferric sulfate are normally used in  conjunction        |  »
     with clarifiers.  Filters are usually of the multi-media pressure        !  ;
     type.                                                                    j  I

     Cold finishing treatment techniques include equalization prior to          ,
     further  treatment,  neutralization  with  lime, caustic or acid,          j
     flocculation with polymer and sedimentation.  Central or combined          |
     treatment practices are used widely with these operations.                 ]
                                                                                j
     The use of recycle is a  common  practice  throughout  the  steel
     industry.    Recycle   of  treated  process  wastewaters  can  be          I
     effectively used as a means of significantly  reducing  discharge          j
     loadings  to  receiving  streams.   Systems including high recycle          «
     rates are demonstrated in several  subcategories.  Recycle may  be          *
     applied  to specific sources such  as barometric condensers (coke)
     or fume scrubbers  (pickling)  or   to  the  effluent  from  final
     treatment facilities.

B.   Advanced Technologies Considered

     The Agency considered advanced treatment systems to  control  the
     levels  of  toxic  pollutants  at   the  BAT, NSPS, PSES, and PSNS
     levels of treatment.  Some  of  these  systems  include  in-plant
     controls,  however,  most  involve the installation of additional
     treatment components.

     In-plant control has been demonstrated in several  subcategories.
     As  a  result,  such  systems have been included in the treatment
     models at the BAT, BCT,   NSPS,  PSES,  and  PSNS  levels.   Rinse
     reduction  technology,  such  as  cascade  rinsing, is a means of
     reducing  wastewater  volumes-   This  technology   significantly
     reduces the volume of wastewater requiring treatment.

     Ocner  in-plant  control measures  such as reduction of wastewater
     generation by process water reduction  and  recycle  and  process
     modifications  have  been considered.  These control measures are
     subcategory  specific  and  are  discur«=ed  in  detail   in   the
     respective subcategory reports.
                                                                         :

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     Add-on  technology  to the BPT model technology is also the basis
     for the BAT, NSPS, PSES, and PSh'S levels of treatment.   Some  of
     these  control  measures  for toxic pollutants include 2-stage or
     extended biological treatment  (cckemaking);  granular  activated
     carbon;      pressure      filtration;      and,      multi-stage
     evaporation/condensation  systems.   Details  on  these  advanced
     systems are presented in Section VI.


Capital and Annual Cost Estimates

Additional  expenditures  will  be  required  by thf steel industry to
achieve  compliance  with  the  promulgated  limitations.    A   short
discussion of the in-place and required capital costs and annual costs
are  presented  below for each level of treatment, based upon the size
and status of the industry as of Julyj, 1981.  All costs are presented
in July 1, 1978 dollars.

A.   BPT

     The Agency estimates that as of July 1, 1981 the  steel  industry
     had  expended  about  $1.5  billion  towards  compliance with BPT
     limitations out  of  a  total  required  cost  of  $1.7  billion.
     Industry   will   incur  annualized  costs  (including  interest,
     depreciation, operating and maintenance) of  about  $204  million
     when  BPT  has  been fully implemented.  The changes in the above
     costs are the result of the Agency's update of the status of  the
     industry  with  respect  to  BPT  compliance  and the deletion of
     plants that have been shutdown.

     Compliance with the BPT effluent limitations will result  in  the
     removal   of   about  36,-700  tons  per  year  of  toxic  organic
     pollutants, 113,500 tons per year of toxic metal  pollutants  and
     13,670,000  tons  per  year  of  other  pollutants from untreated
     wastewaters.  The Agency believes that these  effluent  reduction
     benefits  justify  the  associated costs,  and other environmental
     impacts which are small in relation to these benefits.

B.   BAT

     The Agency estimates that as of July 1, 1981, compliance with the
     BAT and BCT limitations may require the steel industry to  invest
     about  $77  Ml lion  in addition to the BPT investment and to the
     capital already spent on BAT systems.   The annualized  costs  for
     the  steel  industry,  in  addition to the BPT costs, may equal a
     total of about $24 million.

     Compliance with the BAT limitations will result in the removal of
     about 580 tons per year of toxic organic pollutants, 190 tons per
     year of toxic metal pollutants and 12,400 tons per year of  other
     pollutants.   The  Agency  believes  that the costs of compliance
     with the BAT limitations  and  other  environmental  impacts  are


-------
     Add-on  technology  to the BPT model technology is also the basis
     for the BAT, NSPS, PSES, and PSNS levels of treatment.   Some  of
     these  control  measures  for toxic pollutants include 2-stage or
     extended biological treatment  (cokemaking);   granular  activated
     carbon;      pressure      filtration;      and,      multi-stage
     evaporation/condensation  systems.   Details  on  these  advanced
     systems are presented in Section VI.


Capital and Annual Cost Estimates

Additional  expenditures  will  be  required  by the steel industry to
achieve  compliance  with  the  promulgated  limitations.    A   short
discussion of the in-place and required capital costs and annual costs
are  presented  below for each level of treatment, based upon the size
and status of the industry as of July/, 1981.  All costs are presented
in July 1, 1978 dollars.

A.   BPT

     The Agency estimates that as of July 1, 1981  the  steel  industry
     had  expended  about  $1.5  billion  towards  compliance with BPT
     limitations out  of  a  total  required  cost  of  $1.7  billion.
     Industry   will   incur  annualized  costs  (including  interest,
     depreciation, operating and maintenance) of  about  $204  million
     when  BPT  has  been fully implemented.  The changes in the above
     costs are tfie result of the Agency's update of the status of  the
     industry  with  respect  to  BPT  compliance  and the deletion of
     plants that have been shutdown.

     Compliance with the BPT effluent limitations will result  in  the
     removal   of   about  36,700  tons  per  year  of  toxic  organic
     pollutants, 113,500 tons per year of toxic metal  pollutants  and
     13,670,000  tons  per  year  of  other  pollutants from untreated
     wastewaters.  The Agency believes that these  effluent  reduction
     benefits  justify  the  associated costs,  and other environmental
     impacts which are small in relation to these benefits.

B.   BAT

     The Agency estimates that as of July 1, 1981, compliance with the
     BAT and BCT limitations may require the steel industry to  invest
     about  $77  million  in addition to the BPT investment and to the
     capital already spent on BAT systems.  The annualized  costs  for
     the  steel  industry,  in  addition to the BPT costs, may equal a
     total of about $24 million.

     Compliance with the BAT limitations will result in the removal of
     about 580 tons per year of toxic organic pollutants, 190 tons per
     year of toxic metal pollutants and 12,400 tons per year of  other
     pollutants.   The  Agency  b&lieves  that the costs of compliance
     with the BAT limitations  and  other  environmental  impacts  are
                                 86

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1
 \          reasonable  and  justified  in  light  of  the effluent reduction
 !          benefits obtained.

 j     C.   PSES

 |          The Agency estimates that as of July 1,  1981, compliance with the
 !          PSES may require the steel industry to invest about $41  million.
 i          The  Agency estimates that POTW dischargers have already expended
 j          about $132 million for pretreatment facilities.   The  annualizes
 !          costs  for  the  steel  industry  may  equal a total of about $31
 I          million.

            Compliance with the PSES will resut in the removal of about  5600
  ;          tons/year  of  toxic  organic pollutants, 7850 tons/year of toxic
  :          metal pollutants, and 792,000 tons/year  of other pollutants  from
            raw  wastewaters.   The  Agency  believes  that the prevention of
            toxic pollutant pass through achieved with the  promulgated  PSES
  i          justify the associated costs.                  —

       Basis for Effluent Limitations and Standards

       As  noted  briefly  above,  the effluent limitations and standards for
       BPT, BAT, BCT, NSPS, PSES, and PSNS are expressed as mass  limitations
       in  kilograms  per  1000  kilograms  (lbs/1000  Ibs) of product and in
       kilograms per' day.  The mass limitation is derived by  multiplying  an
       effluent  concentration  (determined  from  the  analysis of treatment
       system performance) by a model flow appropriate for  each  subcategory
       expressed   in  gallons  per/ton  of  product,  or  gallons  per  day.
       Conversion factors  were  applied  to  yield  the  appropriate  kg/kkg
       (lbs/1000  Ibs)  and  kg/day  value  for  each limited pollutant.  The
       limitations neither require the installation  of any  specific  control
       technology  nor  the  attainment of any specific flow rate or effluent
       concentration.  Various treatment alternatives or  water  conservation
       practices  can be employed to achieve a particular effluent limitation
       and  standard.   The  model  treatment  systems   presented   in   the
       development  document illustrate one of the means available to achieve
       the limitations and standards.  In most cases, other  technologies  or
       operating  practices  are  available  to  achieve  the limitations and
       standards.

       NPDES permit limitations are specified as mass limitations (kg/day  or
       Ibs/day).   In  order to convert the effluent limitations expressed as
       kg/kkg (lbs/1000 Ibs) to a 30-day  average  or  daily  maximum  permit
       limit,  a  production  rate  in either kkg/day or 10JO Ibs/day must be
       used.  The production rates previously used for NPDES permitting  have
       been  the  highest  actual  monthly  production in the last five years
       converted to a daily value, or production capacity.  Where applicable,
       the effluent limitations expresses as kg/day  are additive to the other
       permit limitations.
                                        87

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Suggested Monitoring Program

The suggested long  term  monitoring  and  analysis  program  includes
continuous flow monitoring, grab sampling for pH and oil and grease  (3      •
grabs/day,  once/week) and the collection of 24-hour composite samples      *
once per week for all other pollutants.  The composite  samples  would      i
be  analyzed  for those pollutants regulated at the BPT, BAT, BCT, and      {
PSES treatment levels for each contributing subcategory.  Due  to  the      !
relatively  high  cost  of  organic analysis ($750-$1000 per sample  in      .
July 1978 dollars), monthly monitoring  of  limited  organics  in  the      f
cokemaking and cold forming subcategories is suggested.                     |

More  intensive  monitoring  is  suggested  for  the  period  of  time      !
necesssary to  determine  initial  compliance  with  the  limitations.      |
Accordingly,  as  of  July 1, 1984,   (the  compliance date for BAT and      ;
BCT), monitoring and analysis should be carried out on a  schedule  of      •
five  daily  composites per week (once per week for GC/MS pollutants).      ;
When the appropriate regulatory authority determines  that  compliance
has  been  demonstrated,  monitoring  can  then-  be  decreased  to the
frequencies indicated in the long term program discussed above.

Although  total  suspended  solids  and  pH  are  regulated  for  each
subcategory,  the  total  number  of  monitored pollutants ranges from
three (alkaline cleaning) to eight (cokemaking).  The type of analysis
influences the overall cost with analysis for toxic organic pollutants
being the most expensive, and pH and the  metals  analyses  being  the
least expensive.

Updated   cost   estimates  were  developed  using  three  alternative
contractural arrangements (in-house laboratory,  contract  laboratory,
and  C.W.  Rice  Laboratory),  to  obtain  an estimate of the range of
monitoring costs and to demonstrate that  the  monitoring  program  is
feasible with the resources available to the industry.

The  subcategory  with  the  largest  annual  monitoring  expenses  is
cokemaking  ($8862-$!1,779/yr).    The  need  for  the  GC/MS   organic
analyses  accounts  largely  for  the  high  cost.   The lowest annual
monitoring  costs  occur  in   the   salt   bath   descaling-oxidizing
subdivision  ($2,513-$5,794/yr).   Annual  monitoring  costs  for  the
remaining subcategories are between $2,648 and $11,276.

The total annual monitoring cost to the industry is  estimated  to  be
approximately  $3.8  million of which $2.3 are expended for monitoring
at the BPT and PSES levels.  However, actual expenses are likely to be
less due to the preponderance of central treatment facilities in  this      '.
industry.   This substantially reduces the number of monitoring points
compared to that  required  with  completely  separate  treatment  and
monitoring  at  each process, as assumed by the Agency to estimate the
monitoring costs.   Total  BPT/BAT/PSES  annual  operating  costs  are
estimated  to be $228 million.  The monitoring cost is roughly 1.7% of
the annual cost of pollution  control.   The  Agency  considers  these
costs reasonable in light of the size and complexity of this industry,
and the potential adverse environmental impacts of these discharges.

-------
                                           /  •'  •                             I
                                                           _              _.«.
;•        Economic Impact on the Industry

;        The  economic  impact of the regulation on the steel industry is fully
I        described in Economic Analysis oj£  Effluent  Guidelines  -  Integrated
\        Iron and Steel Industry.
|
i        Energy and Non-water Quality Impacts

|        The  elimination  or  reduction of one form of pollution may aggravate
i        other environmental problems.   Therefore,  Sections 304(b) and  306  of
\        the   Act  require  the  Agency  to  consider  the  non-water  quality
!        environmental  impacts  (including  energy  requirements)  of  certain
|        regulations.    In   compliance  with  these  provisions,  the  Agency
i        considered the effect of this regulation on air pollution, solid waste
|        generation, water scarcity,   and  energy  consumption.    There  is  no
I        precise methodology for balancing pollution impacts against each other
\        and against energy use.  The Agency believes this regulation to be the
j        best  possible approach to serving these competing national goals with
I        respect to environmental concerns and energy consumption.
i
I        The  non-water  quality  environmental   impacts   (including   energy
i        requirements)  associated with the regulation are described in general
i        below and more specifically in the respective subcategory reports.
i
i        A.    Air Pollution
|
:             Compliance with the BPT,  BAT, and BCT limitations  and  the  NSPS,
             PSES,  and  PSNS  will   not  create any substantial air pollution
             problems.  However, in several subcategories, slight air  impacts
J             may  be  expected.   First,  minimal   amounts of volatile organic
;             compounds may be  released  to  the  atmosphere  by  aeration  in
             biological treatment systems used for the treatment of cokemaking
             wastewaters.    Secondly,   minor  particulate  air   emissions  may
             result as water  vapor  containing  some  particulate  matter  is
             released  from  cooling  tower  Systems  used  in   several of the
             subcategories.  None of these impacts are considered significant.

        B.    Solid Wastes
                                           H

             EPA estimates that 22.2 million tons  per year of solid wastes (at
             30% solids for most dewatered sludges) will be generated  by  the
             industry  when  full  compliance  with BPT, BAT, BCT, and PSES is       j
             achieved.  Of this amount,  20.0 million tons are generated at the       i
             BPT level and 2.2 million tons at PSES.  Solid  waste  generation       5.
             data  by  subcategory  and  by level  is summariz-d in Table I1-7.       :
             These solid wastes are comprised  almost  entirely  of  treatment       j
             plant  sludges.  Much larger quantities of other solid wastes are       j
             generated in the steel  industry such  as electric furnace dust and       {
             blast furnace and steelmaking slags.   However,   these  and  other       j
             solid  wastes are generated by the process and not as a result of       \
             this water pollution control regulation.                                 j
                                        89

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     The data gathered for this study .demonstrate  that  most  sludges
     are  presently produced by treatment systems already installed in
     the industry.  As a result, the industry is  currently  incurring
     disposal  costs  and  finding  necessary  disposal sites.  (It is
     unknown at this time how many of these disposal sites are secure,
     well maintained operations.)  The cost per ton  for  disposal  is
     related  to the type of waste as well as to the amount.  Tonnages
     to be disposed of in the steel industry are high enough  so  that
     lower  costs  per  ton  are  incurred  in  relation to most other
     industries.  For this evaluation the Agency, after  an  extensive
     evaluation,  determined  that sludge disposal costs of $5 per ton
     for non-hazardous wastes and $18 per ton for hazardous wastes are
     appropriate bases for cost estimating purposes.   The  costs  for
     disposal  of  these  sludges are included in the Agency.'s present
     cost estimate.  The Agency has concluded  that,  the  incremental
     solid  waste  impacts  associated  with  this  regulation will be
     minimal.

C.   Consumptive Water Loss

     The question of water consumption in  the  steel  industry  as  a
     result  of  the installation of wastewater treatment systems is a
     remand issue of the 19?4  a'nd  1976  regulations  dealt  with  in
     Section  III.   In  summary,  the Agency concludes that the water
     consumed as a  result  of  compliance  with  this  regulation  is
     justified  on  both  a  national  level  and  on a "water-scarce"
     regional level when compared to the effluent  reduction  benefits
     achieved.

D.   Energy Requirements

     The Agency estimates that compliance  with  the  regulation  will
     result  in the consumption of electrical energy, at the BPT, BCT,
     BAT and PSES levels of treatment as follows:

          Treatment Level          Net Energy Consumption (kwh)

               BPT/BCT                       1.25 billion
               BAT                           0.07 billion
               PSES                          0.12 billion

               Total                         1.44 billion

     This represents 2.5% of the total 57 billion kwhs  of  electrical
     energy  consumed  by the steel industry in 1978, or about 0.4% of
     the total  energy  consumed  by  the  industry.   A  summary,  by
     subcategory  and  by  level,  of energy requirements due to water
     pollution  control  is  presented  in  Table  II-8.    The  Agency
     considers  the expenditure of energy required for compliance with
     this regulation justified by  the  effluent  reductions  benefits
     achieved.
                                90

-------
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-------

                                                   TABU: 11-1
                                   PLANTS SAMi-LED DURIHG 19M AMP STEEL STUDY
Subcategory

A.  Cokeaaking

    1.  Sj-Product
    2.  Beehive
B.  Sintering
C.  Ironaaking
                          Sampling
                            Code
003
MA
006
007
008
009
HA
A
B
C
D

E
F
C
                          016
                          017
                          019
                          H
                          I
                          J
                          K
                          021
                          022
                          023
                          024
                          025
                          026
                          027
                          028
                          029
                          030
                     Plant
                 Reference Code
0732A
0464C
0868A
0860H
0584B
0320
0920F
0684F
0402
0432B
0112
0384A
0272

0428A
0428A
0724A
01120
0432A
0060F
0432A
0291C
0396A
0112B
0196A
0856N
0860B
0860H
0112C
0112D
C432A
0684H
0684F
0112
                                 PUnt
                                  Hue
Sh«n*ngo (Neville Iiland)
Koppert (Erie)
O.S.S. (Fairfield)
U.S.S. (South Worki)
National Steel (Great Lakei)
Ford Motor Co. (Dearborn)
Wheeling-Pit (Folumbet)
Republic STeel (Cleveland)
Irent on Coke (Ironion)
J « L (Pittsburgh)
Bethlehea (Bethlehen)
Inland (Eaat Chicago)
Donner-Hanna (Buffalo)

Jev-11 (Vanaant)
Jevell (Vaniant)
Sharon (Carpenter)
Bethlehen (Burna Harbor)
J 6 L (Aliquippa)
Araco (Houaton)
J i L (Aliquippa)
International Harveaeer (Chicago)
Interlake (Chicago)
Bethlehea (Buffalo-Lackavanna)
CFII (Pueblo)
U.S.S. (Lorain)
D.S.S. (Gary Workl)
0,5.5, (Chicago-SoutEi)
Bethlehea (Johnctown)
Bethlehea (Burnt Harbor)
J I L (Aliquippa)
Republic (Chicago)
Republic (Cleveland)
Beihlehea (Bethlelwa)
                                                             I  ]

                                                             ',  1
                                                                              Iron
                                                                              Iron
                                                                              Iron
                                                                              Iron
                                                                              Iron
                                                                              Iron
                                                                              Iron
                                                                              Iron
                                                                              Iron
                                                                              Iron
                                                     100

-------
TABLE II-}
PLANTS SAMPLED DURI8G IRON AND STEEL STUDY
PAGE 2

Subcategory






D. Stealaaking
i. tor












". Open Hearth



3. Electric Ate
Furnace






C. tacuum Degassing



Sampling
Code
L
M
N
0
P
Q

031
032
033
034
03J
036
038
D*
*
S
T
0
V
042
043
W
Y
OS1

052
059B
AA
AB
Y
Z

062
065
068
Plant
Reference Code
0291C
0396A
0448A
C060P
Oil 21
0112C

0020B
0384A
C8S6B
0856N
0868A
0112D
0684F
0248A
0432A
0060
0112*
03960
0584F
0492A
0864A
0112A
0060
0612

0492A
0060F
0060F
0868B
0432C
05 84 A 6 B

0496
0584F
0684H
                                                                            Plant
                                                                                                        Type  of
                                                                   International Harvester (Chicafo)     Iron
                                                                   Inter lake (Chicago)                  Iron
                                                                   Caiaer (Fontana)                     Iron
                                                                   Armco (Bouaton)                      Iron
                                                                   Bethlehe* (Buffalo-Lackavanna)       Iron
                                                                   Bethlebea (Johnatovn)                FeHn
                                                                   Allegheny-Ladlua (Brackenridte)      W-OC
                                                                   Inland (Indiana Harbor)              U-SC
                                                                   D.S.S. (Edgar Thoeqxon)              W-OC
                                                                   U.S.S. (Lorain)                      W-SC

                                                                   O.S.S. (Fairfield)                   W-OC
                                                                   Bethlebea (Burns Harbor)             W-OC
                                                                   Republic (Chicago)                   W-SC
                                                                   Crucible (Midland)                   W-OC
                                                                   J 4 L (Aliquippa)                    Seeji-»et
                                                                   Araco (Hiddletovn)                   W-SC
                                                                   Bethlehem (Sparrmt Point)           W-OC
                                                                   Interlake (Chicago)                  Semi-Wet
                                                                   Rational (Ueirton)                   W-OC

                                                                   Lone Star (Lone Star)                Wet
                                                                   D.S.S. (Provo)                       Semi-vet
                                                                   Bethlehem (Sparrows Point)           Wet
                                                                   Armco (Niddletoon)                   Wet

                                                                   Korthvestera Steal i Wire            Wet
                                                                   (Sterling)
                                                                   lone Star (Lone Star)                Wet
                                                                   Armco (Houston)                      Semi-wet
                                                                   Armco (Houston)                      Wet
                                                                   D.S.S. (Texas Works, Bsylovn)        Wet
                                                                   J 4 L (Cleveland)                    Semi-vet
                                                                   Rational (Ecorse)                    Semi-vet
                                                                   Lukens (Coatesville)
                                                                   National (Veirton)
                                                                   Republic (Chicago)

-------
TABLE 11-3
PLANTS SAMPLED DURING IRON AMD STEEL STUDY
PACE 3
Sampling
Subcategory Code
AC
AD
I
C
f. Contiauoue Calling
071
072
075
079
AE
AT
B*
D*
Q*
C. Hoc forming
1. Primary 081
082
082

083
D*
E*
H*
K*
M*
Q*
R*
A-:
B-2
C-2 t 088
(Reviaited)
D-2
L'2 (2)
285A2
286A *
288A "
289A12'
PUat
Reference Code •
0584F
0868B
0020B
9856R

0264*
0496
0584F
0060R
0584F
08681
0900
0248A « B
0684D

0176
0496 (140" only)
0496 (140", 206" in
linden)
0860H
0248R
0020B
0248A
0256K
0432J
0684D
0240A
0112B
01128
0684H

0946A
0060
0240A
0432C
OS84F
0684B
                                                                           Plant
                                                                             N«M
tyft of
Oyetnion
                                                                   National  (Ueirton)
                                                                   D.S.S.  (Texat  Worka,  Baytown)
                                                                   Alleghtny-Ludlum (BrackenriOgf)
                                                                   D.S.S.  (Duqucane)
                                                                   Eaaiern StainUaa  (Baltiaort)
                                                                   Lukcna  (Coateav.llt)
                                                                   National (Wtirton)
                                                                   Arvco (Marion)
                                                                   National (Wairton)
                                                                   D.S.S.  (Texaa Wocka,  Baytovn)
                                                                   Washington Steel  (Wathington)
                                                                   Crucible (Midland)
                                                                   Republic (Mamlon)
                                                                   Carpenter Technology (Reading)
                                                                   Lukena (Coateaville)

                                                                   Lukena (Coateaville)

                                                                   U.S.S. (South Chicago)
                                                                   Crucible (Midland)
                                                                   Allegheny-Ludlua (Br^'-enridge)
                                                                   Crucible (MidUn^;
                                                                   Univeraal Cyclopi (Bridgeville)
                                                                   J 6 L (Uarren)
                                                                   Republic (Haiailion)
                                                                   Copperweld (Warren)
                                                                   Bethleheei (Lackaoanna)
                                                                   Bethlehe* (Lackawanna)
                                                                   Republic (Chicago)

                                                                   Wiacontin (Chicago)
                                                                   Aroco (Middleiovu)
                                                                   CopprrweR (Warren)
                                                                   J 4 L (Cleveland)
                                                                   National (Ueirrcn)
                                                                   Republic (Warren)
Bloom
Slab/Rough
Plate
Slab/Rough
Plate
Slab/Bloc*
Slab
Slab
Bloom
Slab/Bloom
Slab/Blooa
Bloom
Bloom
Bloom
Slab
Bloom

Bloom
Slab
Bloom
Slab
Slab/Bloom
Bloom
                                                    102

-------
-r-
- ~-< ,,*-.-*-. -« ;•—*-* -- ,~ f,,r' 	 1 ;-, , 	 .~.^-*-v -„,-.,-, ; -. _ --«, . -_^ , ,_ 	 ,..,.*.,,. ^
TABLE II-3
PLANTS SAMPLED DURING IRON AMD STEEL STUDY
PACE 4
Sapling
Subcategory Code
2Mf(2>
291 t \
293A-;;
294A(Z>
2. Section 083

087
088
088

C«
H*

K*
K*

0* 4 081
(Revisited)
A -2
D-2

E-2

F-2

C-2

8-2
1-2 ...
,.,,(2)
*2)

285»,,;
290B;*'
293»
3. Fl.t 082

082

083


Plant
Reference Code
0856R
08S6B
0856H
0920H
0860B (02 6 03)

0432-02
0684H-02
0684H (01,03,09,06,07)

0424 (01-03)
0248A

02S6K
0432J

0176 (01-03)

0112B
0946A

0196A (09 4 10)

0384A-06

0632A (01 4 02)

0432A-04
08560
008&A
0112
0240A
08561
0856N
0496 (01 4 03)

0496 (02 4 04)

0860K-01


Plant
Na*M
D.S.S. (Duquesne)
D.S.S. (Edgar Thompson)
D.S.S. (Lorain)
Wheeling Pittsburgh (Hingo Jet.)
D.S.S. (South Chicago)

J 4 L (Aliquippa)
Republic (Chicago)
Republic (Chicago)

Jessop (Washington)
Crucible (Mi^UnJ)

Universal Cyclops (Br idgeville)
J 4 L (Warren)

Carpenter Technology
(Reading)
Bethlehe* (Lackaoanne)
Uisconaip. (Chicago)

(741 (Pueblo)

Inland (East Chicago)

Penn-Disie (Joliet)

J 4 L (Aliquippa)
U.S.S. (Cleveland)
Bibcock 4 Wllcox (Koppel)
Bethlehea (BethlenesO
Copperweld (Warren)
D.S.S. C'^quesne)
U.S.S. (Lorain)
Lufcens (Ccatesvil le)

Lukens (Coatesville)

U.S.S. (Couth Chicago)

j
i
1
i
i

Type of
Operat ion
Slab/Bloosi

Slab/Bloosi
Slab
34" 4 Rod
Mill i
14" Mill
34" Mill
">

-









36", 32", 14".
10", 11" Mills \
Bar Mills !
Merchant
Mill
Bar Mill



Billet \
Mill
Bar
MilU


Rail Mill
»2, 5, 4 6 i
Mills
Bar 4
Rod Mi 'Is
12" Bai
Mill
10" 4 12"






Mills
Rod Mill 1
Rod Hill J
Round Mill I
1
Round Mill ! •
|
Kebar Mill
140",112"/I20",
140"/204" >
112"/120",140"
Mills
30" Plate
Mill
                                       103

-------
TABLE 11-3
PUICTS SAMPLED DimiMG IRON AND STEEL STUDY
PACE 5
Stapling
Subcategory Code
086
086
087
D*
E*
F*
0
J-2
r-2
L-2
M-2
N-2
,.,(2)
(2)
284U)
286B(2>
jSg.(2)
(2)
292 (2)
294B12'
4. Pip* and Tub* 087
Ooo
E-2
K-2
II-2
JJ-2
M-2
Wf»
Plant
Reference Code
OU2D-01
0112D-02
0432A
0248B
0020B
0856H
0176
08608-01
0868B
0060
0384A-02
0396D-02
0020B
0112D
0432C
0584S
0584F
0684B
0860B
0920N
0432A-01
0684H
0196A-01
0240B-O5
0916A
0728
0256C
08S6N
0948A
                                                                            Plant
                                                                   Btthletm (Burn* lUrbot)

                                                                   Bethlehem (Burna Harbor)

                                                                   J 4 L (Aliquippa)

                                                                   Crucible  (Midland)
                                                                   Alleftbeny-Ludlum (Brackenridge)
                                                                   O.S.S.  (Bowatead)

                                                                   Carpenter Technology (Reading)

                                                                   U.S.S.  (Cary Work.)

                                                                   U.S.S.  (Baytown)

                                                                   Armco (Middletovn)

                                                                   Inland  (Eaat Chicago)

                                                                   Interlake (Riverdale)

                                                                   Allegheny Ludlua (Brackenridge)
                                                                   Btthlehea (Burna Harbor)

                                                                   J 4 L (Cleveland)
                                                                   National  (Ecorie)
                                                                   National  (Wcirton)
                                                                   Republic  (Warren)
                                                                   D.S.S.  (Gary)
                                                                   Wheeling  Pittsburgh  (Mingo Jet.)

                                                                   J 4 L (Aliquippa)
                                                                   Republic  (Chicago)
                                                                   CF6I  (Pueblo)
                                                                   Ohio  Steel 4 Tube  (Shelby)
                                                                   Wheat land (Wheat land)
                                                                   Sharon (Sharon)
                                                                   Cyclop. (Sauhill)
                                                                   O.S.S.  (Lor.in)
                                                                   J 4 L (Cnpbell)
160" Plate
Mill
80 " Hot
Strip
44" Rot
Strip
Hot Strip
Hot Strip
160" Plate
Mill
»4 Hot
Hill
84" Hot
Strip
160" Plate
Mill
Hot Strip
4 Sheet
80" Hot
Strip
«4 Hot
Strip
Hoi Strip
Hot Strip
4 Plate
Hot Strip
Hot Strip
Hot Strip
Hot Strip
Hot Strip
Hot Strip

Butt Held
Seaatle.a
Seaaleta
Seavle.a
Butt Weld
Butt Weld
Butt Weld
Seaale.i
Scaale.a
                                                       104

-------
                                                  \
TABLE II-3
PLANTS SAMPLED DUllK IIO» AJD STEEL STOUT
PAGE 6
Sampling
BubcatatorT Cod«
H. Salt Bath Deiceling
1. Oxidisias 131
132
13S
C*
L*
2. Reducing 132
139
L*
0*
I. Acid Picklin»
1. Sulfuric Acid 0)2
094
095
096
097
09S
R*
B-2
1-2
0-2
P-2
Q-2
R-2
s-z
T-2
QQ-2
SS-2
TT-2
WU-2
2. Hydrochloric Acid 091
093
095
099
100
Plant
Referenct Code

0424
0176-04
0440A
0424
0440A
0176 (01-03)
0256M
0440A
0684D

0»SA
0948C
0584E
01121
0760
0684P
0240A
0432A
0856P
0590
0312
OS94
0240B
0256C
0792B
05841
0112A
OS56D
0868A
0612
0396D
0584P
05281
0384A
                                                                            Pl.nt
                                                                   jMlop (W«»hington, Ptoiuylvani*)    Plat*
                                                                   Carp«ntlyn (Port Wayna)                  Bar,  Rod
                                                                   Jaiiop (Wtrhington, Paaaaylvania)    Plat*
                                                                   Joalyn (Port Uayna)                "  Bar(Rod

                                                                   Carpcntar Technology                 Bar,Rod
                                                                   (R*adin()                            Strip,Wir«
                                                                   Vnivctsal Cyclop* (Tituavill«)       Bar,Billet
                                                                   Jolyn (Port Wayne)                  Bar,Rod
                                                                   Republic (Maeaillon)                 Strip
                                                                   UN (B*aver Palli)                   B
                                                                   TS4T (Indiana Harbor)                C-N
                                                                   national (Midveit)                   C
                                                                   BethUh*. (Lebanon)                  B-H
                                                                   Stanley (Nev Britain)     ,           C-AD
                                                                   Republic (Hanitlon)      '           B
                                                                   Copperveld (Warren)                  B-K
                                                                   J 4 L (Ali<|uippa)                    B-H, C-H
                                                                   U.S.8. (Cleveland)                   B
                                                                   Malaon Steel (Chicago)               B-AD
                                                                   Pitttiaunt (Youngetoon)              B-AU
                                                                   Walker Steel 4 Wire (Perndale)       B-AU
                                                                   Ohio Sheet 4 Tube (Shelby)           B-N
                                                                   Cyclopa-Sawhill (Sharon)             B-N
                                                                   Tho*peon Steel (Chicago)             C-AI7
                                                                   National (Hidveat)                   C-N
                                                                   Bethlehtn (Sparrova Pt.)             C-N
                                                                   U.S.S. (Itvin)                       C-N
                                                                   U.S.S. (Pairfield)                   C-N

                                                                   Rorthveitern SiW (Sterling)          C-N
                                                                   InterUk. (Riveritale)                C-N
                                                                   Netional (Weirton)                   C-AK
                                                                   HcLouth (Gibraltar)                  C-AR
                                                                   Inland (Eaat Chicago)                C-N
                                                    105

-------
                                                                                                                              "1
                                                                                                                                 •1
TABLE II-3
PUNTS SAMPLED DOKINC IRON AMD STEEL STUDY
PACE 7
Sampling
SubcatcRory Code
1-2
B-2
V-2
W-2
Z-2
Y-2
Z-2
AA-2
BB-2
3. Combination Acid 121
122
123
m
125
A*
C*
D*
F»
i*
L«
0*
0*
J. Cold Forming
1. Cold lollies 101 A 4 l(1>
102
10}
10)
106
D*
I*
P*
X-2
IB
DD-2
EE-2
FF-2
W-2
U-2
rr-2
PUnt
Reference Code
0856P
0480A
0936
-
00601
-
0396D
03B4A
0060
0900
0176
00«8A
004 8 D
0674E
0900
0424
Ci«8A i i
0856B
0432*
0440A
0176
OO'.OO

0020 • 4 C
0384A
OS84F
058* r
0112B
02481
0432K
0156B
00601
0060
0584E
0112D
03S4A
05S4P
06841
04320
                                                                           Plant
                                                                  U.S.S. CCuy«hos«)
                                                                  Hire Sale*, Inc. (Chicago)           BHI
                                                                  Dominion (Hamilton)                  C-AR
                                                                  Araco (Aahland)                      C-Aft
                                                                  Stael Co. oC Canada (Hamilton)       C-AJt
                                                                  Interlake (Riverdale)                C-N
                                                                  Inland (East Chicago)                CHI
                                                                  Araco (Middletovn)                   CHI

                                                                  Waahington Steel (Waahington)        CHI
                                                                  Carpenter Technology                 BHI
                                                                  Babcock 6 Wilcox (Beaver Falli)      BHI
                                                                  Babcock 6 Wilcox Uoppel)            BHI
                                                                  Plymouth Tuba (Dunkirk)              BHI
                                                                  Waahingtoa Steel (Wathington)        CHI
                                                                  Jessop (Washington, Pennsylvania)    BHI
                                                                  Crucible (Midland)                   CHI
                                                                  U.S.S. (Homstead)                   BHI
                                                                  J 6 L (Louiaville)                   C-K
                                                                  Joalyn (Fort Wayne)                  B-N
                                                                  Carpenter Technology                 C-N
                                                                  Tuba Aaaoeiatee (Uouatoa)            3-N
                                                                  Allegheny-Uidlu» (W. Laechburg)      Recirc.
                                                                  Inland  (Eaat Chicago)                Recirc.
                                                                  National  (Weirton)                   Direct Appl.
                                                                  National  (Weirton)                   Recirc.
                                                                  Bethlehem (Lackavanna)               Direct Appl.
                                                                  Crucible  (Midland)                   Recirc.
                                                                  J  4  L  (Louiaville)                   Recirc.
                                                                  Cabot  Steel  (Kokomo)                 Recirc.
                                                                  Armco  ( Vshland)                      Recirc.
                                                                  Araco  (Mlddleton)                    Recirc.
                                                                  National  (Midveit)                   Combination
                                                                  Bethlehett (Burn* Herbor)             Racirc.
                                                                  Inland (East Chicago)                Recirc.
                                                                  National  (Weirton)                   Direct Appl.
                                                                  Republic  (Cadsden)                   Recirc.
                                                                  J  4  L  (Hennepin)                     CaeAiA«r?on
                                                    106

-------
TABU 11-3
PLAMTS SAMPLED DURING IRON AND STEEL STUDY
PACE 8
Sampling
Subcategorv Code
*,{»
302(2
30*"'
305<2>
S0*<"
307
308 2
3'°(2)
312<2)
313<2>
3i5;;i
316 2
318 2
319;,'
320?5
323W'
2. Pipe 4 Tube KH'?2)
332(2)
333<2>
33j(2)
336: :
337'
338(2)
I. Alkaline Cleaning 152
156
157
I*
317 2
L. Hat Coating
1. Calvaniting 111
112
MA
116
Plant
Reference Code
002 OB
0060C
0176
0176
0248B
02A8B
0320
0432C
OA32D
09A8C
058AB
0684
0684B
0856P
0856F
0684D
0060
0492A
0256C
0684L
0684A
0856N
0856Q
0678C
0240B
0176
01121
0432K
0432K
0796A

0612
0396D
0948C
01121
                                                                            Plant
                                                                             Naoe
                                                                   Allegheny Ludluai (W.  Uechburg)
                                                                   Anco  (Zaneiville)
                                                                   C«rp«nter Technology  (Reading)

                                                                   Carpenter Technology  (Reading)

                                                                   Crucible (Midland)
                                                                   Crucible (Midland)
                                                                   Ford Motor Co (Dearborn)
                                                                   J t L  (Cleveland)
                                                                   J 4 L  (Uennepin)
                                                                   J S L  (E. Chicago)
                                                                   National Steel (Detroit)
                                                                   Republic Steel (Cleveland)
                                                                   Republic Steel (Warren)
                                                                   U.S.S. (Cuyahoga Uorkl)
                                                                   U.S.S. (Fairle»)
                                                                   Republic Steel (Maiaillon)
                                                                   Araco  Steel (Middletoon)

                                                                   Lone Star Steel (Lone Star)
                                                                   Cyclop* (Sharon)
                                                                   Republic (Elyria Of.)
                                                                   Republic (Youngar.ovn)
                                                                   U.S.S. (Lorain)
                                                                   U.S.S. (KcKee)
                                                                   Bethlehe* (Lebanon)

                                                                   J • L (Louiaville)
                                                                   J 4 L (Louisville)
                                                                   Tiaken (Canton)
                                                                   Northvettern St«el (Sterling)
                                                                   Interlake (RiverJale)
                                                                   YS4T (£«•i Chicago)
                                                                   Bethlehem (Lebanon)
      4 Oil
        Oil
Continuoua

Batch
4 Cont.
Cont.
Cont.
Batch
                                                      107

-------
TABU 11-3
PLAITS SAMPLED DURING IJUV AND STEEL STUDY
PACE 9

Subcategory






2. TCTM


Saapling
Code
118
119
1-2
V-J
MM-2
m-2
113
00-2
PP-2
Plane
Reference Code
0920E
0476A
08560
0936
0856F
0920E
0856D
0060R
0856D
                                                                            Plant
                                                                             Naae
    3.  Other
                          116
                                           0112Z
                                                                   Wheeling-Pitt  (Martini  Ferry)
                                                                   Laclede  (Alton)
                                                                   U.S.S. (Cleveland)
                                                                   Hire  Salee  (Chicago)
                                                                   O.S.S. (Fairleaa)
                                                                   Wheeling-Pitt  (Martini  Ferry)

                                                                   O.S.S. (Train)
                                                                   Armco (Hiddletovn)
                                                                   O.S.S. (Imin)

                                                                   Bethlahea (Lebanon)
. Aluinuai
(1) Data exiata for aore than one viait.
(2) Verification analyaea protocol uaed afthia plant viait.-
NA: Saaple code nuaber vaa not aaaigned.
*:  Smmfled by Datagraphica.

Key to Abbreviationai

U-OC:  "Vet-Open Co*buation" type air pollution control eyatea.
W-SC:  "Uet-Suppteaaed Coafauation" type air pollution control  ayata
B   t  Bat ch
C   t  Continuoua
AO  i  Acid Recovery
AR  1  Acid Regeneration
                                                     108

-------
                               TABLE II-4

                         INDUSTRY-WIDE  DATA BASE
                          IRON t STEEL  INDUSTRY
Number Sampled for Original Guidelines .Study

Number Sampled for Toxic Pollutant Studies

Total Number Sampled (Rot including re-visits)

Number Responding to the D-DCP'»


Total Number Sampled or Surveyed via D-DCP'a

Number Responding to the DCP'a
  No. of
Operation*

   133

   161

   244

   174 incl.
   44 above

   374

   2023
                              109
                                                                                                t
                                     fe'.i

-------
                               TABLE  I1-5

                 REVISED STEEL  INDUSTRY  SUBCATEGORIZATION

A.  Cokemaking

    1.  Byproduct

        *.  Iron & Steel - Biological
        b.  Iron & Steel - Physical Chemical
        c.  Merchant - Biological
        
-------
TABLE II-5
REVISED STEEL INDUSTRY SUBCATEGORIZAHOH
PAGE 2	
    3.  Flat

        a.  Hot Scrip and Sheet (Carbon and Specialty)
        b.  Plate - Carbon
        c.  Plate - Specialty

    4.  Pipe and Tub*

H.  Salt Bath Deicaling

    1.  Oxidizing

        a.  Batch Sheet/Plate
        b.  Pitch Rod/Wire/Bar
        c.  Bat
-------
TABLE II-5
REVISED STEEL IKDUSTRY SUBCATEGORIIATIOH
PACE 3
J.  Cold Foraing

    1.  Cold Rolling

        a.  Recirculation - Single Stand
        b.  Recirculation - Multi Stand
        c.  Combination
        d.  Direct Application - Single Stand
        e.  Direct Application - Hulti Stand

    2.  Pipe and Tube

        a.  Water
        b.  Oil EauUion

K.  Alkaline Cleaning

    1.  Batch
    2.  Continuous

L.  Hot Coat ing«

    1.  Galvanizing, Terne 6 Other
    2.  FUM Scrubber
                                112

-------
                                         tABU II-6

                         CROSS REFERENCE OF REVISES STEEL INDUSTRY
                        SUBCATECORIZATI0S TO PRIOR SUBCATECORIZATIOH
Revised Subcategorigation

A.  Cokemaking

    1.  By-Product

        a.  Iron & Steel - Biologic*!
        b.  Iron & Steel - Physical Chemical
        c.  Herchant - Biologic«l
        d.  Merchant - Physical Chemical

    2.  Beehive

B.  Sintering

C.  Blast Furnace

    1.  Iron

    2.  Ferromanganeat (BPT only)

D.  Steelmaking

    1.  BOF

        a.  Semi-vet
        b.  Wet - Open Combustion
        c.  Wet - Suppressed Combustion

    2.  Open Hearth - Wet

    3.  EAF

        a.  Semi-wet
        b.  Wet

E.  Vacuum Degassing

F.  Continuous Casting
  Prior Subcategoriiation
(1974 and 1976 Regulations)

A.  By-Product Coke

B.  Beehive Coke
     Remarks
C.  Sintering

D.  Blast Furnace - Iron

E.  Blast Furnace - FeSta
F.  BOF - Se*i-wct

C.  BOF - Wet



H.  Open Hearth - Wet

I.  EAF - Semi-«et

J.  EAF - Wei


K.  Vacuum Degas*ing

L.  Continuous Casting
                               Segment Addej
                               Segment Added
Segment Added
Segment Added
C.  Hot Forming

    1.  Primary
        a.  Carbon and Specialty vo/scarfers
        b.  Caibon and Specialty u/scsrfcr*
M.  Hot Formir.g - Primary

    1.  Carbon wo/scarfers
    2.  Carbon Wacarfers
    3.  Specialty
                                                                              Segments
                                                                              Changed
                                           113

-------
TABLE 11-6
CROSS UFERENCE OF REVISED STEEL INDUSTRY
SCBCATKCORIZATIOM TO FRIOtl SUBCATECORIZATIOH
PACE 2
                                                                                                     "1
Reviled Subcategorization

    2.  Section

        a.  Carboa
        b.  Specialty

    3.  rut

        a.  Hot Strip and Sheet
        b.  Plate - Carbon
        c.  Plate - Specialty


    4.  ripe and Tub*
H.  Scale Removal
    1.  Oxidizing

        a.  Batch Sheet/Plate
       ' b.  Batch Rod/Wire/Bar
        c.  Batch Pipe/Tube
        d.  Contiououa

    2.  Reducing

        a.  Batch
        b.  Continuoua

I.  Acid Pickling

    1.  Sulfuric Acid

        a.  Rod, Hire and Coil
        b.  Bar, Billet and Bloom
        c.  Strip, Sheet and Plate
        d.  Pipe, Tube and Other Product!
        e.  Fume Scrubber
    2.  Hydrochloric Acid

        a.  Rod, Wire and Coil
        b.  Strip, Sheet and Plate
        c.  Pipe, Tube and Other Product?
        d.  Fuae Scrubber
        e.  Acid Regeneration
  Prior Subcategorization
(1974 and  1976 Regulation*)

It.  801 Forming - Section

    1.  Carbon
    2.  Specialty

'0.  Hot Forming - Flat

    1.  Hot Strip * Sheet
    2.  Plate

P.  Hot Forming - Pipe and Tube

    I.  laolated
    2.  Integrated

X.  Scale  Removal

    a.  Kolene
    b.  Hydride
 Remark!
Segment
Changed
                                   Segment!
                                   Changed
Segment a
Changed
Q.  Pickling - Sulfuric Acid -
    Batch and Continuoua

    a.  Batch - (pent  liquor,      Segment!
        no rinaea                  Changed
    b.  Continuoua - Neutralization
        (liquor)
    c.  Continuoua - Neutralization
        (R, FHS)
    d.  Continuous - Acid Recovery
        (new facilitiee)

R.  Pickling - Hydrochloric Acid -
    Batch and Continuoua
    a.  Concentrate! -
        nonregenerat ive
    b.  Regeneration
    c.  Riniei
    d.  Fume hood (crubbera
                                                                                  Segaenta
                                                                                  Changed
                                      114

-------
                                                                                                            .1-
TABLE II-6
CROSS REFERENCE OF REVISED STEEL INDUSTRY
SUBCATEGORIZATION TO PRIOR SUBCATECORIZATION
PACE 3                      	     	
Revived Subcategoritatioo

    3.  Combination Acid

        a.  Rod, Wire and Coil
        b.  Bar, Billet and Bloom
        c.  Cont. - Strip, Sheet and Plate
        d.  Batch - Strip, Sheet and Plata
        e.  Pipe, Tube and Other Producta
        f.  Fume Scrubber

J.  Cold Forming

    1.  Cold Rolling
        a.  Recirculation - Single Stand
        b.  Recirculation - Hulti Stand
        c.  Combination
        d.  Direct Application - Single Stand
        e.  Direct Application - Multi Stand

    2.  Pipe and Tube

        a.  Water
        b.  Oil emulsion

K.  Alkaline Cleaning

    a.  Batch
    b.  Continuou*

L.  Hot Coating*

    1.  Galvanizing, Terne & Other
    2.  FUM Scrubber
  Prior Subcategorization
(1974 and 1976 Regulation*)

W.  Combination Acid Pickling
  .  (Batch and Continuous)
    Subcategory

    a.  Continuou*
    b.  Batch - Pipe and Tije
    c.  Batch - other
S.  Cold Rolling
    a.  Recirculation

    b.  Combination
    c.  Direct Application
   Reaark*

Segment*
Changed
Segment*
Added
                                 Segment Addec
                                 Segment Addcc
Z.  Continuou* Alkaline Cleaning
T.  Hot Coating* - Galvanizing

    a.  Galvanizing
    b.  Fum* acrubber
Subdivision
Added

Segment*
Changed
                                       115

-------

                    TABU 11-7
MtIP HASTE CMSUTIOK COS TO IUTU FOILOTIO* CQRCOt

               IKOH AHP STBEL
BFT (tofla/yr)
Subcateftorr
A.


B.
C.
D.









I.
T.
C.















H.








Cokeawkiaf
1. Iroa 4 Sec*l
2. Merchant
Sinter inj
Iroaatakinf
Statlmakief
t. *or
a. Seai-Wet
b. Wet Suppraaaed
c. Hat Opea
2. Open learta, - Hat

3. Electric Fttraace
a. Seau-Uet
b. Hat
Vacuum Defaaaiae,
Contittuoua Caatiae.
Hot Faniaa.
1. Friaary
a. Carbon a/Scarfer
b. Carboa vo/Scarfer
c. Spec. »/Scurfar
d. Spec. vo/icarttr
2. Sectioa
a. Carboa
b. Specialty
3. flat
a. Carbon KS4S
b. Spec. HS4S
c. Carbon Flita
d. Spec. Plate
4. Fipe 4 Tube
a. Carboa
b. Specialty
Salt Bath Deacaliaf.
J. Oxidiiiat
a. Batch Saeet/Plate
b. Batch lod/vire
c. Batch Pipe/T»be
d. Cootlnuova
2. leducint
a. Batch
b. Cont onove
•a. of
Flanta

11
11
16
43


9
5
13
4


3
*
33
42

30
30
5
12

52
20

30
1
11
3

25
t


5
3
2
7

4
2
BAT (coat/
rr)

Model Ma. of Model to. of
Plant Subcatttory flant • Plant Subcatecor* Flanta

1,239
546
165,940
119,465


too
7,550
65,260
30,3*0


1,500
19,270
to
4OO

80,262
20,718
19,738
6,498

16,577
4,578

38,479
4,883
16,979
5.342

759
2,479


380
440
540
420

160
60

38,409
6,006
2,655,040
5,136,993


7,200
37,750
822,380
121,440


4,500
115,620
2,640
16,800

2,407,8(0
621,540
98,690
77,976

862,004
131,360

1,154,370
34,181
186,769
26,710

18,975
19,«32


1,900
1,320
1,080
2,940

640
120

Z8 •
9 *
13 *
39 550


•
S 70
13 200
* 265


3
6 42
31 40
25 40

30
29
S
11

48
17

30
7
11
5

25
B


3
3
2
7

4
2

*
*
a
21,450


-
350
2,400
1,040


-
252
1,240
1,000


_
.
-

-
-

.
-
-
-

*
-


-
-
-
-

-
-

8
<
1
2


0
1
1
0


0
1
0
7

2
2
0
2

7
1

2
0
1
0

1
0


0
1
0
1

1
0
fttl (toot An)
Modal
Plant 8ubcal«lory

1,314
292
165,940
120,015


800
7,620
63,460
30,625


1,500
19,310
120
440

80,262.(jJ
20,7ie;{:
19738
6,498U)

16,377',
6,578a)

38.479" >
•88J
16,979"}
?,34Jl

759
2,479(1)


380
440
540
420

160
60

10,512
2,336
165,940
240,030


0
7,620
'63,460
1
f
•*•



r^~


\
\


_



0
19,310
0
3,080

160,524
41,436
0
12,996

116,039
6,578

76,938
0
16,979
0




_











j
i
739 j
|._

!
0
440 ;
0
420 j


160 !
0
                                                                                                    i  •-/
                                                                                                    ;  /
                          116

-------
TAIL! II-7
SOLID MASTt CEXZtAlIO* DUt TO HATH POLLUTION
IKOK AMD STUL l«X»T»T
TUX 2
IP? (tont/vr)
Subcateiory
I. Acid Pickliat
1. Sulfuric
• . S/S/7 Brat
b. I/H/C Km
c. 1/8/B Neut
d. p/t M«t
e. S/S/P AO:;:
f. «/a/c AO:;J
». B/./B AU"'
h. P/t AC11'
2* Hydrochloric
«. S/S/P Kent
b. R/W/C Reut
c. P/T Haul
d. S/S/P At
3. Co*blB«tioa
t. Batch S/S/P
ft. Conttauoua S/S/P
c. t/tf/C
d. B/B/B
• - P/T
J. Cold Foraiiag
1. Cold (ollios
a. ftnfla Stead Kecire
b. Multi Stud Bacirc
c. Coe*inailoo
d. Single Stead DA
«. Multi Stud QA
2. CP - Pip* t Tub*
a. Water
t>. Oil
t. Alkaline Cleaning
1. Ketch
2. Coot inuott*
L. lot Costing
1. C-tlvaniriaf
e. S/S'M vo/PS
b. S/S/'H «/fS
c. w/r »o/rs
d. HP/F WPS
2. Terue
e. S/S/H «o/n
b. S/S/K WPS
3. Othtt
d. S/I/H M/PS
b. S/.l/M WPS
c. UP, r IK/PS
d. UP/P WPS
TOTALS
(1)1 Beaed upon current pract
(2)t Perrou* aulfate cryttel
- t No liait it toBA/vtanderda
* > Sludie ertaeret ioo at thi
lk>. ot


23
16
IS"
17
2
5
0
1

21
7
2
4

9
14
9
3
11


13
21
10
9
10

9
19

22
22


11
12
10
t

1
3
"
4
0
2
0

icta of POTV
diapoaal
etc being pr
• level it ai
SAT (tona/yr)
Modal No. ot Hodel • Mo. of


74,780
16,260
22,720
13,360
13,440
2,340
4,680
1,360

83,280
3,640
3,140
41,440

3,080
27,640
8,120
4,360
4,740


40
700
9,300
340
1,600

140
420

20
260


1,380
1,640
440
320

240
340

960
1,220
80
100

diichergea.

oeulgatcd for
aieul and it


1,719,940
260,150
340,600
227,120
26,680
11,700
0
1,560

1,790,860
25,480
6,280
165,760

45,720
386,960
73,080
13,680
52,140


520
14,700
93,000
3,060
16,900

1,260
7,980

440
5,720


24,840
19,680
4,400
3,120

240
1,020

3,840
0
160
	 0
19,963,367


thia tubdivia
ine lud*d In th


23
16
15
17
2
5
0
1

21
7
2
4

9
14
9
3
11


13
21
10
9
10

9
19

22
22


14
11 *
9
6 *

1
3 •

3
0 *
2
0 •



ion.
• KPT Ml>.j4»* ••


4
18
3
9
0
0
0
0

3
8
1
0

0
i
6
1
8


3
3
0
0
0

2
0

9
9


2
• 1
7
• 7

1
• 0

0
• 0
4
	 ; o
27,952



PSES (ton./yr)
Plant


74,780
16,260
22,720
13,360
.
.
.
-

85,280
3,640
3,140


3,080
27,640
8,120
4,360
4,740


40
700
9,300
340
1,800

.
1,320

_
-


1,380
1,640
440
520

240
340

960
1,220
60
100




Subeatee.ory


299,120
292,680
68,160
120,240
.
.
_
-

255,840
29,120
3,140


0
27,640
64.960
4,560
37,920


120
2, IOC
0
0
0

_
0

_
-


2,760
1,640
3,060
3,640

240
0

0
0
320
	 f
2,162,«7



                                                          117
                                                                                                                                                  4

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-------
                               VOLUME I

                             SECTION III

                  REMAND ISSUES ON PRIOR REGULATIONS
Introduction

After reviewing the 1974 (Phase I) and 1976 (Phase II) regulations for       ||
the  steel  industry,  the  Court of Appeals ordered EPA to reconsider
several matters.  This section provides  a  summary  of  the  Agency's
evaluation  and  response  to  the  "remand  issues".   The respective
subcategory reports provide  the  Agency's  responses  to  subcategory
specific remand issues.

1.   Site-Specific Costs

     In its challenge to the Phase I regulation, the industry asserted
     that EPA's cost estimates did not include allowances  for  "site-
     specific"  costs.   The  industry  submitted  no data showing the       \'$
     magnitude of site-specific costs.  The Agency responded  that  it       '"™
     included  all  costs which could be reasonably estimated and that
     it believed its estimates were  sufficiently  generous  to  cover
     site-specific  costs.   On  this  basis,  the court rejected this
     challenge to the regulation.  American Iron and  Steel  Institute
     v.  EPA, 526 F.2d 1027 (3d Cir. 1975), modified i_n part, 560 F.2d
     589 (3d Cir. 1977), cert, den. 98 S. Ct 1467 (1978).

     In the Phase II proceedings, however, evidence  of  the  possible
     magnitude  of "site-specific" cost was presented.4 On this basis,
     the court ordered EPA to reevaluate its cost estimates  in  light
     of  site-specific costs.   In particular, the court ordered EPA to
     include these costs, or analyze the generosity of  its  estimates
     by  comparing model cost estimates with actual reported costs, or       !?|
     explain why such an analysis could not be done.                         iy
                                                                             S
     In response to the court's decisions, the Agency reevaluated  its       l ^
     cost  estimates  for Phase I and Phase II operations.  First, the
     Agency included in its estimates many "site-specific" costs which
     were not included in prior estimates.5  In the Agency's view,  it
     has included all "site-specific costs" that can be reasonably and
     accurately estimated without detailed site-specific studies.  The
4This evidence consisted of the  plant-by-plant  compliance  estimates
for facilities located in the Mahoning Valley region of Eastern Ohio.

5These newly added cost items include:  land acquisition  costs,  site
clearance   costs,  utility  connections,  and  miscellaneous  utility
requirements.  (Reference is made to Section VII)
                                12:
Preceding page blank

-------
     remaining  "site-specific"  costs  not  included  are  so  highly
     variable and inherently site-specific  that  reasonably  accurate
     estimates  would  require  an  evaluation  of the factors as they
     apply to  each  operation.   It  should  be  noted  that  studies
     commissioned  by  AISI, itself, also exclude site-specific costs.
     For example, in Arthur D, Lictle's Steel and the Environment -  A
     Cost  Itnpact  Analysis,  site-specific costs and land acquisition
     costs were excluded ". . .because  detailed  site-specific  studies
     would be required."

     Second,  the Agency included in its cost estimates allowances for
     unforeseen expenses.  The model-based  cost  estimates  for  each
     subcategory include a  15% contingency fee.*
     Third,   the   Agency  has  based  its  cost  estimates  on  many
     conservative assumptions.  For instance, in  most  subcategories,
     the  Agency's  cost estimates are based upon individual treatment
     of wastewaters from all operations  within  each  subcategory  at
     each  plant  site.   In fact, however, the industry has installed
     and will continue to  install  less  costly  "central  treatment"
     systems   to   treat   combined   waste   streams   from  several
     subcategories.  Additionally, EPA's model based estimates reflect
     off the shelf parts  and  costs  for  "outside"  engineering  and
     construction services.7 In fact,  however, the industry often uses
     "in-house"  engineering  and construction resources, and improves
     wastewater quality by "gerrymandering' existing treatment systems
     and upgrading operating and maintenance practices.  The  Agency's
     cost  estimates  reflect  treatment  in  place  as  of  1976  and
     treatment to have been installed  by  January  1978  [based  upon
     survey  (DCP)  responses);  and facilities in place as of July 1,
     1981.  Tiie Agency updated the status of the industry from January
     1978 to July 1981 from personal knowledge of  Agency  experts  on
     the  industry;  NPDES  records;  and,  in  some  cases, telephone
     surveys.

     Fourth, EPA has compared its model-based cost  estimates  to  the
     costs  reported  by the industry.  This comparison shows that the
     Agency's estimates  are  sufficiently  generous  to  reflect  all
     costs,  including  "site-specific"  costs.   Model-based estimates
     cannot be expected to precisely reflect the costs incurred or  to
     be incurred by each individual plant.  Variations of greater than
     i.50%  would  not  be considered outside normal confidence levels.
     For example, in  Steel  and  the  Environment  -  A  Cost  Impact
     Analysis,   a study t/ Arthur D. Little, Inc., commissioned by the
     AISI, the authors irJUcated that cost estimates were within ± 50%
•This contingency fee was also included in previous cost estimates
7The model estimates include 15% for engineering services.
                                12C

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     for individual process steps and t 85%  for  individual  plants.'
     Often,  variations from model estimates cannot be explained.  The
     validity of model estimates, therefore, should be judged  by  the
     ability  to depict actual costs for subcategories of the industry
     for the industry, as a whole where several treatment systems  are
     evaluated collectively.

     The  Agency's  comparison of model-based cost estimates and costs
     reported by industry involved two complimentary analyses.  First,
     the Agency compared actual reported  treatment  costs  (including
     all  site-specific  costs)  to  the  model cost estimates for the
     treatment components in place at  the  reporting  plants.   These
     comparisions  include costs for all plants for which sufficiently
     detailed cost information were provided, taking into account  the
     level  of treatment in place.  To generate valid comparisons, the
     model cost estimate was scaled to the actual  production  of  the
     reporting  plant  by  the application of the accepted engineering
     "six-tenths" factor.  The Agency scaled production of  the  model
     to actual production of the reporting plant because, in its view,
     this   produces  the  most  reliable  cost  comparison.   Another
     possible method of comparison would be to scale the f1 ow  of  the
     model  to the actual flow of the reporting plant.  This method of
     scaling would overstate treatment costs because costs are  highly
     dependent  on  flow  volume (higher flows require larger and more
     costly treatment systems) and many plants in the industry use and
     discharge more water than necessary.  Also,  flow  data  are  not
     available  for all plants while production data are available for
     most operations and plants in  the  industry.   This  comparative
     analysis  is  summarized  below for those subcategories where the
     Agency was able to  obtain  reliable  subcategory-specific  costs
     from the industry.
                                                                             I .
•See pages B-64 and B-65 of Steel and the Environment - A Cost  Impact
Analysis which AISI submitted to EPA during the Phase II ruiemaking.

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  Treatment In Place v. Model Estimates for Same Treatment
Subpart Actual
(process) Cost
(SxlO-*)
A.
B.
C.
D.
E.
F.
G.
Cokemaking
Sintering
Ironmaking
Steelmaking
Vacuum Degassing
Continuous Casting
Hot Forming
Total
56.05
6.43
110.12
37.61
2.19
29.38
78.87
320.65
EPA
Model
Estimate
(SxlO-*)
54.24
10.53
123.39
42.32
2.32
23.00
107.46
363.26
Actual as %
of Model
103
61
89
89
94
128
73
88.3
This  summary  shows  that actual reported costs for the industry
(including all site-specific costs) represent about  88%  of  the
model  estimates  for  the  same  treatment  components.  On this
basis,  the  Agency  concludes  that  its  model  estimates   are
sufficiently generous to reflect site-specific costs.

In  the  second comparison of reported costs and model estimates,
the  Agency  compared   the   reported   costs   (including   all
site-specific  costs) of plants meeting BPT (or BAT) to the model
estimates  for  the  BPT  (or  BAT)   treatment   system.    This
methodology, vhich the Agency presented in its brief in the Phase
II  proceedings,  demonstrates  that the effluent limitations and
standards can be achieved with treatment  systems  comparable  to
the Agency's treatment models at costs comparable to the Agency's
estimated  costs.   This  comparison,  which  also  is based upon
scaling of production by the "six-tenths factor,"  is  summarized
below:
                           12C

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                          SUMMARY

    Complying Plant Costs v, Model Compliance Estimates
Subcategory Actual
(process) Costs
($x10-*)
A.
B.
C.
D.
E.
F.
G.
Cokemaking
Sintering
Ironmaking
Steelmaking
Vacuum Degassing
Continuous Casting
Hot Forming
40.71
5.92
33.16
37.61
2.08
19.36
77.64
Model
Estimate
($xlO-«)
40.60
6.35
51.97
47.74
2.48
18.61
106.22
Actual as %
of Model
100
93
64
79
84
104
73
Total
216.48
273.97
                                                            79.0
Again,  this  summary  shows that total reported costs (including
all site-specific costs) for  plants  meeting  required  effluent
levels  is  about  79%  of  model  estimates.  On this basis, EPA
likewise  concludes  that  its  model-based  cost  estimates  are
sufficiently generous to reflect site-specific costs.

As .noted  in  the  subcategory  reports for many of the Phase II
operations,  central  treatment  of  wastewaters  from  finishing
operations  is  common  in  the  steel  industry.   The cost data
reported by the industry for these central treatment systems  are
often  not  directly  usable  for  the  purpose  of verifying the
Agency's cost  estimates  for  individual  subcategory  treatment
systems.  As noted earlier, the Agency considered co-treatment of
wastewaters at  plants within subcateogries, but did not consider
co-treatment   or   central  treatment  across  subcategories  in
developing cost  estimates.   To  determine  the  impact  of  the
extensive  amount  of  central  treatment  in the industry on the
Agency's  ability  to  accurately  estimate  costs,  the   Agency
compared   actual  industry  central  treatment  costs  with  the
Agency's  model  based  cost   estimates   for   the   respective
subcategories   included  in  the  industry's  central  treatment
systems.  This comparison is shown below.
                                                               \

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                                                                   1.
        ACTUAL COSTS vs. EPA CO-TREATMENT ESTIMATES
PLANT

0112B
0112H
0432K

0/96 &
0796A
0868A
0868A
0176
0460A
0612

0728
                                Section)
     SUBCATEGORIES

     Hot Forming (Primary, Secti
     Pickling (HC1, Combination)
     Pickling, Scale Removal, Alkaline
       Cleaning
     Vacuum Degassing, Continuous
     Casting, Hot Forming (Primary,
     Section, Pipe and Tube),
     Pickling (H,S04), Cold Rolling
     Cold Rolling, Pickling
     (HC1, H,S04), Hot Coating,
     Alkaline Cleaning
     Hot Forming (Primary, Section)
     Hot Forming (Primary and Section),
     Cold Rolling (Direct Application),
     Cold Worked Pipe and Tube, Pickling
     (HC1, H*S04, Combination), Scale
     Removal, Alkaline Cleaning
     Hot Forming (Primary, Section)
     Hot Coating (Galvanizing),
     Pickling (HC1)
     Hot Forming (Pipe and Tube),
     Pickling (H,S04), Hot Coating
     (Galvanizing)
ACTUAL COST

$ 2,578,000
    746,000
                                                   9,350
                                              16,770,000
                                               4,857,000
                                                 303,000
                    TOTAL
                                               3,060,000
                                                 340,000

                                               1,645,000


                                                 198,000

                                              31,432,000
 MODEL COST

$ 5,133,000
    882,000

  1,374,000
                                                              15,793,000
                  5,235,000
                  2,317,000
                  5,587,000
                  1,017,000

                  3,914,000
                                                                 437,000

                                                              41,689,000
These data clearly indicate that in total, the Agency's estimates
for separate subcategory-specific treatment  systems  far  exceed
those  costs  reported by the industry for central treatment.  Of
particular interest are the data reported for plants  0796-0796A,
a  central  treatment  facility that achieves the BAT limitations
for the operations included in the  central  treatment  facility.
The  Agency's  estimate  is within six percent of the actual cost
reported by the company.  This system includes several  miles  of
retrofitted  wastewater  collection  and  distribution piping not
likely to be included in most central treatment  systems.   Based
upon   the   above,   the  Agency  concludes  that  its  separate
subcategory-specific cost estimates for the Phase  II  operations
are  sufficiently  generous  to include those site specific costs
likely to be incurred for most central treatment facilities,  and
may  be  overly  generous  in depicting potential costs for steel
finishing operations as a whole.

Another approach to judging the sufficiency of the Agency's model
estimates, to account for "site-specific" costs, is to  determine
the  adequacy  of  the  Agency's cost estimates for several steel
mills located in the Mahoning Valley of Ohio.  Studies  of  these
plants  completed  in 1977 included cost estimates for compliance
with the previously promulgated and proposed Phase I and Phase II
                           130

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                                                      /
                                                     /
     requirements.  These eight plants were among the  oldest  in  the
     country.  Estimated compliance costs were furnished by the owners
     of the plants, based upon actual site inspections and engineering
     studies, aT;5 were verfied by the Agency's engineering contractor.

     The  tables  summarizing  those  studies,  which were part of the
     record of * he Phase II rulemaking, are reproduced as Tables III-l
     through III-3.  Table III-l summarizes the  estimated  compliance
     costs  for  the Youngstown Sheet and Tube Corporation Brier Hill,
     Campbell, and Struthers Works.  Column II shows  YS&T's  estimate
     of  BAT  compliance  costs,  totaling  $54,106,000, including all
     site-specific  costs.*   The   Agency's   contractor   estimates,
     $51,214,000,  is  shown  in Column 12.  In Columns #3 and 14, the
     Agency's contractor scaled the flow and  production  of  the  BAT
     cost  model  to  the  actual  flow  and  production  of the mills
     involved, yielding cost estimates of $53,218,000 and $60,568,000,
     respectively.  By either method of scaling, the Agency's estimate
     is representative of YS&T's estimate which includes site-specific
     costs.  In fact, the estimate scaled by  production  (the  method     I
     now  used  for  all  cost  estimates) more than accounted for the
     significant "site-specific" costs the industry claimed the  model
     could not reflect.10

     Analyses  of  estimated  compliance costs for facilities owned by
     United States Steel Corporation and  Republic  Steel  Corporation
     yield  similar  results.   Table  III-2  shows  that U.S. Steel's
     $33,110,000 BAT estimate (including $13,145,000 site  costs)  for
     its  McDonald  Mills  and Ohio Works plants is within 4% of EPA's
     model estimate of $34,389,000 (scaled by production).  Similarly,
     Table  II1-3  shows  that  Republic  Steel's  BPT   estimate   of
     $70,099,000  (including  $15,590,000  site costs) for its Warren,
     Youngstown, and Niles plants is within 4% of the  Agency's  model
     estimated  cost  of  $72,640,000  for physical/chemical treatment
     (scaled by production) and  within  5%  of   the  Agency's  model
     estimate  of  $73,486,000  for  biological  treatment  (scaled by
     production).
*Column 15 reflects the  judgment  of  the  Agency's  contractor  that
YS&T's $54,106,000 estimate (Column II) included "site-specific" costs
of $18,176,000.
l°Columns 16 and |7 add site-specific costs to model estimates  scaled
by   flow   and  production,  yielding  $71,394,000  and  $78,744,000,
respectively.    If   accurate   estimation   required   addition   of
"site-specific"  costs  to  model estimates, &s industry claimed, then
YS&T's compliance costs would be overstated by $17,288,000 (scaled  by
flow) or $24,638,000 (scaled by production).
                                131

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     As a final comparison, the Agency has compared its  model  Cost*1
     estimate  for  a  blast  furnace  wastewater  treatment  facility
     against that prepared by an engineering company as comissioned by
     one of its clients.  This company  costs  the  BAT-2  system  (as
     identified  in  the  1979  draft  development document) for blast
     furnaces and supplied its costs estimate to  the  Agency  in  its
     comments  to  the  October  1979 draft development document.  The
     company's cost and flow basis is compared below to  the  estimate
     made by the Agency.  Both estimates are based upon the same model
     size ironmaking operation.

                     EPA Estimate       Company Estimate

          Flow        50 gal/ton          100 gal/ton
          Capital     $2.49 million       $3.94 million

     If both estimates are costed on the same flow basis (100 gal/ton)
     the costs are as follows:

                     EPA Estimate       Company Estimate

                    $3.78 million          $3.94 million

     These  data show that the Agency's estimate is within 4.1% of the
     estimate made by the engineering firm.  This  comparison  further
     substantiates  the  reasonableness  and  accuracy of the Agency's
     cost models and costing methodology.

     In  summary,  EPA  has  thoroughly  reevaluated  its  model  cost
     estimates  in  light  of  "site-specific"  costs.   It  has added
     additional site costs to the models (see Section  Vin;  included
     contingency   fees   in   the   models;  used  conservative  cost
     assumptions; compared reported costs for treatment  in  place  to
     model  estimates  for  similar treatment; compared reported costs
     for compliance and model estimates for compliance; and,  compared
     plant-by-plant   compliance   estimates   with  model-based  cost
     estimates.  Based upon the above, the Agency concludes  that  its
     cost    estimates    are   sufficiently   generous   to   reflect
     "site-specific" costs and other compliance  costs  likely  to  be
     incurred by the industry.

2.   The  Impact  of  Plant  Age  on  the  Cost  or   Feasibility   of
     Retrofitting Control Facilities

     The industry challenged both the 1974 and 1976 regulations on the
     basis  that  the  Agency  had  failed  to adequately consider the
     impact of plant age.  In the Phase I  decision,  the  Court  held
"Volume  3,  Draft  Development  Document   for   Proposed   Effluent
Limitations   Guidelines   and   Standards  for  the  Iron  and  Steel
Manufacturing Point Source Category; the Agency 440/l-79/024a, October
1979.
                                132

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that while the Agency had adequately considered the impact of age
on  wastewater characteristics and treatability, it had failed to
adequately consider the impact of age on the "cost or feasibility
of retrofitting" controls.

In the Phase II proceedings, the Agency strenuously  argued  that
plant  age  was  not  a meaningful criteria in the steel industry
because  plants  are  continually  rebuilt  and  modernized.   In
response to this argument, the Court stated:

"Were  we  writing  on a clean slate, we might find this argument
convincing.  But since the facts in this case cannot be  properly
distinguished  from  the facts in the earlier case we must reject
EPA's contention ... We note, however, that we have not dismissed
the EPA's resolution of the retrofit question on the merits.   We
merely  require  that  the  Agency reexamine the relevance of age
specifically as it bears on retrofit."  568 F.2d at 299-300.

In light of these decisions, the Agency  has  throughly  examined
the  impact  of  plant  "age"  on  the  "cost  or feasibility" of
retrofitting controls.   First,  in  the  basic  Data  Collection
Portfolio  (DCP) sent to owners or operators of all "steelmaking"
operations and about 85% of "forming and  finishing"  operations,
the   Agency   solicited  information  on  the  "age"  of  plants
(including the first year of on-site production and the dates  of
major  rebuilds  and .modernizations); and, the "age" of treatment
facilities  in  place.   Next,  the  Agency  sent  Detailed  Data
Collection  Portfolios  (D-DCPs) for a selected number of plants,
asking owners of these plants, among other things, for a detailed
report of the costs of treatment in  place  and  the  portion  of
those  costs  attributable  to "retrofitting" controls.  Finally,
the Agency and its engineering consultant evaluated these data to
determine wiiether plant "age" affected the "cost  or  feasibility
of retrofit',  ng" and, if so, whether altered subcategorization or
relaxed reqi  rements for "older" plants are warranted.

The  Agency's  evaluation  of  all  available  data  confirms its
earlier conclusion that plant "age" does not significantly affect
the "cost or feasibility of retrofitting" pollution  controls  to
existing  production  facilities  in  the steel industry.  In the
first  place,  plant  "ac;^"  is  not  a  particularly  meaningful
criteria  in  the  industry.   "Age"  is  extremely  difficult to
define.  Judcing from the first "car of on-site  production,  the
industry,  as  a whole, is "o)d."  But, production facilities are
continually rebuilt and modernized, some on  periodic  "campaign"
schedules.   Moreover,  "campaign"  schedules  for  operations in
different subcategories, or even for operations within  the  same
process  (e.g., coke batteries) are different.  Complicating this
further is the fact that integrated mills contain many  processes
of  different  "ages"  with  different  dates  of  first  on-site
production and different rebuild schedules.


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Therefore,  the  year  of  first  on-site  production  does   not
represent  the  true  plant "age."  For instance, at the "oldest"
(1901) cokemaking facility (based upon first year of production),
the "oldest': active battery dates from 1968.   At  several  "old"
plants (based upon first year of production), the "oldest" active
batteries  range  between  1953  and 1973 and the "newest" active
batteries date between 1967 and 1980.

The "age" of coke plants, therefore,  changes  dramatically  with
the  criteria  for  determining  "age."   Based upon the "oldest"
active battery, 7.4% of the plants date from 1920 or before; 5.9%
date between 1921- 1940; 65.5% date between 1941-1960; and  20.8%
date  between  1961  and  the  present.  Based on "newest" active
battery,  4.4% of the plants date from 1920 or before, 40.2%  date
between 1941-1960, and the "age" of most (55.2%) of the plants is
between   1960  and  the  present.   Depending  en  the  criteria
selected, the age  of  a  particular  cokemaking  plant,  or  the
cokemaking industry as a whole, can vary significantly.

In   the  ironmaking  subcategory,  the  date  of  first  on-site
production ranges between 1883 and  1974.   However,  most  blast
furnaces  undergo major rebuilds every 9 or 10 years.  Therefore,
the age when determined by the last year of major  rebuild  would
be  significantly  less  than  that  based upon the first year of
production.

Among most of the other subcategories, the situation is  similar.
Table  111-4  summarizes,  by subcategory, the "age" of plants in
the steel industry.   In  each  case,  the  "age"  of  plants  is
difficult   to   define   because   production   facilities   are
periodically rebuilt and modernized.  In many  of  the  remaining
subcategories  and  subdivisions,  such as electric arc furnaces,
"age" is not relevant because all plants are of  essentially  the
same vintage.

Modernization  of  production  facilities provides an impetus fcr
construction or modernization of treatment facilities.  Thus, the
Agency concluded that because of  the  continual  rebuilding  and
modernization  of  production  tacilities,  plant  "age" is not a
meaningful factor in the  steel  industry.   This  conclusion  is
supported  by studies commissioned by the industry.  For example,
in Steel  and the Environment - A Cogt Impact Analysis, which AISI
submitted to EPA in its comments on the 1976  rulemaking,  Arthur
D. Little, Inc. concluded (at page 464) that:

"In the iron and steel industry it is difficult to define the age
of  a plant because many of the unit operations were installed at
different times and also are periodically  rebuilt  on  different
schedules.   Thus,  by  definition,  the  age of steel facilities
should offer only limited benefits as  a  means  of  categorizing
plants for purposes of standard setting or impact analysis."
                           134

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Despite  the  Jifficulty  of defining plant "age," the Agency did
not terminate its analysis of the impact of "age" on the "cost or
feasibility" of retrofitting  controls.   On  the  contrary,  the
Agency  selected  determinants  of  "age"  and  then analyzed the
impact on the "cost or feasibility" of retrofitting.

With regard to the "feasibility" of retrofitting, the evidence is
conclusive:   Plant  "age"  does  not  affect   the   "ease"   or
"feasibility"  of  retrofitting  pollution controls.  Table IH-5
shows that, in all subcategories, some of the "oldest" facilities
(based on first  year  of  on-site  production)  have  among  the
"newest"  and  most  efficient wastewater treatment systems.  The
characteristics and treatability of wastewaters  from  plants  of
all  ages  within  each  subcategory  are similar.  Moreover, the
Agency found that treatment systems applied to wastewaters within
each subcategory produced similar effluent loads,  and  that  the
same effluent limitations can be met regardless of the age of the
plant.   Among  coke  plants,  for example, the oldest by-product
plant  (0024B)  was  retrofitted  with, water  pollution  control
facilities  as recently as 1977.  Moreover, Plant 0863A, which is
one of the oldest coke plants (first year of production in 1912),
retrofitted  pollution  control   facilities.    This   treatment
facility produces an effluent which is among the best observed in
the  industry.   In  fact,  the  Agency  has  used this treatment
facility as a model and has established the BAT limitations based
upon the performance of this plant.  Clearly, age has  no  affect
on  the  feasibility of retrofitting pollution control equipment.
The Agency did find, however, that the "ease" or "feasibility" of
retrofitting and, to seme extent, the cost of retrofitting one of
its model treatment technologies (cascade rinse systems for  acid
pickling  and  hot coating operations) is significantly different
for new sources vs. existing sources of  any  age.   Accordingly,
the  Agency  selected this technology as the basis for new source
performance standards and pretreatment standards for new  sources
and  did  not  use  this  technology to establish limitations and
standards for existing sources.  The factor?  considered  by  the
Agency  in  making  this  determination  are  set out in the Acid
Pickling subcategory report.

With regard to the cost of  retrofitting,  the  impact  of  plant
"age"  is  more  difficult  to  ascertain.  Costs attributable to
retrofitting pollution control facilities were reported for  only
15%  of  the  plants for which responses to Agency questionnaires
were received.  For those  plants  where  "retrofit"  costs  were
reported,  retrofit  costs  of  less than 6% of pollution control
costs were reported for 73% of the plants.  On the basis of these
Survey responses, the Agency concludes that "age" of plants  does
not  have  a  significant  impact  on  the  cost  of retrofitting
pollution controls on an industry wide basis.

The Agency's examination  of  the  Mahoning  Valley  plants  also
supports   the   conclusion   that   "age"  of  plants  does  not
significantly impact the "cost or feasibility"  of  retrofitting.
                          135                                             t.

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     This  examination,  discussed  above in regard to "site-specific"
     costs, showed that,  for  eight  of  the  oldest  plants  in  the
     country,  the  industry's  estimated compliance costs do not vary
     significantly from the agency's model cost estimates.

     On the basis of the foregoing, the Agency  concludes  that  plant
     "age"  does not significantly affect the "cost or feasibility" of
     retrofitting water pollution controls.   However,  even  assuming
     that "age" does significantly impact the "cost or feasibility" of
     retrofitting, the Agency concludes that altered subcategorization
     or  relaxed  requirements within subcategories for "older" plants
     are not warranted.  "Older" steel facilities are responsible  for
     as  much water pollution as "newer" facilities.  Thus, even if it
     could  be  shown  that  plant  "age"  did  affect  the  "cost  or
     feasibility" of retrofitting controls, the Agency would not alter
     its  subcategorization or provide relaxed effluent limitations or
     standards within subcategories for "older" plants as  control  of
     the  discharge  of  pollutants  from  those  plants  justify  the
     expenditures of reasonable additional costs.

     Based upon the above, the Agency finds that both  old  and  newer
     production  facilities  within  each subcategory generate similar
     raw  wastewater  pollutant  loadings;  that   pollution   control
     facilities can be and have been retrofitted to both old and newer
     production  facilities  without  substantial retrofit costs; that
     these pollution control facilities can and are achieving the same
     effluent quality; and., that further subcategorization or  further
     segmentation  within  each subcategory on the basis of age is not
     appropriate.

3.   The Impact of the Regulation on Consumptive Water Loss

     In the 1974 BPT and BAT regulation for the  steeimaking  segment,
     many  of  the  Agency's  model  treatment systems include partial
     recycle of wastewaters.  Some of  these  model  systems  included
     evaporative  cooling  towers  to  insure  that the temperature of
     recycled wastewater not reach excessive levels for process use.*2
     CF&I Steel Corporation, located in Pueblo, Colorado, claimed that
     cooling  through  evaporative  means   would   cause   additional
     consumptive  water  losses which would be inconsistent with state
     law and would aggravate water  scarcity  in  arid  and  semi-arid
     regions  of  tne country.  The Court held that to the extent that
     the regulations were inconsistent with state law,  the  Supremacy
     Clause  of  the  U.S.  Constitution required that federal law and
»*The treatment models that included evaporative cooling  towers  were
the  BPT and BAT models in the cokemaking, blast furnace, steeimaking,
vacuum degassing,  and  continuous  casting  subcategories.   Although
there  are  other available means of temperature equalization (such as
lagoons and nonevaporative coolers), only cooling towers were included
in those treatment models.
                                136

-------
»JThe treatment models that included evaporative cooling  towers  were
the BAT models in the hot forming subcategories.
    regulations prevail.  The Court agreed  with  CF&I,  however,  in       |
    holding  that  the  Agency  had failed to adequately consider the       j
    impact of the regulation on water sources in arid  and  semi-arid       j
    regions.                                                                j

    The  1976  regulation  for the forming and finishing segment also       t
    included treatment models with evaporative cooling towers.»»   In       *
    its response to CPU's comments, the Agency stated:                     |
                                                                            •'
    "A means to dissipate heat is frequently a necessity if a recycle       j
    system  is  to  be employed.  The evaporation of water in cooling       j
    towers or from ponds is  the  most  commonly  employed  means  to
    accomplish  this.   However, fin-tube heat exchangers can be used       5
    to achieve cooling without evaporation of  water.   Such  systems
    are  used  in  the  petroleum  processing  and  electric  utility       ;
    industries.                                                             I
                                                                            v
    The Agency also feels that  recognition  of  the   evaporation  of
    water   in  recycle  systems  (and  hence  loss of  availability to
    potential downstream users) should be balanced  with  recognition       ,
    that  evaporation  also  occurs  in onCe-through systems, when the       ;
    heated  discharge causes evaporation in the stream.  This  is  not
    an   obvious  phenomenon,  since  if occurs  downstream  of  the
    discharge point, but to the downstream user it is  as real as with
    consumptive in-plant usage.  Assuming that the stream  eventually       j
    gets  back  to  temperature  equilibrium with its  environment, it
    will get there primarily  by  evaporation,  i.e.,  with   just  as
    certain a  loss  of  water.   Additionally, the use of a recycle       •
    system  permits lessening the intake  flow  requirements."   41  FR       ;
     12990.                                                                  I

     In  addition,  in   its  brief  the Agency argued that, because of
    current evaporative  losses, the  itr.pact of the regulations was not
    as severe as  claimed by CF&I, and that the water   scarcity   issue
    was  pertinent only  in arid and  semi-arid regions  of the  country.
    The Court, however,  held:

     "...Since EPA may have proceeded under a mistaken   assumption  of
    fact  as  to  the   water   loss   attributable  to  the interim final
     [Phase  II] regulations, the matter will be remanded to  the  Agency
     for  further consideration  of whether fin-tube heat exchangers  or
    dry   type  cooling   towers may  be employed despite any  fouling or
    scaling problems -  assuming that cooling  systems   of   some  kind
    will  be  employed   in  order   to  meet   the  effluent  limitations
    prescribed  in the regulations.

     Also,  the Agency may not  decline to  estimate  the water   loss  due
     to  the  interim  final  regulations as  accurately  as  possible  on the
                                137                                          ^ „
                                                                            N

-------
                                                                            %-J
 grounds   that,   whatever   the  cost   in   water   consumption,   the
 specified effluent  limitations  are justified.   In order  to insure
 that  the Agency  completes  a  sufficiently   specific  and   definite
 study of the water  consumption  problem on re;nand,  the Agency  must
 address   the question  of  how often the various cooling systems
 will  be  employed, or  present reasons  why  it  cannot make   such  an
 assessment."

 In  light  of these  decisions,   the Agency   has  evaluated the
 "consumptive water  loss" issue  in  the context of this regulation.
 Several  of the underlying  modsl -treatment systems include recycle
 of  wastewaters  with  evaporative cooling  systems.    Although
 cooling  can be accomplished  by  several means (i.e.,lagoons, spray
 ponds, dry cooling  towers),  the model treatment systems  are based
 upon   evaporative   cooling  towers,   which  are the most commonly
 used,  least space intensive,  and among the least costly  means  of
 cooling   wastewaters.   Additionally,  evaporative cooling towers
 have  the highest water  consumption rates.   Thus,   the   Agency's
 estimates  of water  loss  are conservative and overstate actual
 water loss.   In  evaluating  possible   consumptive  water  losses,
 however,   the Agency  has  also  analyzed the  effects of several
 cooling  mechanisms  other than evaporative cooling towers.

 On  the average,  the steel  industry currently   uses  5.7  billion
 gallons   of  process  water per  day.   Not  all of the process water
 requires cooling.   A  breakdown  of  this water usage by subcategory
 is  given in Table III-6.   Large volumes of this process  water are
 currently recycled  through cooling towers,  cooling  ponds,   and
 spray ponds as 'shown  below:
 Cooling Device*

 (1)  Cooling Tower
 (wet-mechanical  draft)
 (2)  Cooling ponds
 (3)  Spray ponds
  Approximate
Evaporation Rate
     2.0%
     1.7%
     2.0%
% Utilization
     75%
     20%
      5%
_,*     The Agency does not  expect any  significant use of dry
      cooling towers  in  the steel industry.

 Based  upon  the foregoing,  the Agency estimates that evaporative
 losses from currently installed recycle/cool ing systems,  and from
 once-through discharges of heated water is  about 16.0 MGD or 0.3%
 of  total industry process water usage.   The Agency estimates that
 nearly 50% ot this  consumption  results from  the  once-through
 discharge of heated  wastewater  and run-of-the-river cooling.

 Assuming  that  the   relative  utilization   rate  of  the various
 cooling mechanisms remains the  same,  the Agency  estimates  that
 total  evaporative  water  losses will  be  19.8  MGD or 0.3%  of
 process water usage  at  the BPT  level,  and 20.2  MGD  or  0.4%  of
 process water usage  at  the BAT  level  when fully implemented.
                            13C

-------
The Important factor for regulatory purposes, however, is not the
ahove  gross  water  losses, but the additional or net water loss
attributable to compliance with the  regulation.   This  analysis
indicates  that  net water losses attributable to compliance with
the regulation will be 3.8 MGD or less than 0.1% of process water
usage at the BPT level and 4.2 MGD or 0.1% of process water usage
at the BAT level, including water  consumed  at  the  BPT  level.
This  analysis is detailed for those subcategories, where recycle
and cooling  systems  are  envisioned,  in  Table  III-7  and  is
summarized below•
                            Flow per Day
                                (MGD)

Total process water used        5744
Present water consumption1        16.0
Gross water consumption S> BPT     19.8
Net water consumption & BPT        3.8
Gross water consumption 3> BAT2    20.2
Net water consumption a) BAT2       4.2
% of Total

   100.0
     0.
     0.
     0.07
     0.4
     0.07
1 As of January 1, 1978.
2 This total includes the water consumed at BPT.
Assuming  that  cooling  towers  will  be installed at all plants
requiring additional cooling  (rather  than  current  utilization
devices),  the  net  water losses attributable to compliance with
the regulation would be 5.7 MGD or 0.1% of  total  process  water
usage at the BPT level and 6.0 MGD or 0.1% of process water usage
at  the  BAT level.  For purposes of estimating consumptive water
losses on a subcategory basis, the Agency made  the  conservative
assumption  that  evaporative cooling towers would be used in all
cases where a cooling device of some kind was  deemed  necessary.
12454

In  the  Agency's  view,  the  water  consumption attributable to
compliance with the regulation is not significant  when  compared
to the benefits derived from the use of recycle systems.  The use
of  recycle  systems at the BPT,  BAT, and PSES levels will result
in a 70% reduction in  the  total  process  water  usage  of  the
industry.   This  reduction  will  prevent 4.0 billion gallons of
water per day from  being  contaminated  in  steel  manufacturing
processes.    Moreover,  recycle systems permit a redjction in the
load of pollutants by over 11 million tons per year  at  the  BAT
level  (including  131,500  tons/year  of toxic organic and toxic
inorganic pollutants).  Finally,  it is significant to  note  that
the  use  of  recycle  systems is often the least costly means to
reduce  pollution.    On  a  nation-wide  basis,  therefore,   EPA
concludes that the environmental  and economic benefits of recycle
systems  justify  the  evaporative  water  losses attributable to
cooling mechanisms.
                           139

-------
                                                                          ;«.•*•*§
In addition, the Agency evaluated the water consumption issue  as
it  relates  to plants in arid and semi-arid legions.  The Agency
surveyed the four major steel plants i- considers to be  in  arid
or  se^i-arid  regions  of  the  country.   Those  plants  are as
follows.

0196A     CF&I Steel Corporation
          Pueblo, Colorado
0448A     Kaiser Steel Corporation
          Fontana, California
0492A     Lone Star Steel Comp*. .,
          Lone Star, Texas
0864A     United States Steel Corporation
          Provo, Utah

The Agency finds that most of the recycle and evaporative cooling
systems included in the model treatment  systems  which  are  the
bases  for  the  promulgated  limitations and standards have been
installed-at  those  plants.   Thus,  these  plants  are  already
incurring  most,  if  not  all,  of  the consumptive water losses
associated with  compliance  with  the  regulation.   Hence,  the
incremental  impact  of  the  regulation  on water consumption at
steel plants located in  arid  or  semi-arid  regions  is  either
minimal or nonexistant.

Despite the significant benefits and relatively small evaporative
losses  from  recycle/cooling   ystems, CF&I of Pueblo, Colorado,
claims that recycle/cooling systems will cause severe problems by
compounding the water scarcity problems in the arid and semi-arid
regions of the country.  Therefore, this  company  suggests  that
required effluent levels be based on once-through systems or less
stringent recycle rates in arid or semi-arid areas.

The  Agency  believes  this  proposal  to be deficient in several
respects.  First, discharging the heated waste*aters once-through
would not conserve a significant amount of water.   For  example,
for  an  average  sized  steel  mill with a 100 MGD process flow,
discharging wastewaters once-through would only conserve 0.4  MGD
or  0.4%  of  the  total  process  water flow, a very small water
savings.  The savings is small because  even  in  a  once-through
system,  a certain amount of water is evaporated (the evaporation
will occur in the receiving body of water as the  temperature  of
the  heated wastewaters approaches the equilibrium temperature of
the receiving stream or lake).  In  this  case,  the  evaporation
rate  is  approximately  one-half  of  the  evaporation rate of a
cooling tower.   However, while a small water savings is achieved,
certain disadvantages result, some of which are outlined below:

a.   A heated discharge (potentially up to 150°) which may  cause
     localized  environmental  damage  will be allowed to enter a
     receiving water.
                           140


-------
     b.   The once-through system will allow  a  significantly  higher
          pollutant load to enter the receiving water.

     c.   The once-through system will require additional water to  be
          taken  from  the water supply to meet the water requirements
          of the steelmaking operations.

     While the use of recycle/cooling  systems  now  results  in  some
     additional   evaporative  water  losses  in  arid  and  semi-arid
     regions, the Agency believes that  here,  too,  the  benefits  of
     recycle  systems  justify  these  losses.   The Agency considered
     establishing alternative limitations for  facilities  located  in
     arid  and  semi-arid  regions,  but  concluded  that  alternative
     limitations   and,   thus,   separate   subcategories   are   not
     appropriate.

With  respect to fouling and scaling of wet cooling towers, the Agency
believes that the only operation at which this  could  possibly  be  a
problem   is  blast  furnace  recirculation  systems.   The  industry,
however, has not indicated  it  has  had  no  significant  fouling  or
scaling problems with these systems.
                                                                             5

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                                                                                                            I
                                        TABLE III-5

                       EXAMPLES OP PLANTS THAT HAVE DEMONSTRATED THE
              ABILITY TO RETROFIT  rOLLCTICTt COHTROL EOUIPHEHT BY SUBCATECOBY
Subcategory

A.  Cokeaakinf.
B.  Sintering
C.  Irwmaking
  Plant
Reference
  Code

012 A
024A
024B
112A
272
396A
432B
464C
464E
S84F
Aad Other*

060B
060F
112B
112C
44 BA
548C
584 C
864A
868A
920F
946A

060B
112A
320
396A
396C
426
432A
432B
5B4C
584 D
And Other*
Plant Age*
  (Ye«r)

1920
1916
1901
1920
1919
1906-1955
1919-1961
1925-1973
1914-1970
1923-1971
1958
1957
1950
1948
1943
1959
1959
1944
1941
1944
1939

1942
1941
1920-1947
1907-1909
1903-1905
19S8
1910-1919
1900-1966
1956-1961
1904-1911
                  Treatment
                     (Year)

                  1977
                  1953-1977
                  1S69-1977
                  1977
                  1957-1977
                  1972
                  1930-1972
                  1971
                  1914-1977
                  1977
                  1968
                  1975
                  1970
                  1960
                  1971
                  1965
                  1965
                  1962
                  1954
                  1973
                  J972

                  1958
                  1948
                  1976
                  1929
                  1929
                  1979
                  1951
                  1930
                  1965
                  1953
                                             147

-------
TABLE III-5
EXAMPLES OP PLAKTS THAT HAVE DEMONSTRATED THE
ABILITY TO RETROFIT POLLUTION CONTROL EQUIPKEItr BT S0BCATECORY
PACE 2
Subcategory

D.  Steelaaking

    1.  Basic Oxygen rurn«c«




    2.  Open Hearth





    3.  Electric Furnace




E.  Vacuum Defeating


P.  Continuous Casting
C.  Hot Forming

    1.  Hot Forming - Primary
  Plant
Reference
  Code
432C
684C
684 T
724P

060
112A
492A
864A
74 8C

060P
432C
52 8A
612

B8A
496

084 A
432A
476A
584
652
780
020B
060D
0601
0880
112
112A
112B
176
.88 A
IS6B
248C
320
And Other*
Plant Age*
  (Year)
1961
1970
1966
1966

1952
1957
1953
1944
i952

1951
1959
1949
1936

1963-1968
1965

1970-1975
1969
1969
1968
1968
1966-1975
1948
1910
1941
1959
1907
1930
1928
I9J7
1959
1940
1962
1936
Treatment Age
	(Year)
1964
1971
1976
1976

1970
1971
1966
1962
1967

1968
1964
1954
1971

1971
1971

1975
1974
1977
1970
1971
1975
197J
1959
1958
1971
1979
1970
1970
1965
1970
1946
1975
1952
                                            148

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TABLE III-S
EXAMPLES OF PLANTS THAT HAVE DEMONSTRATED THE
ABILITY TO RETROFIT POLLUTION CONTROL EQUIPMENT BY  SOBCATECORY
PACE 3
Subcategory

    2.  Hot Forcing - Section
    3.  Hot Forming - Flat

        •.  Plat*
        b.  Hot Strip I Sheet
    4.  Pipe and Tube
  Plant
Reference
  Code

060C
060P
0601
06GK
068D
112
112A
112F
136B
316
112C
424
44 8A
490
860B

020B
396D
432A
476A
684F
8560
856P

060C
060F
060R
432A
476A
54 8A
652A
728
856N
8S6Q
And Others
Plant Age*
  (Year)

1913
1942
1956
1920
1962
1907
1937
1922
1908
1959
1902
1970
1943
1918
1936

1953
1960
1957
1915
1937
1938
1929

1913
1950
1930-1%7
1957-1958
1930
1945-1960
1954
1929
1930
1930
Treatment Age
   (Year)

1920-1975
1965
1958
1955
1971
1954-1979
1971-1977
1947-1978
1959-1969
1966
1964
1971-1978
1948
1948-1977
1967

1971
1970
19/4
1977
1969
1980
1966

1948
1971
1961
1974
1977
1969
1962
1952
1961
1963
                                             149

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TABLE III-5
EXAMPLES Of PUNTS THAT HAVE DEMONSTRATED THE
ABILITY TO RETROFIT POLLUTION CONTROL EQOIPMEKT BY  SUBCATECORY
PACE 4
Subcategorv

a.  Scale Reaoval
I.   Acid Pickling

    1.  Sulforic Acid
    2.   Hydrochloric Acid
    3.   Conbi nation Acid
   PUnt
 Reference
   Code

 0601
 088A
 256L
 424
 284A
 176
 256K
 248B
020B
048P
060D
06 OH
088A
088D
112
!12C
2<>6F
35.A
And Other*

02oc
112B
176
320
384A
3960
432C
44 8A
SWA
And Other*

020B
088A
112A
112H
256P
2H4A
584 n
860F
And Other*
PUnt Age*
  (Ye«r)

1970
1962
1962
1971
1957
1941
1956
1950
                                                           1954
                                                           1944
                                                           1957
                                                           1970
                                                           1936
                                                           1962
                                                           1922
                                                           1926
                                                           1953
                                                           1958
                                                           1946
                                                           1936
                                                           1961
                                                           1936
                                                           1932
                                                           1967
                                                           1952
                                                           1954
                                                           1962
                                                           1947
                                                           1952
                                                           1926
                                                           1940
                                                           1953
                                                           1957
                                                           1940
                                                           1962
Treatment Age
   (Ye«r)

1972
1969
1969
1978
197'.
1965
1971
1978
                  1974
                  1969
                  1968
                  1977
                  1969
                  1971
                  1977
                  1977
                  1975
                  1964
                  1977
                  1971
                  1956
                  1955
                  1970
                  1969
                  1964
                  1970
                  1967
                  1974
                  1969
                  f>77
                  .951
                  J975
                  1971
                  1970
                  1977
                                            150

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TABLE III-5
EXAMPLES OF PLANTS THAT HAVE  DEMONSTRATED THE
ABILITY TO RETROFIT POLLOTIOH CONTROL EQUIPMENT BY SUBCATECORY
PAGE 5            	
Subcategory

J.  Cold Forming
K.  Alkaline Cleaning
L.  Hot Coating
                                          Plant
                                        Reference
                                          Code
020C
060
112A
112B
176
396D
432B
44 8 A
58'A
684 D
And Other*

112A
1121
240B
256N
1B4A
432A
44 8A
476A
548A
580A
And Other*

112B
112C
3B4A
44 6 A
460A
476A
492A
580A
584C
640
                   Plant Age*
                     (Year)
                                                           1951
                                                           1936
                                                           1947
                                                           1936
                                                           1921
                                                           1938
                                                           1937
                                                           1952
                                                           1948
                                                           1939
1936
1927
1938
1956
1968
1940
1959
1960
1957
1962
1962
1922
1968
1967
1932
1930
1962
1962
1956
1936
                  Treatment Age
                     (Year)
                  1975
                  1967
                  1971
                  1971
                  1963
                  1959
                  1966
                  1969
                  1971
                  1970
1971-1977
1950-1977
1968
1973
1970
1970
1969
1977
1967
1967
1971
1973
1970
1970
1968
1977
1976
1967
1965
1961
* Where rangea of agea are lilted,  thia  ahowa  that  theaa are Bultiple facilities on
  ait* that vary in age aa indicated.

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                                        ZA>U XII-6

                             WATB8 USAGE IM THE STEEL IKDUSTRY
                                                                                                          f
Subeategory

A.  Cokeaaking
B.  Sintering
C.  Irooaaking
D.  Sieclacking
E.  Vacuuv Degaating
F.  Cootinuoui Catting
C.  Hot Forcing
H.  Salt Bath Defeating
I.  Acid Pickling
J.  Cold Forming
K.  Alkaline Cleaning
L.  Hot Coating
                           Total Procete
                           Hater U««ge (KCP)
Water Recycled Over
  Cooling Syate*a
   at BFT (MCD)
Water Recycled Over
  Cooling Syttnn
   at BAT (MCD)
                              5,744.2
   1012.5
                                                                           1032.4
(1) Flow not  included aa part of the total proceta vatcr flow.
                                               152

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                               VOLUME I

                              SECTION IV

                      INDUSTRY SUBCATEGORIZATION
To develop the regulation it was necessary for the Agency to determine
whether   different  effluent  limitations  and  standards  should  be
developed  for  distinct  segments  or  subcategories  of<  the   steel
industry.   The Agency's subcatecjorization of the industry included an
examination of  the  same  factors  and  rationale  described  in  the
Agency's previous studies.  Those factors are:
     1.   Manufacturing processes and equipment
     2.   Raw materials
     3.   Final products
     4.   Wastewater characteristics
     5.   Wastewater treatment methods
     6.   Size and age of facilities
     7.   Geographic location
     6.   Process water usage and discharge rates
     9.   Costs and economic impacts

For    this   regulation,   the   Agency   has   adopted   a   revised
subcategorization  of  the  industry  to   more   accurately   reflect
production  operations and to simplify the use of the regulation.  The
Agency found that the manufacturing process is  the  most  significant
factor  and divided the industry into 12 main process subcategories on
this basis.  Section IV of each subcategory report contains a detail*d
discussion of the factors considered and the rationale  for  selecting
and   subdividing  the  subcategor it-s.   The  Agency  determined  that
process-based subcategorization is warranted in many cases because the
wastewaters of the  various  processes  contain  different  pollutants
requiring  treatment  by  different  control systems (e.g., phenols by
biological systems  in  cokemaking).   However,  in  some  cases,  the
wastewaters   of  different  processes  were  found  to  have  similar
characteristics.  In  those  instances,  the  Agency  determined  that
subcategorization was  appropriate because the process water usage and
discharge flow rates varied significantly, thus affecting estimates of
treatment   system   costs   and  pollutant  discharges.   The  twelve
subcategories of the steel industry are as follows:
                                                   Preceding page blank

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     A.   Cokemaking
     B.   Sintering
     C.   Ironmaking
     D.   Steelmaking
     E.   Vacuum Degassing
     F.   Continuous Casting
     G.   Hot Forming
     H.   Salth Bath Descaling
     I.   Acid Pickling
     J.   Cold Forming
     K.   Alkaline Cleaning
     L.   Hot Coating

The subcategories of the  steel  industry  are  defined  below.   Also
discussed   are   any   subdivisions  and  segments  within  the  main
subcategories and the rationale for the subdivision and segmentation.

Subcategory A:  Cokemaking

Cokemaking operations involve the production of coke in by-product  or
beehive  ovens.   The production of metallurgical coke is an essential
part of the steel industry,  since  coke  is  one  of  the  basic  raw
materials necessary for the operation of ironr.aking blast furnaces.

Significant  variations  exist  in  the  quantity and quality of waste
generated between the old  beehive  ovens  and  the  newer  by-product
ovens.   In  order  to prepare effluent limitations and standards that
would adequately  reflect  these  variations,  a  subdivision  of  the
Cokemaking  subcategory  was  necessary.   The  first  subdivision  is
By-Product Cokemaking, a method employed by 99  percent  of  the  coke
plants  in  the  U.S.   In by-product ovens, coke oven gas, light oil,
ammonium sulfate  and  sodium  phenolate  are  recovered  rather  than
allowed  to  escape  to  the  atmosphere.   This  subdivision has been
further segmented to reflect the slightly different wastewater  volume
generation  rates  between  coke  plants  located  at integrated steel
plants and at merchant coke plants.  Within both segments,  there  are
further  distinctions  based upon type of treatment (physical/chemical
and biological), type of  ammonia  recovery  process  utilized  (semi-
direct  vs.  indirect) and an added allowance for plants employing wet
desulfurization systems.

Beehive  Cokemaking  is  the  other  subdivision  in  the   Cokemaking
subcategory.   This  process  is only found in one percent of the U.S.
Cokemaking operations.  In beehive ovens no effort is made to  recover
volatile  materials generated by the process so there is no wastewater
generated  from  gas  cleaning  as  in  the  by-product  plants.   The
wastewater  results  from the direct spraying of water on the hot coke
to stop the coking process.

Subcategory B:  Sintering

Sintering operations involve the production of an agglomerate which is
then reused as a feed material  in  iron  and  Steelmaking  processes.
                                156
                              __-
                              _./

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This  agglomerate  or  "sinter"  is  made  up  of  large quantities of       >
particulate matter (fines, mill scale,  flue  dust)  which  have  been
generated  by  blast  furnaces, open hearth furnaces, and basic oxygen
furnaces, and scale recovered from hot forming operations.

Wastewaters are generated in sintering operations as a result  of  the       :
scrubbing  of  dusts  and  gases  produced  in  the sintering process.       j
Quenching and  cooling  of  the  sinter,  practiced- at  some  plants,
generates  additional  wastewaters.   The Agency determined that model
plant effluent flow rates can be achieved at sinter  plants  with  wet
air pollution controls on all parts of the sintering operation.  Since
there  are  no significant variations in wastewater quality from these
operations, the Agency did not subdivide sintering operations  on  the
basis of the type of wet air pollution control system used or the part
of  the  sintering  operation  controlled by wet air pollution control
systems.

Subcategory C:  Ironmaking

Ironmaking  operations  involve  the  conversion   of   iron   bearing
materials,  limestone,  and  coke  into  molten  iron  in  a  reducing
atmosphere in a tall cylindrical furnace.  The  gases  produced  as  a
result  of  this  combustion  are  a  valuable heat source but require
cleaning prior to reuse.  Blast furnace wastewaters are generated as a
result of the scrubbing and cooling of these off-gases.  Both pig-iron
and ferromanganese  can  be  produced  in  blast  furnace  operations.
Because the wastewaters produced at these two types of operations vary
significantly,  different  BPT limitations were promulgated.  However,
BAT, NSPS, PSES and PSNS were promulgated only  for  ironmaking  blast
furnaces   since  no  ferromanganese  furnaces  are  in  operation  or
scheduled for operation  and  ferroalloy  production  has  shifted  to
electric furnaces.

Subcategory D:  Steelmaking

Steelmaking  operations  involve  the  production  of  steel  in basic
oxygen, open  hearth,  and  electric  arc  furnaces.   These  furnaces
receive  iron  produced  in  blast furnaces along with scrap metal and
fluxing materials.  During  Steelmaking,  large  quantities  of  fume,
smoke,  and  waste gases are generated which require cleaning prior to
emission to the atmosphere.  Steelmaking wastewaters are generated  as
a result of some of the gas cleaning operations.

Each  of  the  three  types  of  furnaces operates differently.  These
differences result in significant  variations  in  wastewater  volume,
pollutant  loads  generated, and wastewater characteristics.  In order
to develop effluent limitations that would  adequately .reflect  these
variations,  the Agency determined that subdivision of the Steelmaking
subcategory into the  following  three  subdivisions  is  appropriate:
Basic  Oxygen  Furnace; Open Hearth Furnace; and Electric Arc Furnace.
The Agency also determined that further segmentation of  the  BOF  and
EAF  subdivisions is appropriate because of differences in the methods
used to clean and condition furnace gases.
                                157

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Three different scrubbing systems, each of which  could  result  in  a
wastewater  discharge,  are  presently  used to clean waste gases from
basic  oxygen  furnaces:  semi-wet;  wet-suppressed  combustion;   and
wet-open  combustion.   Water  is used in semi-wet systems to cool and
condition  furnace  gases  to  optimize   the   performance   of   the
electrostatic precipitators or baghouses that are relied upon to clean
the  gases.  These systems are characterized by wastewaters containing
relatively small quantities  of  particulate  matter  having  a  large
particle  size.   Wet  systems  result  in  much higher raw wastewater
pollutant loadings due to the increased amount of water used.   In  an
open  combustion  system,  90  percent  of  the  particulates are of a
submicron size, because combustion is more complete.   By  comparison,
suppressed combustion systems generate larger particles, of which only
30-40  percent  are  of  submicron  size.   Since  much of the heavier
particulate matter  remains  in  the  furnace,  the  suspended  solids
loadings  in  the  wastewaters  from suppressed combustion systems are
much lower.

Both semi-wet and wet systems are used at electric furnaces wnile only
wet systems are used at open hearth furnaces.  The subdivision of  the
Steelmaking   subcategory   takes  the  wastewater  flow  and  quality
differences into account.

Subcategory E:  Vacuum Degassing

Vacuum degassing is the process whereby molten steel is subjected to a
vacuum in order to remove gaseous impurities.  It is  advantageous  to
remove  hydrogen,  nitrogen, and oxygen from the molten steel as these
gases can impart undesirable qualities to  certain  grades  of  steel.
The  vacuum  is  most  commonly  produced  through  the  use  of steam
ejectors.  The venturi action of the steam in the ejector  throat  and
the  condensation  of  the  steam  combine to produce the vaccum.  The
particle laden steam corning from the steam ejectors  is  condensed  in
barometric  condensers,  thus  producing  a  wastewater which requires
treatment.

The industry uses various  types  of  degassers  and  degasses  steels
containing a variety of different components.  However, the Agency has
determined  these  variations do not affect the quantity or quality of
wastewaters produced in the vacuum degassing operations to the  extent
that further subdivision of this subcategory is warranted.

Subcategory F:  Continuous Casting

The  continuous casting process is used to produce semi-finished steel
directly from molten steel.  The molten  steel  from  the  Steelmaking
operation is ladeled into a tundish from where it is continuously cast
into  water  cooled copper molds of the desired shapes.  After leaving
the copper mold, the semi-solidified steel is sprayed with  water  for
further  cooling  solidifications.   In addition to cooling,  the water
sprays also serve to remove scale and other impurities frosr, the  steel
surface.   The  water  that directly cools the steel and guide rollers
                                irc
\
                                                -x

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contains participates and roller lubricating oils, and must be treated
prior to discharge.

Although there are three types of continuous casters in use, they only
differ in physical orientation.  When the Agency  analyzed  these  and
other factors relating to the continuous casting subcategory, it found
no  significant  variations  in the quantity or quality of wastewaters
generated.  Therefore, the Agency determined that further  subdivision
of the Continuous Casting subcategory is not appropriate.

Subcategory G:  Hot Forming

Hot  forming  is  the  steel  forming  process  in  which hot steel is
transformed in size and shape through a series  of  forming  steps  to
ultimately  produce  semi-finished  and finished steel products.  Feed
materials may be ingots, continuous  caster  billets,  or  blooms  and
slabs  from  primary hot forming mills (as feed to hot forming section
or hot forming flat mills).  The steel products consist of many  types
of  cross-sections,  sizes  and  lengths.  Four different types of hot
forming mills are used to produce the many types of hot  formed  steel
products.   The  four types of mills (primary, section, flat, and pipe
and tube) are the bases for the  principal  subdivisions  of  the  Hot
Forming  subcategory.   Variations  in  flow  rates and configurations
among these subdivisions were the most  important  factors  in  making
these  subdivisions.   The  Agency  found that further segmentation is
necessary to reflect variations due to product shape, type  of  steel,
and process used.

Wastewaters  result  from  several  sources in hot forming operations.
The hot steel is reduced in size by a number of  rolling  steps  where
contact  cooling  water is continuously sprayed over the rolls and hot
steel product to cool the steel rolls and the flush away scale  as  it
is  broken  off  from  the surface.  Scarfing is used at some mills to
remove  imperfections  in  order  to  improve  the  quality  of  steel
surfaces.   Scarfing  generates  large  quantities of fume, smoke, and
waste  gases  which  require  scrubbing.   Scrubbing  of  these  fumes
generates additional wastewater.

The  Agency  found variations in the quantity of wastewaters generated
in the four subdivisions of the Hot Forming subcategory.  The  quality
and  treatability  of  hot  forming  wastewaters  is not significantly
different.

The Primary mill subdivision has been split into  two  segments:   (1)
carbon  and  specialty  mills  without  scarfing,  and  (2) carbon and
specialty mills with scarfing.  The use of scarfing equipment  results
in an additional applied process flow of 1100 gal/ton.

The  Section  mill  subdivision  has  also  been  separated  into  two
segments, carbon and specialty steels.  On the average,  1900  gal/ton
more  water  is  used  on  carbon section mills.  For this reason, the
Agency determined that it is appropriate to further divide the section
mill subdivision into carbon and specialty mill segments.
                                                       \ •
                                                        Y

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The Flat mill subdivision has been split into three segments:  (1) hot
strip and sheet (both carbon and specialty), (2)  plate  (carbon)  and
(3)  plate  (specialty).   As with section mills, carbon and specialty
plate operations differ significantly in several  areas.   About  1900
gal/ton  more  water  is  used in carbon flat plate operations than in
specialty flat plate operations.  Also, carbon plate mills  are  about
three  times  as large as specialty plate mills.  While no differences
were  noted  between  carbon  and  specialty  hot  strip   and   sheet
operations,  hot strip operations in general require 3900 gal/ton more
water than do plate operations.  That difference resulted in  the  hot
strip and sheet segment in the hot forming flat subdivision.

TH;w;We  Agency  determined  that the distinction between isolated and
integrated operations in the Hot Worked Pipe and Tube subdivision made
in the prior regulation is not appropriate.  This former  segment  was
deleted.

Subcategory H:  Salt Bath Descaling

Salt bath descaling is the operation in which specialty steel products
are  processed  in molten salt solutions for scale removal.  Two types
of scale removal operations are in use: oxidizing and  reducing.   The
oxidizing  process  uses  highly  oxidizing salt baths which react far
more aggressively with the $cale than with base netal.  This  chemical
action  causes  surface  scale  to  crack  so that subsequent pickling
operations are more effective in removing the scale.   Reducing  baths
depend  upon  the  strong  reducing  properties  of  sodium hydride to
accomplish the same purpose.  During that operation most scale forming
oxides are reduced to base metal.

Flow rates and wastewater characteristics differ between the two types
of operations.   Wastewaters  from  reducing  operations  can  contain
quantities  of  cyanide  not  contained  in wastewaters from oxidizing
operations.   Wastewaters  from  oxidizing  operations  contain  large
amounts  of  hexavalent  chromium,  which  are  not  usually  found in
reducing bath wastewaters.  In order to develop  effluent  limitations
that  would adequately reflect these variations, the Agency determined
that subdivision of the scale removal subcategory into  oxidizing  and
reducing operations is appropriate.

The  Agency  has  also  concluded  that the method of operation, i.e.,
batch or continuous, significantly  affects  w&ter  use  requirements.
Hence,  it  has  segmented both subdivisions.  In addition, because of
variations in water use rates, related to the type  of  product  being
processed in batch oxidizing operations, the Agency has segmented this
subdivision further to reflect these differences.

Subcategory I:  Acid Pickling

Acid  pickling  is the process of chemically removing oxides and scale
from the surface of the steel by the  action  of  water  solutions  of
inorganic  acids.    The three major wastewater sources associated with
acid pickling operations are spent pickle liquor,  rinse  waters,  and
                                160

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                                                                            n !
the  water  used  to  scrub  acid vapors and mists.  These wastewaters
contain free acids and ferrous salts in addition to other organic  and
inorganic  impurities.   Most carbon steels are pickled in strifuric or
hydrochloric acids.  Most stainless and alloy steels are pickled in  a
mixture   of   nitric   and   hydrofluoric  acids.   Since  wastewater
characteristics are  dependent  on  the  acid  used,  the  Agency  has
established  three  primary  subdivisions  of  this subcategory; i.e.,
sulfuric, hydrochloric, and combination acid pickling operations.

The Agency has concluded that, within each of the three acid  pickling
subdivisions,  further segmentation, primarily on the basis of product
type rather than on  wastewater  source  or  treatment  technique,  is
appropriate.   Additionally,  segments  have  been established in each
subdivision to separa ely limit the discharges from scrubbers.

The Sulfuric Acid Pickling subdivision has been further separated into        I
five segments, four of which reflect the  different  water  use  rates        j
associated  with product groupings and one reflective of the water use      ,  I
rate in fume scrubbers.  Since water use in a  fume  scrubber  is  not        j
related  to  the tonnage of product pickled, limitations and standards        !
for this segment have been established on the basis of  kg/day  rather        !-
than kg/kkg of product.                                                       I
                                                                              !
The  Hydrochloric Acid Pickling subdivision was further separated into        ,
five segments, three of which reflect the different  water  use  rates        1
associated  with  product  groupings,  and the other two reflective of        <
water use rates on fume scrubbers.  In this subdivision, scrubbers are        1
used for  fume  collection  over  the  pickling  baths  and  for  fume        j
collection  at  the  acid  regeneration  plant  absorber  vents.   The        <
differences  in  water  use  rates  are  reflected  in   the   further        1
segmentation.    Limitations  and  standards  in  both  fume  scrubber
segments are established on tne basis of kg/day.

The Combination Acid Pickling subdivision was further  separated  into
six  segments,  five  of  which  reflect the different water use rates
associated with product groupings, and the other based upon the  water
use  rate  in  fume scrubbers.  As above, limitations and standards in
the fume scrubber segment  have  been  established  on  the  basis  of
kg/day.

Subcategory J:  Cold Forming

The Cold Forming subcategory is separated into two subdivisions:  Cold
Rolling  and  Cold  Worked  Pipe  and Tube.   The Agency concluded that
subdivision is appropriate because of  the  differences  in  equipment
used   to  form  flat  sheets  and  tubular  shapes,  and  because  of
differences in rolling solution characteristics, wastewater flow rates
and treatment and disposal methods.

Cold rolling is used to reduce the thickness of a steel product, which
produces a smooth dense surface  and  develops  controlled  mechanical
properties  in  the metal.  An oil-water emulsion lubricant is sprayed
on the material as it enters the work rolls of a  cold  rolling  mill.
                               161

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and  the  material is usually coated with oil prior to recoiling after
it has passed through the mill.   The  oil  prevents  rust  while  the
material  is  in transit or in storage.  It must be removed before the
material can be further processed or formed.  Oil from the  oil  water
emulsion   lubricant  is  the  major  pollutant  load  in  wastewaters
resulting from this operation.

In the Cold Rolling subdivision three methods of oil  application  are
used.    The   methods  are  direct  application,  recirculation,  and
combinations of the two.  Because recycle rate is dependent  upon  the
oil  application system, flow rates vary for the three systems.  These
differences in flow  rates  make  further  segmentation  of  the  Cold
Rolling  subdivision appropriate.  Within the recirculation and direct
application segments, the number of rolling stands  used  affects  the
watvr  use  rate.   This  is  reflected in separate limitations within
these segments based upon whether a mill has a single stand or whether
the mill has multiple stands.

In the Pipe and Tube subdivision of the Cold Forming subcategory, cold
flat  steel  strips  are  formed  into  hollow  cylindrical  products.
Wastewaters  are  generated  as  a  result of continuous flushing with
water or soluble oil lubricating solutions, resulting  in  significant
differences  in  the  quantity and quality of wastewaters generated by
these  methods.   Therefore,  the  Agency  determined   that   further
separation of the Pipe and Tube subdivision into water type operations
and oil solution type operations, is warranted.

Subcategory K:  Alkaline Cleaning

Alkaline cleaning baths are used to remove mineral and animal fats and
oils  from steel.  The cleaning baths used are not very aggressive and     j
therefore do not generate  many  pollutants.   The  alkaline  cleaning     j
solution  is  usually  a  dispersion  of chemicals such as carbonates,     j
alkaline silicates, and phosphates in water.  The cleaning bath itself     !
and the rinse water used are the two sources  of  wastewaters  in  the
alkaline  cleaning  process.  Both continuous and batch operations are     <
used by the industry.  The Agency, after further review  of  available     :
wastewater  flow  data,  has concluded that significant differences in     '. . .
the  quantity  of  wastewaters  generated  at  batch  and   continuous
operations  should  be  reflected in the limitations and standards for     '
alkaline  cleaning  operations.   Therefore,  the  Alkaline   Cleaning     ;~
subcategory has been subdivided into batch and continuous operations.      .  —

Subcategory L:  Hot Coating

Hot  coating processes involve the immersion of clean steel into baths
of molten metal for the purpose of depositing  a  thin  layer  of  the
metal  onto  the  steel surface.  These metal coatings can impart such
desirable qualities as corrosion resistance or a decorative appearance
to the steel.  Hot coating processes can be carried out in  continuous
or  batch operations.  The physical configuration of the product being
coated usually determines the method of coating to be used.                 J
                                1C2

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The Hot Coating subcategory has been divided into  three  subdivisions
based  upon  the  type of coating used.  Galvanizing is a zinc coating
operation.  Terne coating consists of a lead and tin coating  of  five
or  six  parts lead to one part tin.  Other metal coatings can include
aluminum, hot dipped tin, or  mixtures  of  these  and  other  metals.
These  operations  generate  different polutants due to the variety of
metals used.

However, the control  technologies,  except  for  hexavalent  chromium
reduction  required  for  galvanizing  lines with chrornate passivating
dips,  are  the  same  for  all  hot  coating  operations.   The  lime
precipitation  and  clarification process will adequately control each
of the toxic metals.  There is a considerable difference in the  water
use rates based upon the type of product coated.  Therefore the Agency
has  concluded  that  further separation of the galvanizing, and terne
and other coatings subdivisions into two segments based  upon  product
type   is  warranted.   These  segments  are  the  strip,  sheet,  and
miscellaneous products segment and  the  wire  product  and  fasteners
segment.   The  Agency  has also provided a segment for fume scrubbers       T
applicable to any hot coating operation with fume scrubcors.                 '
                                                                            \
                                                                             \
                                                                            /  •
                               163

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                               VOLUME I

                              SECTION V

                  SELECTION OF REGULATED POLLUTANTS
Introduction

Three types of pollutants were considered for regulation in the  steel
industry:  conventional  pollutants,  nonconventional  pollutants, and
toxic pollutants.  To  determine  the  presence  and  level  of  these
pollutants   in  steel  industry  wastewaters,  the  Agency  conducted
extensive monitoring at several representative plants in the industry.
Average wastewater concentrations of each  pollutant  were  determined
for  each  subcategory.  These concentrations, in conjunction with the
waste loading, formed the basis for determining whether  a  particular
pollutant was considered for regulation.

Development of Regulated Pollutants

The  concentration data were reviewed for 141 pollutants; 130 toxic, 8
nontoxic noncorrventional,  and 3  conventional.   These  values  ranged
from  "not  detected"  to 71,000 mg/1 (ppm).  The concentration values
were  reviewed  and  each  pollutant  was  assigned  to  one  of  four
categories.

1.   Not Detected - Reserved for any pollutant which was not  detected
     during industry-wide plant sampling.

2.   Environmentally Insignificant - Pollutants detected at levels  of      ]
     0.010  mg/1  (10  ppb)  or  less  in  industry-wide sampling; or,      i
     pollutants not  normally  occurring  in  wastewaters  from  these      [
     sources.

3.   Not Treatable - Pollutants detected at levels greater than 10 ppb
     but at levels below the trea"ability level  determined  for  that      $
     pollutant.                                                             f|

4.   Regulation Considered - Any pollutant detected at a level greater
     than the corresponding  treatability  level  was  considered  for
     regulation.

The  results of the categorization are presented in Table V-l,  Of the
141 pollutants initially considered, 60 (50 toxics and 10 others) have
been considered for regulation.    In  order  to  further  analyze  the
source   of  these  pollutants,   their  presence  by  subcategory  was
tabulated.    Table  V-2  lists  pollutants  appearing  in  the  twelve
subcategories  at  levels  greater  than  treatability.    The physical
properties, toxic effects in humans and aquatic life, and behavior  in
POTWs  of  these  60  pollutants  are  discussed in Appendix D to this
document.  In compiling this material, particular weight was given  to
«
                                                     Preceding page blank

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documents  generated by the Criteria and Standards, and Monitoring and
Data Support Divisions of EPA.


Regulated Pollutants                                       •

Most of the toxic pollutants (29) are found in two subcategories: Cold
Forming and Cokemaking.  In order to  avoid  costly  analytical  work,
four  organic  pollutants  (benzene,  naphthalene,  benzo-a-pyrene and
tetrachloroethylene) are limited and serve  as  indicator  pollutants.
Other   toxic  pollutants  known  to  be  present  in  wastewaters  in
significant quantities are also limited.

The list of pollutants directly limited by the regulation is found  in
Table  V-3.   This list consists of 16 pollutants; 9 toxic, 4 nontoxic
nonconventional,  and 3 conventional.  Table V-4 lists  the  pollutants
limited in each subcategory.
                                166
J

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                                           TABLE V-l

                            DEVELOPMENT OP REGULATED POLLUTANT LIST
                           	IRON & STEEL INDUSTRY	
                                                                  ;1
Ho.   Pollutant

001   Acen«phthene
002   Acrolein
003   Acrylonitrile
004   Bcntene
005   Beniidine
006   Carbon tetrachloridt
007   Chlorobenten*
008   1,2,4-trichlorobeniene
009   Bexachlorobensenc
010   l,2-dichlorocthan«
Oil   l,I,l-tnchloro«th«ne
012   Rexaehloreihane
013   1,1-dichlnrocthane
014   l,I,2-trichloro«thane
01)   1,1,2,2-tetrachloroethanc
016   Chloroethane
01?   bii(chloroM(hyl)ether
018   bii(2-chloro«chyl)«ther
019   2-chloroethyl »inyl ether
020   2-chloroniphth«len«
021   2,4,6-trichlorophcnol
022   P«rtchloro»et«cre»c>l
023   Chlorofora
024   2-chloroph*nol
02}   l,2-dich>orot>enxen*
026   ItJ-dichlorobenr»n«
027   1,4-dichlorobenicnc
028   3,3'-dichlorob*niidin»
029   1,1-dichloroethylen*
030   l,2-tr«n«-dichloroethyl*o«
031   2,4-dichlorophcnol
032   l,2-dichloroprop«n*
033   I,2-dichloropropylene
034   2,4-diacihyl phenol
03}   2,4-dinitrotoluene
036   2,6-dinH rocoluenc
037   tt2-diphenylhydraiinc
038   E(hylb«nzcn«
039   Pluoranlhcn*
040   4-chlorpphenyl phcnyl cthtr
041   4'broaopheny1 phcnyl ether
042   bi»(2-chloroi«opropyl) ether
043   bit(2-chloroethoxy) •ethane
044   Kethylene chloride
  Hot       Environmentally.
Detected    Inaigniftcant
                                                                        Not
                                                                               ...
                                                                               ^
                                             Regulat ion
                                             Considered
                                                Jt
                                                 X
X
X
X

X
X
X
                                 X
                                 X
                                              167

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TABLE V-l
DEVELOPMENT OF REGULATED POLLUTANT LIST
IRON ft STEEL INDUSTRY                                                                                         1
PACEJ	                                                                     ";;
	                                                                     1

                                                                                                             i
                                        Hot       Environment ally.      Not    ...    Regulation             ;
Bo.   Pollutant                       Detected    Iniitnificant       Treatable       Considered

04}   Methyl chloride                    X
046   Methyl broeude                     X
047   bro»o(or»                          X
048   DichlorobroBoaethane               -
049   Trichlorofluoroewthane             X                                                                   . ,,.
050   Dichlorodifluoroaethane            X               -                -               ~                  <
051   Chlorodibio»o»ethane               X                                                                   1
052   Hcxachlorobutadiene                X               -                -               -                  '
053   Hcxachlorocyclopentadiene          X               -                                                   '
054   Itophorone                         ~               ~                X               •                  ;
055   Naphthalene                                                                         X
056   Nitrobvnxene                       -                                X               -
057   2-nitrophenol                      -                                X               -
058   4-nitrophenol                      -                                                X
059   2,4-dinitropQenol                  -                                X               -
060   4,6-dinitro-o-cretol               -                                                X
061   N-nitroiodiaetbylaaine             X                                -               ~
062   N-nitroiodiphenyla»ine             X
063   N-nitruiodi-n-propylaoiine          X                                -
064   Pentachlotopiienol                  -                                                X
065   Phenol                             -                                                X
066   bi«(2-ethylhexyl)phth«late         -                                                X
067   Butyl bcniyl phthalate             -                                                X
068   Di-n-butyl phthalate               -                                                X
069   Di-n-oclyJ phthalate               -                                                X
070   Diethyl  phthalate                  -                                                X
071   Diacthyl phthalate                 -                                                X
072   Benxo(a)anthracene                 -                                                X
073   Benzo(a)pyr*ne                     -                                                X
074   3,4-bcr.zof luoranthene              ~               X                •               -
075   B«nio(k)(luor«nth«n»               -               X                -
076   Chrysene                           -                                                X
077   Acenaphthylen*                     -                                                X
078   Anthracene                         -                                                X
079   benio(£hi)perylene                 -               X                     «
080   Fluorene                           -                                                X
081   Phenathrene                        -                                                X
062   Dibento(a,h)anthracene                             X                -
083   lnd«no(I,2,3>cd)pyrene             -X                -
OS*   Pyrene                             -                                                X
085   Tetrachloroethyiene                -                                                X
086   Toluene                            -                                                X
087   Tr ichlorethylene                   ••               -                                X
088   Vinyl chloride                                     X                -
089   Aldrin                                             X
                                                                               \

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TABU V-l
DEVELOPMENT Of RZGULATED FOLUJTAMT LIST
IRON fc STEEL  INDUSTRY
PACE 3

No.
090
091
092
093
094
093
096
097
098
099
100
101
102
103
104
10S
106
107
108
109
110
111
!12
113
114
115
116
117
113
119
130
121
123
124
125
126
127
126
129

Pollutant
DUUrin
Chlordane
4,4'-6DT
4,4'-DDE
4,4'-DDD
a-endotul fan-Alpha
b-*ndo*ul fan-Bet a
Eadoeulfan eulfete
Eodr in
Endrio aldehyde
Heptachlor
tUptachlor epoxide
a-BHC-Alpha
b-BKC-B«ta
r-BHC-CaMM
(-BHC-Delta
PCS- 1242
PCB-12J4
PCB-1221
PCB-1232
PCB-1248
PCB-1260
PCB-1016
Toxepbene
Ant l Bony
Ar««nic
A*be*tof
Beryllium
Cadaiua
Cntcmiam
Copp«r
Cyaotde
Mercury
Nickel
S«l«niua
Sil>«r
Th«l liu»
Zinc
2, 3,7,8- t«tt«ch lord ibtnto-
Not
Detected
.
-
-
-
-
-
-
-
-
-
-
-
"
-
-
-
-
-
-
-
-
-
-
-
-
•
-
-
-
-
-
•
-
-
-
-
-
-

                                                    Iniignific«nt

                                                           X
                                                           X
                                                                          Not
                                                                                 Regulat ion
                                                                                 Con»id«r«d
                                                                                              X
                                                                                              X
                                                                                              X
                                                                                              X
                                                                                              X

                                                                                              t
                                                                                              X
                                                                                              X
                                                                                              X
                                                                                              X
 130
p-dioxin
Xyteoe
                                                  169
/-=**-•-nitiflflfl- ' rfffr

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TABLE V-l
DEVELOPMENT Of REGULATED fOLLUTAKT LIST
IRON » STEEL INDUSTRY
PACE 4
                                        Hot       Environment ally.      Not    ...    Regulation
Ho.   Pollutant                       Detected    Insignificant       Treatable       Considered

      Alusunua                           -                                                X
      Aasonia                            ~                                                X
      Dissolved Iron                     -                                                X
      Fluoride                           -                                                X
      lUxavalent Chromiis                -                                                X

      Oil and Create                     -                                                X
      pH                                 ...               x
      Phenol (AAAP)                      -                                                X
      Chlorine Residual                  -                                                X
      Total Suspended Solids             -                                                X
Xl  Indicates heeding which applies to pollutant.
-I  Indicate* heading which doe> t.^t apply to pollutant.

(1) Pollutent* detected at Utels of 0.01 «g/l or let* for pollutants not no really
    occur ing in we*i*««tcr irca the*e lource*.
(2) Concentration of pollutant found at level* below tr*at«bility.
    However, pollutant load cculd be reduced by recycle.
                                               170

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       TABLE V-3

REGULATED POLLUTANT LIST
 IRON & STEEL INDUSTRY
    4  Benzene
    55  Naphthalene
    73  Benzo(a)pyrene
    85  Tetrachloroethylene
   119  Chrottiua
   121  Cyanide
   122  Lead
   124  Nickel
   128  Zinc

       Anaemia
       Oil & Crease
       PH
       Phenol (4AAP)
       Chlorine Residual
       Total Suspended Solids
       Hexavalent Chromiuo
        173

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                               VOLUME I

                              SECTION VI

           WATER POLLUTION CONTROL AND TREATMENT TECHNOLOGY
A.   Introduction

     This  section  describes  in-plant  and  end-of-pipe   wastewater
     treatment  technologies  currently in use or available for use in
     the steel industry.  The technology descriptions are  grouped  as
     follows:  recycle;  suspended  solids removal; oil removal; toxic
     metal  pollutant  removal;  toxic  organic   pollutant   removal;
     advanced  technologies;  and,  zero  discharge technologies.  The
     application  and   performance;   advantages   and   limitations;
     reliability;  maintainability;   and  demonstration status of each
     technology are presented.  The treatment processes  include  both
     technologies  presently  demonstrated  within the steel industry,
     and  those  demonstrated  in  other   industries   with   similar
     wastewaters.

B.   End of Pipe Treatment

     Recycle Systems

     Recycle is both an in-plant and end of pipe  treatment  operation
     used  to  reduce the volume of  wastewater discharged.   Wastewater
     reuse  reduces  the  discharge   flow  and  the   pollutant   load
     discharged from the process.

     Application and Performance

     Recycle  is  included  in the model treatment systems for nine of
     the twelve steel industry subcategories.   The  Agency  estimates
     that  the  use  of  these  recycle  systems can result in a 68.5%
     reduction in process water discharges at the BF-T level and a  63%
     reduction  at  the  BAT level.   To achieve these reductions, high
     degrees  of  recycle  demonstrated  in  the  industry  have  been
     included in model treatment systems as shown below:
                               177
                                                      Preceding page blank
                                                                          j


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Subcategory

Cokemaking (Barometric Condenser)

Sintering
Ironmaking
Steelmaking
Vacuum Degassing
Continuous Casting
Hot Forming
Acid Pickling (fume scrubber)
Hot Coating (fume scrubber)
     BAT
Recycle Rate (%1

      95

      92
      98
      96-100
      98
      99
      60-77
      95-98
     f5
Higher  rates  of  recycle  are  demonstrated  in these and other
subcategories.  For example, rates  of  recycle  up  to  99%  are
common for hot forming operations.

At  high  recycle rates, two problems can be encountered.  First,
if the wastewater is contaminated, a build-up of dissolved solids
in the recycled water can cause  plugging  and  corrosion.   This
problem  can  be avoided by providing sufficient treatment of the
wastewater prior to recycle, by  adding  chemicals  that  inhibit
scaling  or corrosion, and by having sufficient blowdown to limit
the build-up of  dissolved  solids  and  other  pollutants.   The
second  problem  that can occur is excessive heat build-up in the
recycled water.  If the temperature of the water to  be  recycled
is  too high for its intended purpose, it must be cooled prior to
recycle.  The most common method of reducing  the  heat  load  of
recycled  water  in  the  steel industry is with mechanical draft
cooling towers.  Mechanical draft evaporative cooling systems are
capable of  handling  the  wide  range  of  operating  conditions
encountered  in  the steel industry.  Cooling towers are included
in  the  model  treatment  systems  for   four   of   the   eight
subcategories  (cokemaking  final cooler and barometric condenser
recycle systems, ironmaking,  vacuum  degassing,  and  continuous
casting) where recycle systems are considered.  Heat accumulation
in  the  other  subcategory recycle systems is not detrimental to
the operation.

Advantages and Limitations

As discussed  above,  recycle  systems  can  achieve  significant
pollutant  load reductions at relatively low cost.  The system is
controlled  by  simple  instrumentation  and  relatively   little
operator attention xs required.

A  potential limitation on the use of recycle systems is plugging
and scaling.  However, based  upon  the  industry's  response  to
basic  and detailed questionnaires, the Agency believes that with
proper attention and maintenance, plugging and scaling should not
presen'; a significant problem with achieving  the  recycle  rates
used as a basis for this regulation.
                           178
                                                                           i *

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Operational Factors

1.   Reliability

     The reliability of recycle systems is high, although  proper
     monitoring  and  control are required for high rate systems.
     Chemical aids  are  often  used  in  the  recycle  loops  to
     maintain optimum operating conditions.

2.   Maintainability
                                                                           i
     Most recycle systems include only simple pump  stations  and
     piping.   These  components  require  very  little attention
     aside from routine maintenance.  However, for those  recycle
     systems  associated  with wet air pollution control devices,
     higher maintenance costs are incurred to chemically  control
     the   recycled  water  to  remove  suspended  and  dissolved
     constituents and to prevent fouling and scaling.

Demonstration Status

Recycle systems are well demonstrated in the  steel  industry  as
we.1!  as  in  numerous  other industral applications.  Full scale
recycle systems have been used in the  steel  industry  for  many
years.   The  recycle  rates used to develop effluent limitations
and standards for each subcategory are  demonstrated  on  a  full
scale basis in the industry.

Suspended Solids Removal

Many  types of suspended solids removal devices are in use in the
steel industry including clarifiers, thickeners,  inclined  plate
separators,  settling  lagoons,  and  filtration (mixed or single
media;  pressure  or  gravity).   Three  broad  categories   that
encompass  virtually  all methods of suspended solids removal are
reviewed: (1) settling lagoons, (2) clarification which  includes
clarifiers,  thickeners,  and  inclined  plate separators and (3)
filtration.

).   Settling Lagoon (or Basin)

     Settling (sedimentation) is a process  which  removes  solid            ]
     particles  from a liquid matrix by gravitational force.  The            f
     operation reduces the velocity of the wastewater stream in a            |
     large volume tank or lagoon so that  gravitational  settling            !
     can occur.   Because of the large wastewater volumes involved            j
     in  the  steel industry, lagoons are generally large, on the            f
     order of 0.1 to 10 acres of surface area, typically  with  a            |
     standard  working  depth  of 7 to 10 feet.  The industry has
     found lagoons up to 400 acres.

     Long   retention   times   are   generally   required    for            f
     sedimentation.    Accumulated   sludge   is  removed  either            f
                                                                          ••   1

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periodically  or  continuously  and   either   manually   or
mechanically.   But because simple sedimentation may require
an  excessively  large  settling  area,  and  because   high
retention  times  (days  as compared with hours) are usually
required to effectively treat the wastewater,  the  addition
of  settling  aidr  such as alum or polymeric flocculants is
often used.

Sedimentation is often preceded  by  chemical  precipitation
and  coagulation.  Chemical precipitation converts dissolved
pollutants  to  solid  form,  while   coagulation   enhances
settling  by  gathering together suspended precipitates into
larger, faster settling particles.

Application and Performance

Settling lagoons are used  to  treat  wastewaters  from  all
steel  industry  subcategories.  Most are terminal treatment
lagoons which serve as  a  final  treatment  step  prior  to
discharge.   Often  these  lagoons  are  a main component in
central  treatment  systems  and  are  used  to  settle  out
suspended solids from several process waste streams.

A  properly  operated  sedimentation  system  is  capable of
efficiently  removing  suspended  soMds  (including   metal
hydroxides),  and  other  impurities  from wastewaters.  The
performance of the lagoon depends primarily on overflow rate
and a variety of other factors, including  the  density  and
particle  size  of  the  solids, the effective charge of the
suspended particles, and the types  of  chemicals  used  for
pretreatment, if any.

Advantages and Limitations

The   major   advantage   of  suspended  solids  removal  by
sedimentation is the simplicity of the process.   The  major
problem  with  simple  settling  is  the long retention time
necessary to achieve  a  high  degree  of  suspended  solids
removal, especially if the specific gravity of the suspended
matter  is  close  to  that  of  water.   Retention  time is             v
directly related to lagoon  volume.   Thus,  long  retention             N
time  means  large  area  requirements not available at some
steel plants.   Another  limitation  is  that  dissolved  or
soluble pollutants are not removed by sedimentation.

Operational Factors

a.   Reliability:   Sedimentation  is  a   highly   reliable
     technology  for  removing suspended solids.  Sufficient
     retention time and regular sludge removal are important
     factors  affecting  the  reliability  of  all  settling
     systems.    The   proper   control   of   pH,  chemical
                      180
             \

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                                                                           1
          precipitation,  and  coagulation  or  flocculation  are
          additional factors which affect settling efficiencies.

     b.   Maintainability:  Little maintenance  is  required  for
          lagoons other than periodic sludge removal.

     Demonstration Status

     Based upon the survey of the industry through questionnaires
     and  sampling  surveys,  the Agency estimates that there are
     over 140 settling lagoons in use at 39  steel  plant  sites.
     Hence,   settling  lagoons are well demonstrated in the steel
     industry.

2.   Clarifiers

     Clarifiers are another type of sedimentation  device  widely
     used   in   the  steel  industry.    The  chief  benefits  of
     Clarifiers over lagoons are that Clarifiers  are  less  land
     intensive  and  provide  for  centralized sludge collection.
     Suspended SOI ids removal efficiencies are generally  in  the
     same  range  as  that  for  settling  lagoons.  Conventional
     Clarifiers consist of a circula- or  rectangular  tank  with
     either   a  mechanical  sludoe  collecting  device  or with a
     sloping funnel-shaped bottom designed for sludge collection.
     In alternative clarifier designs,  inclined plates  or  tubes
     may  be  placed  in  the  clarifier  tank  to  increase  the
     effective settling area and thus increase  the  capacity  of
     the  clarifier.  As with settling lagoons, chemical aids are
     often added prior  to  clarification  to  enhance  suspended
     solids  removal.

     Appl i cat, ion and Performance

     The  application  of  clarification  is very similar to that
     described above for settling lagoons.  Clarifiers  are  used
     to  treat  wastewaters  from every subcategory for suspended
     solids  removal.  Performance data are presented in  Appendix
     A.


     The Agency statistically analyzed long-term data for several
     clarification  systems.   The  Agency  calculated  the mean,
     standard deviation and other common statistical  values,  as
     well  as  the  30-day  average and daily maximum performance
     standards.  A 30-day average  concentration  was  calculated
     based  upon  a  95  percentile value while the daily maximum
     concentration was calculated with  a  99  percentile  value.
     The  methods used to determine these values are explained in
     Appendix A.

     Based  upon  the  data  presented  above,  and  other   data
     presented  in  the subcategory reports,  the Agency concludes
                           181

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     that a 30-day average concentration of 30  mg/1  TSS  and  a
     daily  maximum  concentration  of  70  mg/1  TSS or less are
     attainable  with  clarifiers   for   most   steel   industry
     wastewaters.   Biological treatment of cokemaking wastewaters
     produces  low density suspended solids that are difficult to
     settle.  Higher concentrations have been used in  developing
     the limitations for this subcategory.

     Advantages and Limitations

     Clarification  is  more  effective  for  removing  suspended
     solids than simple settling lagoons, requires less area, and
     provides for centralized sludge  collection.   However,  the
     cost  of  installing  and  maintaining clarifiers is greater
     than the costs associated with simple settling lagoons.

     Inclined  plate  and  slant  tube  settlers   have   removal
     efficiencies  similar to conventional clarifiers, but have a
     greater capacity per unit area.

     Operational Factors

     a.   Reliability:  Similar to  lagoon  systems  with  proper
          control   and   maintenance.   Clarifiers  can  achieve
          consistently low concentrations  of  solids  and  other
          pollutants in the wastewater.

          Those   advanced  clarifiers  using  slanted  tubes  or
          inclined  plates  may  require  prescreening   of   the
          wastewater  in  order  to eliminate any materials which
          could potentially clog the system.

     b.   Maintainability:   The  systems   u«s*d   for   chemical
          pretreatment and sludge dragout must be maintained on a
          regular basis.  Routine maintenance of mechanical parts
          is also necessary.

     Demonstration Status

     Clarifiers  are  used  extensively to treat wastewaters from
     all subcategories of the steel industry.  While  the  design
     may vary slightly depending on the wastewaters being treated
     (i.e.,  steelmaking  vs. pickling), all systems operate in a
     similar manner.

3.    Filtration

     Filtration is another common method used to remove suspended
     solids, oil and grease, and toxic metals from steel industry
     wastewaters.   Several types of filters and filter media  are
     used  in  the  industry  and all work by similar mechanisms.
     Filters may be pressure or gravity type;  single,  dual,  or

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                                                                         f -
mixed  media; and the media can be sand, diatomaceous earth,
walnut shells or some other material.

A filter may use a single media such as sand.   However,  by
using  dual or mixed (multiple) m<*dia, higher flow rates and
efficiencies can be achieved.  The dual media filter usually
consists of a fine bed  of  sand  under  a  coarser  bed  of
another  media.   The  coarse  media  removes  most  of  the
influent  solids,  while  the  fine  sand   performs   final
polishing.

In  the steel industry, several considerations are important
when filter systems are designed.  While either pressure  or
gravity  systems  may be used, the pressure systems are more
common and provide some advantages, including  smaller  land
area requirements.

For typical steel industry applications, filter rates arc in
the  range  of  6  gpm per square foot to perhaps 18 gpm per
square foot.  The efficiency of suspended solids removal  is
dependent upon the filtration rate, the filter media and the
particle  size.   A  knowledge  of  particle  density,  size
distribution,  and  chemical  composition  is  useful   when
selecting a filter design rate and media.

Filter media must be selected in conjunction with the filter
design  rate.   The size and depth of the media is a primary
consideration and other important factors are  the  chemical
composition,  sphericity,  and hardness of the media chosen.
The presence of relatively  large  amounts  of  oil  in  the
wastewater  to be filtered also affects the selection cf the
appropriate media.

During the filtration process,  suspended  solids  and  oils
accumulate  in  the  bed  and  reduce  the  ability  of  the
wastewater to flow through the media.  To function properly,
all filters are backwashed.  The method of  backwashing  and
the  design  of  backwash systems is *n integral part of any
deep-bed filtration system.  Solids  penetrate  deeply  into
the   bed   and   must  be  adequately  removed  during  the
backwashing  cycle  or  problems  may  develop  within   the
filtration   system.    Occasionally,  auxiliary  means  are
employed to aid filter cleaning.  Water jets used just below
the surface of the expanded bed  will  aid  solids  and  oil
removals.   Also,  air  can  be used to augment the cleaning
action of the backwash water to  "scour"  the  bed  free  of
solids and oils.

Filter  system  operation  may  be manual or automatic.  The
filter backwash cycle may be on a timed  basis,  a  pressure
drop basis with a terminal value which triggers backwash, or
on   a  suspended  solids  carryover  basis  from  turbidity
                      183

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  monitoring of the outlet stream.
  well demonstrated.

  Application and Performance
         Each of these  methods  is
   In  wastewater  treatment plants, filters are often employed
   for finel treatment following  clarification,  sedimentation
   or  other similar operations.  Filtration thus has potential
   application  in  nearly  all   industrial  plants.   Chemical
   additives which enhance the upstream treatment equipment may
   or  may  not  be  compatible   with or enhance the filtration
   process.  Normal operating flow rates for various  types  of
   filters are as follows:
  Slow Sand
  Rapid Sand
  High Rate Mixed Media
2.04-5.30 1/sq m/hr
40.7i-51.48 1/sq m/hr
81.48-122.22 1/sq m/hr
  Suspended   solids  are  commonly  removed  from  wastewater
  streams by filtering through a deep  0.3-0.9  m   (1-3  feet)
  granular  filter  bed.  The porous media bed can  be designed
  to  remove  practically  all  suspended   particles.    Even
  colloidal   suspensions  (roughly  1   to  100  microns)  are
  adsorbed on the surface of the media grains as they pass   in
  close proximity in the narrow bed passages.

  Data  gathered  from  short-term  sampling  visits show that
  filter plants in all subcateg
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     b.   Nalntalnability:  Deep bed filters may be operated with
          either manual  or  automatic  backwashing.   In  either
          case,  they  must  be  periodically inspected for media
          retention, partial plugging and particulate leakage.

     pemonstratiQn Status

     Filtration is one of the more common treatment methods  used
     for steel industry wastewatet;- especially in the hot forming
     subcategory.   This technology is used to treat a variety of
     wastewaters with similar results.  Its ability to reduce the
     amount of solids, oils and metals in the wastewater is  well
     demonstrated with both short and long-term data in the steel
     industry.

Oil Removal

Oils  and greases are removed from process wastewaters by several
methods in the, steel industry including oil skimming, filtration,
and air flotation.  Also, ultraf iltration is  used  at  one  cold
rolling  plant  to  remove  oils.   Oils may also be incidentally
removed through other treatment processes such as  clarification.
The  source  of these oils is usually lubricants and preservative
coatings  used  in  the   various   steelmaking   and   finishing
operations.

As a general matter, the most effective first step in oil removal
is  to  prevent  the  oil  from  .•nixing  with  the  large  volume
wastewater flows by segregating the sumps in all cellars  and  by
appropriate  maintenance of the lubrication and greasing systems.
If the segregation is accomplished, more  efficient  removals  of
the  oils  ar.d greases from wastewaters can be accomplished.  The
oil removal equipment used in the  steel  industry  is  described
below.

1 .   Skimming

     Pollutants with a specific  gravity  less  than  water  will
     often  float  unassisted  to  the surface of the wasfcewater
     Skimming is used tc remove these floating wastes.   Skimming
     normally  takes  place  in  a  tank  designed  to  allow the
     floating debris to rise and remain on the surface, while the
     liquid flows to an outlet located below the floating  layer.
     Skimming  devices  are  there! 01 e  suited  to the removal of
     nonemulsif ied  oils  from  untreated  wastewatfrrs.    Corroion
     skimming  mechanisms  include  the rotating drum type, which
              oil from the surface  of  the  water  as  the  drum
                A  doctor  blade  ^crapes  oil  from the drum and
              it in a trough for disposal or  reuse.   The  water
              is  allowed  to  flow  under the rotating drum.  An
               baffle is usually ins:alled after the  drum;  this
picks up
rotates.
collects
portion
underflow
                                                        oil which
                                                       is  pulled
has  the  advantage  of  retaining  any  floating
escapes the drum skimmer.  The belt type skxmmer

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vertically  through  the water, collecting oil which is then
scraped off from the belt surface and collected  in a storage
tank.  The industry also uses  rope  and  belt   skimmers  of
various  design  that function in the same fashion.  Gravity
separators, such as the API type, use overflow and underflow
baffles to skim a layer of floating oil from the surface  of
the wastewater.  An overflow-underflow baffle allows a small
amount  of  wastewater (the oil portion) to flow over into a
trough for disposition or reuse  while  most  of  the  water
flows  underneath  the  baffle.   This  is  followed  by  an
overflow baffle, which is set at a height  relative  to  the
first  baffle  such  that  only the oil bearing  portion will
flow over the first baffle during normal plant operation.  A
diffusion device, such as a vertical slot  baffle,  aids  in
creating  a  uniform  flow through the system and increasing
oil removal efficiency.

Application and Performance

Skimming may be used on any wastewater containing pollutants
which float to the surface.  It is commonly used to  remove
free  oil,  grease, and soaps.  Skimming is always used with
air  flotation  and  often  with  clarification  to  improve
removal of both settling and floating materials.

The  removal  efficiency  of  a skimmer is a function of the
density of the material to be floated and the retention time
of the wastewater in the tank.  The retention time  required
to  allow  phase  separation  and subsequent skimming varies
from  1   to   15   minutes,   depending   upon   wastewater
characteristics.

API  or  other  gravity-type  separators  tend   to  be  more
suitable for use where the amount  of  surface   oil  flowing
through  the system is fairly high and consistent.  Drum and
belt type skimmers are suitable where oil can be allowed  to
collect  in  a  treatment  device for periodic or continuous
removal.   Data  for  various  oil  skimming  operations  are
presented in Appendix A.

Advantages and Limitations

Skimming  as pretreatment is effective in removing naturally
floating waste material.   It also improves  the  performance
of subsequent downstream treatments.

Many  pollutants,  particularly dispersed or emulsified oil,
will not float "naturally" but require additional treatment.
Therefore, skimming alone may not remove all the  pollutants
capable  of  being  removed  by  air flotation or other more
sophisticated technologies.
                      106

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     Operational Factors

     a.   Reliability:  Because of its simplicity, skimming is  a
          very  reliable technique.  During cold weather, heating
          is usually required for the belt-type skimmers.

     b.   Maintainability:   The  skimming   mechanism   requires
          periodic  lubrication,  adjustment,  and replacement of
          worn parts.

     Demonstration Status

     Skimming is a common method used to remove floating  oil  in
     many  industrial   categories,  including the steel industry.
     Skimming is used  extensively to treat wastewaters  from  hot
     forming, continuous casting, and cold forming operations.

2.   Filtration

     As explained above, filtration is also used to  remove  oils
     and  greases from steel industry wastewaters.  The mechanism
     for removing oils is very  similar  to  the  solids  removal
     mechanism.     The  oils  and  greases,  either  floating  or
     emulsified types, are directed into the  filter  where  they
     are   adsorbed   on   the  filter  media.   Significant  oil
     reductions can be achieved  with  filtration,  and  problems
     with the oils are not experienced unless high concentrations
     of  oils  are  allowed  to  reach the filter bed.  When this
     occurs the bed can  be  "blinded"  and  must  be  backwashed
     immediately.   If  too much oil is in the filter wastewater,
     frequent backwashing is necessary which makes the use of the
     technology unworkable.  Therefore,  proper  pretreatment  is
     essential for the proper operations of filtration equipment.

     Application and Performance

     The   discussion   presented  above  for  filtration  systems
     applies here as well.   The  filter  will  reduce  oil  from
     moderate  levels   down  to  extremely low levels.  Long-term
     data for eight filtration systems demonstrate  that  an  oil
     and  grease  performance  standard as low as 3.5 mg/1 can be
     readily attained  on a 30-day average basis and 10  mg/1  oil
     and grease can be readily attained on a daily maximum basis.
     However,  because  of  problems  with  obtaining  consistent
     analytical  results in the range of 5 mg/1,  the  Agency  has
     decided  to establish only a maximum effluent limitation and
     standard based upon a daily maximum concentration of 10 mg/1
     for hot forming operations and other operations with similar
     wastewaters.

     Operational Factors and Demonstrated Status

     See prior discussion on filtration.
                           187

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3.   Flotation

     Flotation is a process which causes particles such as  metal
     hydroxides  or  oils to float to the surface of a tank where
     they are concentrated and removed.  Gas bubbles are released
     in the wastewater and attach to the solid  particles,  which
     increase  their  buoyancy  and  causes  them  to  float.  In
     principle, this process is the opposite of sedimentation.

     Flotation is used primarily in the treatment of  wastewaters
     that  carry  finely divided suspended solids or oil.  Solids
     having a specific gravity only slightly  greater  than  1.0,
     which  require  abnormally  long sedimentation times, may be
     removed by flotation.

     This process  may  be  performed  in  several  ways:   foam,
     dispersed  air, dissolved air, gravity, and vacuum flotation
     are the most commonly used techniques.   Chemical  additives
     are  often  used to enhance the performance of the flotation
     process.  For example, acid and chemical aids are often used
     to break oil emulsions in  cold  rolling  wastewaters.   The
     emulsions are part of rolling solutions used in the process.
     Emulsion  breaking is necessary for proper treatment of most
     cold rolling wastewaters by flotation.

     The  principal  difference  between   types   of   flotation
     techniques  is  the  method  of  generating  the  minute gas
     bubbles (usually air) needed to float  the "oil.   Chemicals
     may  be  used  to improve the' efficiency of any of the basic
     methods.  The different flotation techniques and the  method
     of bubble generation for each process are described below.

     Froth   .Flotation:    Froth  flotation  is  based  upon  the
     differences in  the  physiochemical  properties  of  various
     particles.    Wetability   and   surface  properties  affect
     particle affinity to gas bubbles.  In froth  flotation,  air
     is blown through the solution containing flotation reagents.
     The  particles  with  water  repellent surfaces stick to air
     bubbles and are brought to the surface.  A mineralized froth
     layer, with mineral particles attached to  air  bubbles,  is
     formed.   Particles  of  other  minerals  which  are readily
     wetted by watrr do not stick to air bubbles  and  remain  in
     suspension.

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

     Dissolved   Air  Flotation:   In  dissolved  air  flotation,
     bubbles are produced as a result of the release of air  from
     a  supersaturated  solution  under relatively high pressure.
                           ice

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There are two types of contact between the gas  bubbles  and
particles.   The first involves the entrapment of rising gas
bubbles in the flocculated particles  as  they  increase  in
size.   The  bond  between the bubble and particle is one of
physical capture only.  This  is  the  predominant  type  of
contact.   The  second  type  of contact is one of adhesion.
Adhesion results from the intermolecular attraction  exerted
at  the  interface  between  the  solid particle and gaseous
bubble.

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

Application and Performance

Flotation is commonly used  to  treat  cokemaking  and  cold
forming  wastewaters.   Gas  (hydrogen) flotation is used at
several  cokemaking  operations  to  control   oil   levels.
Dissolved  air  flotation  is used extensively to treat cold
rolling wastewaters.  The flotation process  is  used  after
emulsion  breaking  and  prior  to final settling.  Data for
three steel industry flotation units are presented below.

   Performance of Flotation Units
                      Oil & Grease (mq/1)
   Plant              In              Out

0684F (cokemaking)    93              45
0684F (cold rolling)  NA               7.3
0060B                 41,140          98

Advantages and Limitations

The advantages of the flotation  process  include  the  high
levels  of  solids  and oil separation which are achieved in
many applications; relatively low energy requirements;  and,
the  capability  to  adjust  air  flow  to  meet the varying
requirements of treating  different  types  of  wastewaters.
The  limitations  of  flotation  are  that it often requires
                       189

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     addition of chemicals to  enhance  process  performance;  it
     requires  properly  trained  and attentive operators; and it
     generates large quantities of solid wastes.

     Operational Factors

     a.    Reliability:  The reliability of a flotation system  is
          normally  high  and  is governed by proper operation of
          the sludge collector mechanism and by  the  motors  and
          pumps used for aeration.

     b.    Maintainability:  Maintenance  of  the  scraper  blades
          used  to  remove  the  floated material is critical for
          proper operations.  Routine maintenance is required  on
          the  pumps  and motors.  The sludge collector mechanism
          is subject to possible corrosion or  breakage  and  may
          require periodic replacement.

     Demonstration Status

     Flotation is extensively demonstrated in the steel industry,
     particularly  for  the  treatment  of  cokemaking  and  cold
     rolling wastewaters.

4.    Ultrafiltration

     Ultrafiltration  (UF)  includes  the  use  of  pressure  and
     semipermeable  polymeric membranes to separate emulsified or
     colloidal  materials  suspended  in  a  liquid  phase.   The
     membrane of an ultrafiltration unit forms a molecular screen
     which   retains   molecular   particles   based  upon  their
     differences in size, shape,  and  chemical  structure.   The
     membrane  permits  passage  of  solvents and lower molecular
     weight molecules.  At present, Ultrafiltration  systems  are
     used to remove materials with molecular weights in the range
     of   1,000  to  100,000 and particles of comparable or larger
     sizes.

     In. the Ultrafiltration process,  the  wastewater  is  pumped
     through  a  tubular  membrane  unit.   Water  and  some  low
     molecular weight materials pass through the  membrane  under
     the  applied  pressure  of  10  to 100 psig.  Emulsified oil
     droplets and suspended particles are retained, concentrated,
     and  removed  continuously.    In   contrast   to   ordinary
     filtration,  retained  materials are washed off the membrane
     filter rather than held by it.

     Application and Performance

     Ultrafiltration has potential application  in  cold  rolling
     operations  for separating oils and residual solids from the
     process wastes.  Because of the ability to remove emulsified
     oils with little or no pretreatment, Ultrafiltration is well
                           190


                                                                       .X

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suited for many of the wastewaters generated at cold rolling
mills.  Also, some organic compounds of  suitable  molecular
weight  may  be  bound in the oily wastes which are removed.
Hence, ultrafiltration could prove to be an effective  means
to  achieve  toxic  organic  pollutant  removal for the cold
rolling subdivision.

The following test data depict  ultrafiltration  performance
for the treatment of cold rolling wastewaters at one plant:

           UHrafiltration Performance

                          Feed (mg/1)    Permeate (mg/1)

Oil (freon extractable)     82,210            140
TSS                          2,220            199
Chromium                     6.5              1.2
Copper                       7.5              0.07
2-chlorophenol              35.5              ND
2-nitrophenol               70.0              0.02

When  the  concentration  of pollutants in the wastewater is
high (as above)  the  ultrafiltration  unit  alone  may  not
adequately  treat  the wastewater.  Additional treatment may
be required prior to discharge.

Advantages and Limitations

Ultrafiltration is an  attractive  alternative  to  chemical
treatment   in   certain   applications   because  of  lower
installation and operating costs,  high  oil  and  suspended
solids removal, and little required pretreatment.  It places
a  positive  barrier  between  pollutants and effluent which
reduces the possibility of extensive pollutant discharge due
to operator error or upset in settling and skimming systems.
Another possible application is recovering  alkaline  values
from alkaline cleaning solutions.

A  limitation  on  the  use  of ultrafiltration for treating
wastewaters is  its  narrow  temperature  range  (18  to  30
degrees  C)  for  satisfactory  operation.  Membrane life is
decreased with higher temperatures, but  flux  increases  at
elevated   temperatures.    Therefore,   the   surface  area
requirements are a function  of  temperature  and  become  a
tradeoff between initial costs and replacement costs for the
membrane.   Ultrafiltration  is  not  suitable  for  certain
solutions.  Strong oxidizing  agents,  solvents,  and  other
organic  compounds  can  dissolve  the membrane.  Fouling is
sometimes a problem,  although  the  high  velocity  of  the
wastewater   normally  creates  enough  turbulence  to  keep
fouling at a  minimum.   Large  solids  particles  are  also
sometimes  capable  c:  puncturing  the membrane and must be
                      191

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     removed  by  gravity  settling  or   filtration   prior   to
     ultrafiltration.

     Operational Factors

     a.   Reliability:   The   reliability   of   ultrafiltration
          systems   is  dependent  upon  the  proper  filtration,
          settling or other treatment of incoming wastewaters  to
          prevent  damage  to the membrane.  Pilot studies should
          be  completed  for  each   application   to   determine
          necessary  pretreatment steps and the specific membrane
          to be used.

     b.   Maintainability:    A   limited   amount   of   regular
          maintenance  is  required  for  the pumping system.  In
          addition, membranes must be periodically changed. -  The
          maintenance  associated  with  membrane plugging can be
          reduced by selecting a membrane with  optimum  physical
          characteristics  and  providing  sufficient velocity of
          the wastewater.  It is necessary to  pass  a  detergent
          solution  through  the  system  at regular intervals to
          remove an oil and grease film which accumulates on  the
          membrane.  With proper maintenance membrane life can be
          greater than twelve months.

     Demonstration Status

     The   ultrafiltration   process   is   well   developed  and
     commercially  available  for  treatment  of  wastewater   or
     recovery  of  certain high molecular weight liquid and solid
     contaminants.  Over TOO units are presently in operation  in
     the  United  States.  Ultrafiltration is demonstrated in the
     steel industry in the cold forming subcategory.

Metals Removal

Steel industry wastewaters contain significant  levels  of  toxic
metal  pollutants  including chromium, copper, lead, nickel, zinc
and others.  These pollutants are generally removed  by  chemical
precipitation  and  sedimentation  or  filtration.   Most  can be
effectively  removed  by  precipitating   metal   hydroxides   or
carbonates  through  reactions  with  lime,  sodium hydroxide, or
sodium carbonate.  Sodium sulfide,  ferrous  sulfide,  or  sodium
bisulfite  can  also  be  used  to  precipitate metals as sulfide
compounds with low solubilities.

Hexavalent chromium  is  generally  present  in  galvanizing  and
oxidizing  salt  bath  descaling  wastewaters.  Reduction of this
pollutant to the trivalent form is required if  precipitation  as
the  hydroxide is to be achieved.  Where sulfide precipitation is
used, hexavalent chromium can be reduced directly by the sulfide.
Chromium reduction using sulfur dioxide or sodium bisulfite or by
                          192
                                                                     „ ' 1

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n
           electrochemical  techniques  may  be  necessary,  however,   when
           hydroxides are precipitated.

           Details on various metal removal technologies are presented below
           with typical treatability levels where data are available.

           1.   Chemical Precipitation

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

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

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

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

                These  treatment  chemicals may be added to a flash mixer or
                rapid mix  tank,  a  presettling  tank,  or  directly  to  a
                clarifier  or other settling device.  Coagulating agents may
                be added to facilitate settling.  After the solids have been
                removed, a final pH adjustment may be required to reduce the
                high pH created by the alkaline treatment chemicals.

                Chemical precipitation as a mechanism  for  removing  metals
                from wastewater is a complex process made up of at least two
                steps:   precipitation of the unwanted metals and removal of
                the precipitate.   A  small  amount  of  metal  will  remain
                dissolved  in  the  wastewater after complete precipitation.
                The amount  of  residual  dissolved  metal  depends  on  the
                treatment  chemicals  used,  the solubility of the metal and
                co-precipitation effects.  The effectiveness of this  method
                of  removirir;  any  specific metal depends on the fraction of
                the specific metal in  the  raw  waste  (and  hence  in  the
                precipitate)  and  the  effectiveness  of  suspended  solids
                removal.

                Application and Performance

                Chemical precipitation is  used  extensively  in  the  steel
                industry  for  precipitation  of  dissolved metals including
                                     193

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aluminum, antimony, arsenic, beryllium,  cadmium,  chromium,
cobalt,  copper, iron, lead, manganese, mercury, molybdenum,
nickel, tin, and zinc.  The process is  also  applicable  to
any substance that can be transformed into an insoluble form
such  as fluorides, phosphates, soaps, sulfides, and others.
Chemical precipitation is simple and effective.

The performance of chemical precipitation depends on several
variables; the most important are:

a.   Maintenance  of   an   alkaline   pH   throughout   the
     precipitation reaction and subsequent settling.

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

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

d.   Effective   removal   of   precipitated   solids   (see
     appropriate   technologies   discussed   under  "Solids
     Removal").

A discussion of the performance  of  some  of  the  chemical
precipitation  technologies  used  in  the steel industry is
presented below.

Lime Precipitation - Sedimentation Performance

Lime is sometimes used  in  conjunction  with  sedimentation
technology to precipitate metals.  Numerous examples of this
technology  are  demonstrated  in the steel industry, mostly
for treatment of steel finishing wastewaters.  Data for  one
plant  and  the  median  effluent concentration of long term
averages for several plants using this technology are  shown
below.    Plant  0584E has a lime precipitation/sedimentation
treatment  system  which  treats  wastewaters  from  several
finishing  operations, including electroplating which is not
covered as part of the steel industry category.  The  median
data  for  the  other  plants  were  used  to  establish the
effluent limitation for carbon  steel  finishing  operations
and are review in Appendix A of this volume.
                      194

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  Lime Precipitation - Sedimentation Performance
Pollutant
  Concentration of Pollutants
  	(mq/1)	
                     Median
                  Performance*
Dissolved Iron
Chromium
Copper
Lead
Nickel
Tin
Zinc
TSS
PH
Plant 0584E
 In     Out
    0.25
    4.4
                                 Out
    4.4
    0.11
  322
2.9-6.8
0.01
0.054
—
-
-
0.0
0.02
4.5
7.0-7.4
<0.02
0.03
0.04
0.10
0.15
—
0.06
25
6.0-9.








0
*See Appendix A

Lime Precipitation - Filtration Performance

A  metals  removal  technology  that  is  used  in the steel
industry similar to the lime/sedimentation  system  includes
lime precipitation and filtration.  These systems accomplish
better  solids  and  oil  removal and also achieves slightly
better control of the effluent concentration of the metallic
elements.   Data   for   two   plants   that   employ   lime
precipitation/filtration   technology   are   shown   below.
Pickling and galvanizing wastewaters are  treated  at  plant
0612,  while  pickling,  galvanizing  and  alkaline cleaning
wastewaters are treated at plant 01121.   The median effluent
concentrations of long term average for several plants which
were  used  to  establish  the  effluent   limitations   for
filtration systems are also presented below.  These effluent
data  are  more  thoroughly,  reviewed in Appendix A of this
volume.  Pilot plant data for  steelmaking  wastewaters  are
also presented in Appendix A.
                      195
                                                          1

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                                                                  -~—
   Lime Precipitation - Filtration Performance
               Concentration of
               	(mq/1)
                 Pollutants
 Pollutant
 Chromium
 Copper
 Lead
 Nickel
 Zinc
 TSS
 PH
Plant 0612
Plant 01121

                      Out

                       Out
1 .60
0.60
2.400
0.60
285.00
350.00
2.9-
3.9
0.04
0.08
0. 18
0.02
0.12
11.00
8.3-
8.5
0.12
0.17
C.19
0.08
18.00
199.00
5.2-
5.6
0.03
0.02
<0. 10
0.03
0.13
1.00
7.3-
7.7
  Median
Performance*
  Out

  0.03
  0.03
  0.06
  0.04
  0.10
  9.8
  6.0
  9.0
 *See Appendix A

 Sulfide Precipitation

 Most metal sulfides are less soluble than hydroxides and the
 precipitates  are  frequently  more  dependably removed from
 water.   Solubilities  for  selected  metal  hydroxides  and
 sulfide precipitates are shown below:

Theoretical Solubilities of Hydroxides and Sulfides
	of Heavy Metals in Pure Water	
 Metal

 Cadmium(Cd+2)
 Chromium (Cr*J)
 Copper (Cu+2)
 Iron (Fe+z)
 Lead (Pb+2)
 Nickel (Ni+z)
 Silver (Ag+2)
 Tin (Sn+2)
                        Solubility of Metal,  mq/1
     As hydroxide
2.3
8.4
2.2
8.9
2.1
6.9
13.0
1 .1
x
x
X
X
X
X
X
X
10-*
10-*
10-z
io-»
io-°
io-j
io-°
io-«
          As sulfide

          6.7 x ID-*0
          No precipitate
          5.8 x 10-»«
          3.4 x 10-*
          3.8 x 10-'
          6.9 x 10-«
          7.4 x 10-»2
          2.3 x 10~7
 Sulfide treatment has not been used in the steel industry on
 a  full-scale  basis.   However,   it  has been used in other
 manufacturing process (e.g.  electroplating) to remove metals
 from wastewaters with similar characteristics and pollutants
 to those of the steel industry.

 In assessing whether this technology is transferable for use
 in steel industry,  the Agency consulted numerous references;
 contacted sulfide precipitation equipment manufacturers, and
 gathered data from operating sulfide precipitation  systems.
 The  wastewaters  treated  by  these  sulfide  precipitation
 systems were contaminated with many of the same toxic metals
                       196

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found  in  steel  industry  wastewaters   and   at   similar
concentrations.   Accordingly,  the  Agency concluded that a
transfer  of  the  effectiveness  of  this   technology   is
possible.   However,  as noted above there are no full scale
systems currently in use in the steel industry.

Data for several sulfide/filtration systems are shown below.

   Sulfide Precipitation/Filtration Performance

   	Concentration of Pollutants (mq/1)	
Pollutant

Chromium
Iron
Nickel
Zinc
TSS
PH
Data Set II
 In    Out
                         Data Set ft2
            2.0
            85.0
            0.6
            27.0
            320
            2.9
       0.04
       0.10

       4.6
       8.2
In

2.4
108
0.68
33.9
                                Out
0.60

<0. 1
7.7   7.4
Another benefit of the sulfide precipitation  technology  is
che   ability  to  precipitate  hexavalent  chromium  (Cr+»)
without  prior  reduction  to  the  trivalent  state  as  is
required  in the hydroxide process.  When ferrous sulfide is
used as the precipitant, iron and sulfide  act  as  reducing
agents   for   the  hexavalent  chromium  according  to  the
reaction:

Cr04= + FeS «• 4H,0-»Cr(OH)3 + Fe(OH), * S * 20H-

In this reaction, the sludge  produced  consists  mainly  of
ferric  hydroxides,  chromic hydroxides and various metallic
sulfides.  Some excess hydroxyl ions are generated  in  this
process, possibly requiring a downward pre-adjustment of pH.

Advantages and Limitations

Chemical   precipitation   is  an  effective  technique  for
removing many pollutants from  industrial  wastewaters.   It
operates  at  ambient  conditions  and  is  well  suited  to
automatic control.  The use of chemical precipitation may be
limited due to interference of  chelating  agents,  chemical
interferences   from   mixing   wastewaters   and  treatment
chemicals, and  potentially  hazardous  situations  involved
with  the  storage and handling of those chericals.  Lime is
usually  added  as  a  slurry   when   used   in   hydroxide
precipitation.   The  slurry  must  be  well  mixed  and the
addition lines periodically checked to prevent fouling.   In
addition,  hydroxide precipitation usually makes recovery of
the  precipitated   metals   difficult,   because   of   the
heterogeneous  nature  of  most hydroxide sludges.  As shown
                                                                         m
                                                                         ^S",
                                                                         1
                      197

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above,  lime  precipitation  of  steel  industry   finishing
wastewaters  can  produce  effluent  quality similar to that
shown for sulfide precipitation.

The low solubility of most metal sulfides,  allow  for  high
metal  removal  efficiencies.  Also, the sulfide process has
the ability to  remove  chromates  and  dichromates  without
preliminary  reduction  of  the  chromium  to  the trivalent
state.  Sulfide precipitation can  be  used  to  precipitate
metals  complexed  with  most  coit.plexing  agents.  However,
Sulfids precipitation can be used to care must be  taken  to
maintain the pH of the solution at approximately 10 in order
to  prevent  the generation of toxic sulfide gas during this
process.  For this reason ventilation of the treatment tanks
may be a necessary precaution in  most  installations.   The
use  of  ferrous sulfide reduces or virtually eliminates the
problem of hydrogen sulfide evolution.   As  with  hydroxide
precipitation,  excess  sulfide ion must be present to drive
the precipitation reaction to completion.  Since the sulfide
ion itself is toxic,  sulfide  addition  must  be  carefully
controlled  to  maximize  heavy  metals precipitation with a
minimum of excess sulfide to avoid  the  necessity  of  post
treatment.  Where excess sulfide is present, aeration of the
effluent stream can aid in oxidizing residual sulfide to the
less  harmful  sodium sulfate (Na2S04).  The cost of sulfide
precipitants  is   high'  in   comparison   with   hydroxide
precipitants,  and  disposal of metallic sulfide sludges may
pose problems.  An essential element  in  effective  sulfide
precipitation is the removal of precipitated solids from the
wastewater  and  proper  disposal  in  an  appropriate site.
Sulfide precipitation will also generate a higher volume  of
sludge  than  hydroxide  precipitation,  resulting in higher
disposal and dewatering costs.  This is especially true when
ferrous sulfide is used as the precipitant.

Sulfide precipitation may be used as a final tratement  step
after hydroxide precipitation-sedimentation.  This treatment
configuration may provide the better treatment effectiveness
of  sulfide  precipitation  while minimizing the variability
caused by changes in raw waste and reducing  the  amount  of
sulfide precipitant required.

Operational Factors

a.   Reliability:   The  reliability  of  alkaline  chemical
     precipitation  is  high, although proper monitoring and
     control are necessary.  Sulfide  precipitation  systems
     provide similar reliability.

b.   Maintainability:  The major maintenance  needs  involve
     periodic  upkeep  of  monitoring  equipment,  automatic
     feeding  equipment,   mixing   equipment,   and   other
     hardware.   Removal  of accumulated sludge is necessary
                       193

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          for       the       efficient       operation        of
          precipitation-sedimentation systems.

     Demonstration Status

     Chemical  precipitation  of  metal  hydroxides  is a classic
     wastewater treatment technology used  throughout  the  steel
     industry.  Chemical precipitation of metals in the carbonate
     form  alone  has  been  found to be feasible and,  is used in
     commercial application to permit metals recovery  and  water
     reuse.   Full  scale  commercial sulfide precipitation units
     are in operation at numerous  installations,  however,  none
     are presently installed in the steel industry.

2.   Filtration (for Metal Removal)

     As discussed previously,  filtration is a  proven  technology
     for the control of suspended solids and oil and grease.   The
     filtration mechanism which reduces the concentrations of the
     suspended  solids and oils also treats the metallic elements
     present in particulate form.  To determine the  treatability
     levels  for  metals using filtration the Agency compiled all
     available  data  for  such  systems.   Data  for   seventeen
     filtration  systems  were  averaged  to  develop the treated
     effluent  concentrations.    The  average  treated    effluent
     concentrations    and    the    proposed   monthly   average
     concentration for five toxic metals are shown below:

          Metal Removal with Filtration Systems

                   Monthly Average            Daily Maximum
     Pollutant   Concentration (mg/1)    Concentration  (mg/1)

     Chromium           0.04                      0.12
     Copper             0.04                      0.12
     Lead               0.08                      0.24
     Nickel             0.05                      0.16
     Zinc               0.08                      0.24

     For purposes of developing effluent limitations, the  Agency
     is  using  30  day  average  concentrations of 0.10 mg/1 and
     daily maximum concentrations of 0.30  mg/1  for  each  toxic
     metal  except  zinc.   For zinc, the Agency is using a 30 day
     average  concentration  of  0.15  mg/1  and  daily   maximum
     concentration  of  0.45 mg/1,  since the performance standard
     for zinc was greater than 0.10 mg/1.  The Agency rounded the
     zinc performance standard to 0.15 mg/1.   Reference  is  made
     to  Appendix  A  for  development  of  toxic metals effluent
     concentrations.
                          199

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     Advantages and Limitations

     See prior discussion on filtration systems.

     Operational Factors and Demonstration Status

     See prior discussion on filtration systems.

Organic Removal

Thirty-three organic toxic  pollutants  were  detected  in  steel
industry  wastewaters above treatability levels.  Because some of
these pollutants are present in significant  levels,  the  Agency
considered  two  demonstrated  treatment  alternatives  for these
pollutants  in  several  subcategories:  carbon  adsorption   and
biological  treatment (activated sludge).  These technologies are
discussed separately below.

1.    Carbon Adsorption

     The  use  of  activated  carbon  for  removal  of  dissolved
     organics from water and wastewater has been demonstrated and
     is  one  of  the  most  efficient  organic removal processes"
     available.  Activated carbon has also been shown  to  be  an
     effective   adsorbent   for  many  toxic  metals,  including
     mercury.   This  process  is   reversible,   thus   allowing
     activated  carbon  to  be  regenerated  and  reused  by  the
     application of heat and steam or solvent.    Regeneration  of
     carbon  which  has adsorbed significant metals, however, may
     be difficult.

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

     Activated  carbon  removes  contaminants  from  water by the
     process of adsorption (the attraction  and  accumulation  of
     one  substance on the surface of another).  Activated carbon
     preferentially adsorbs organic  compounds  and,  because  of
     this  selectivity,  is  particularly  effective  in removing
     toxic organic pollutants from wastewaters.

     Carbon adsorption requires pretreatment (usually filtration)
     to  remove  excess  suspended  solids,  oils,  and  greases.
     Suspended solids in the influent should be less than 50 mg/1
                           200

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to  minimize  backwash  requirements.  A downflow carbon bed
can handle  much  higher  levels  (up  to  2000  mg/1),  but
frequent backwashing is required.  Backwashing more than two
or  three  times  a  day  is  not desirable.  Oil and grease
should be less than about 15 mg/1. A high level of dissolved
inorganic material in the influent may cause  problems  with
thermal  carbon  reactivation  (i.e.,  scaling  and  loss of
activity) unless appropriate  preventive  steps  are  taken.
Such  steps  might include pH control, softening, or the use
of an acid wash on the carbon prior to reactivation.

Activated carbon is available in both powdered and  granular
form.  Powdered carbon is less expensive per unit weight and
may  have slightly higher adsorption capacity but it is more
difficult to handle and to regenerate.

Application and Performance

Activated carbon has been used in a variety of  applications
involving   the   removal   of   objectional  organics  from
wastewater streams.  One of the more  frequent  uses  is  to
reduce  the  concentration of oxygen demanding substances in
POTW effluents.  It is also used to remove specific  organic
contaminants  in  the  wastewaters  of various manufacturing
operations such as petroleum refining.  There are  two  full
scale  activated carbon systems in use in the steel industry
for treating cokemaking wastewaters.

Tests performed on single  compound  systems  indicate  that
processing with activated carbon can achieve residual levels
on  the order of 1 microgram per liter for many of the toxic
organic  pollutants.   Compounds  which  respond   well   to
adsorption   include   carbon   tetrachloride,   chlorinated
benzenes,   chlorinated   ethanes,   chlorinated    phenols,
haloethers,  phenols,  nitrophenols,  DDT  and  metabolites,
pesticides, polynuclear aromatics and  PCB's.   Plant  scale
systems treating a mixture of many organic compounds must be
carefully designed to optimize certain critical factors.

Factors  which  affect  overall  adsorption of mixed solutes
include relative molecular  size,  the  relative  adsorptive
affinities,  and  the relative concentration of the solutes.
Data indicate that column  treatment  with  granular  carbon
provides  for  better  removal  of  organics  than clarifier
contact treatment with powdered carbon.

Data from two activated carbon column systems  used  in  the
steel   industry   and  EPA  treatability  data  for  carbon
adsorption systems  were  combined  to  develop  performance
standards   for   carbon   column   systems.    The  average
concentration  values  attainable  with  carbon   adsorption
systems  are  shown  in  Table VI-1  for those toxic organics
                      201

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     found  above   treatability   levels   in   steel   industry
     wastewaters.

     Advantages and Limitations

     The major benefits of carbon treatment include applicability
     to   a   wide  variety  of  organics,  and  a  high  removal
     efficiency.  The system is  not  sensitive  to  fairly  wide
     variations  in  concentration and flow rates.  The system is
     compact, and recovery of  adsorbed  materials  is  sometimes
     practical.   However,  the destruction of adsorbed compounds
     often occurs during thermal regeneration.  If carbon  cannot
     be thermally desorbed, it must be disposed of along with any
     adsorbed  pollutants.   When  thermal  regeneration is used,
     capital and operating costs are  generally  economical  when
     carbon  usage  exceeds  about 1,000 Ib/day.  Carbon does not
     efficiently remove low molecular weight  or  highly  soluble
     organic compounds.

     Operational Factors

     a.   Reliability:  This system is very reliable with  proper
          pretreatment and proper operation and maintenance.

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

     Demonstration Status

     Carbon adsorption  systems  have  been  demonstrated  to  be
     practical  and  economical for the reduction of COD, BOD and
     related pollutants in  secondary  municipal  and  industrial
     wastewaters; for the removal of toxic or refractory organics
     from  isolated  industrial  wastewaters; for the removal and
     recovery of certain organics from wastewaters; and  for  the
     removal,  at  times  with  recovery,  of  selected inorganic
     chemicals  from  aqueous  wastes.   Carbon   adsorption   is
     considered  a  viable and economic process for organic waste
     streams containing up to 1 to 5  percent  of  refractory  or
     toxic  organics.   It  also  has  been  used to remove toxic
     inorganic pollutants such as metals.

     Granular carbon adsorption is demonstrated on a  full  scale
     basis  at  tow  plants in the cokemaking subcategory and one
     blast furnace  and  sintering  operation.   Additionally,  a
     powered   carbon   addition   study  has  been  piloted  for
     biological treatment of cokemaking wasterwaters.

2.    Biological Oxidation

     Biological treatment  is  another  method  of  reducing  the
     concentration  of  ammonia-n,   cyanide,  phenols  (4AAP) and
                           202

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toxic   organic   pollutants   from   process   wastewaters.
Biological  systems,  both  single  and two-stage, have been
used  effectively  to  treat  sanitary   wastewaters.    The
activated  sludge  system  is well demonstrated in the steel
industry,  although   other   systems   including   rotating
biological disks have also been studied.

In  the  activated  sludge  process, wastewater is stablized
biologically in a reactor  under  aerobic  conditions.   The
aerobic  environment  is  achieved by the use of diffused or
mechanical aeration.  After the wastewater is treated in the
reactor, the resulting biological mass is separated from the
liquid in  a  settling  tank.   A  portion  of  the  settled
biological  solids  is  recycled  and  the remaining mass is
wasted.  The level at which the biological  mass  should  be
maintained  in the system depends upon the desired treatment
efficiency, the particular pollutants that are to be removed
and other considerations related to growth kinetics.

The  activated  sludge  system  generally  is  sensitive  to
fluctuations    in   hydraulic   and   pollutant   loadings,
temperature and certain pollutants.   Temperature  not  only
influences  the  metabolic activities of the microbiological
population, but also has an effect on such  factors  as  gas
transfer  rates  and  the  settling  characteristics  of the
biological solids.  Some pollutants are extremely  toxic  to
the  microorganisms  in  the system, such as ammonia at high
concentrations  and  tocix  metals.   Therefore,  sufficient
equalization and pretreatment must be installed ahead of the
biological  reactor  so that high levels of toxic pollutants
do  not  enter  the  system  and  "kill"  the  microorganism
population.   If  the  biological conditions in an activated
sludge plant are upset, it can be a matter of days or  weeks
before biological activity returns to normal.

Application and Performance

Although  a  great  deal  of information is available on the
performance  of  activated  sludge  units   in   controlling
phenolic  compounds,  cyanides,  ammonia,  and  BOD, limited
long-term data  are  available  regarding  toxic  pollutants
other  than phenolic compounds, cyanides, and ammonia.  Only
lately has there been an emphasis upon  the  performance  of
the activated sludge units on the toxic organic pollutants.

Originally,  advanced levels of treatment using a biological
system  were  expected  to  involve  multiple   stages   for
accomplishing selective degradation of pollutants in series,
e.g., phenolic compounds and cyanide removal, nitrification,
and  dentrification.   The Agency sampled the wastewaters of
two  well  operated  biological  plants  in  the  cokemaking
subcategory.  Both of these plants achieved good removals of
toxic  pollutants with organic removal averaging better than
                       203

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     90%   and   completely   eliminating   phenolic   compounds,
     naphthalene,  and  xylene.   The  monitoring data for one of
     these plants were used to develop performance standards  for
     ammonia-N,   cyanide,  phenols  (4AAP),  and  toxic  organic
     pollutants  for   biological   oxidation   systems.    These
     standards are shown in Table VI-1 for those toxic pollutants
     found  in  the steel industry wastewaters above treatability
     levels.

     Advantages and Limitations

     The activated sludge system achieves significant  reductions
     of  most  toxic  organic  pollutants  at  significantly less
     capital and operating  costs  than  for  carbon  adsorption.
     Also,  consistent  efflut-nt  quality  can  be  maintained if
     sufficient pretreatment is practiced and shock  loadings  of
     specific pollutants are eliminated.  The temperature, pH and
     oxygen  levels  in  the  system  must  be  maintained within
     certain ranges or fluctuating removal efficiencies  of  some
     pollutants will occur.

     Operational Factors

     a.   Reliability:  Thj.s system is very reliable with  proper
          pretreatment and proper operation and maintenance.

     b.   Maintainability:  As long as adequate  pretreatment  is
          practiced, high effluent quality can be maintained.  If
          the system is upset, the operation can be brought under
          control   by  seeding  with  biological  floe  or  POTW
          sludges.

     Demonstration Status

     Activated sludge systems are well demonstrated in the  steel
     industry.   Biological  oxidation  systems  are installed at
     eighteen cokemaking operations.

Advanced Technologies

The Agency considered other advanced  treatment  technologies  as
possible alternative treatment systems.  Ion exchange and reverse
osmosis  were considered because of their treatment effectiveness
and because, in certain applications, they allow the recovery  of
certain process material.

1.    Ion Exchange

     Ion  exchange  is  a  process  in  which   ions,   held   by
     electrostatic  forces  to  charged  functional groups on the
     surface of the ion exchange resin, are exchanged for ions of
     similar charge from the  solution  in  which  the  resin  is
     immersed.   This  is  classified  as  an  absorption process
                           204

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because the exchange occurs on the surface of the resin, and
the exchanging  ion  must  undergo  a  phase  transfer  from
solution  phase to solid phase.  Thus, ionic contaminants in
a wastewater can be exchanged for the harmless ions  of  the
resin.

Low  exchange  systems  used to treat wastewaters are always
proceeded by filters to remove suspended matter which  could
foul  the  low  exchange  resin.  The wastewater then passes
through a cation exchanger which contains tjhe  ion  exchange
resin.   The  exchanger  retains metallic impurities such as
copper, iron, and trivalent  chromium.   The  wastewater  is
then   passed  through  the  anion  exchanger  which  has  a
different  resin.   Hexavalent  chromium,  for  example,  is
retained   in   this   stage.   If  the  wastewater  is  not
effectively treated in one pass through  it  may  be  passed
through  another  series  of  exchangers.  Many ion exchange
systems are equipped with more than one  set  of  exchangers
for this reason.

The  other  major portion of the ion exchange process is the
regeneration of the resin, which  holds  impurities  removed
from  the wastewater.  Metal ions such as nickel are removed
by an acid cation exchange resin, which is regenerated  with
hydrochloric  or sulfuric acid, replacing the metal ion with
one or more hydrogen ions.  Anions such  as  dichromate  are
removed   by   a   basic  anion  exchange  resin,  which  is
regenerated with sodium hydroxide, replacing the anion  with
one or more hydroxyl ions.  The three principal methods used
by industry for regenerating the spent resins are:

a.   Replacement Service:  A regeneration  service  replaces
     the spent resin with regenerated resin, and regenerates
     the  spent resin at itc own facility.  The service then
     treats and disposes of the spent regenerant.

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

c.   Cyclic Regeneration:  In this process, the regeneration
     of the spent .resins takes place within the ion exchange
     unit itself in alternating cycles with the ion  removal
     process.   A regeneration permits operation with a very
     small quantity of resin and  with  fairly  concentrated
     solutions,  resulting in a very compact system.  Again,
     this process varies according to application,  but  the
     regeneration  cycle generally begins with caustic being
     pumped through the anion exchanger, which  carries  out
                      205

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     hexavalent chromium, for example, as sodium dichromate.
     The  sodium  dichromate  stream  then  passes through a
     cation exchanger, converting the sodium  dichromate  to
     chromic  acid.  After being concentrated by evaporation
     or other means, the chromic acid can be returned to the
     process  line.   Meanwhile,  the  cation  exchanger  is
     regenerated  with  sulfuric  acid, resulting in a waste
     acid stream containing the metallic impurities  removed
     earlier.   Flushing the exchangers with water completes
     the cycle.  Thus, the wastewater is  purified  and,  in
     this  example,  chromic  acid  is  recovered.   The ion
     exchangers, with newly regenerated  resin,  then  enter
     the ion removal cycle again.

Application and Performance

The list of pollutants for which the ion exchange system has
proven  effective includes, among others, aluminum, arsenic,
cadmium,  chromium  (hexavalent  and   trivalent),   copper,
cyanide,  gold,  iron,  lead,  manganese,  nickel, selenium,
silver, tin, and zinc.  Thus, it can be applied  at  a  wide
variety  of  industrial  concerns.   Because  of  the  heavy
concentrations of metals in metal finishing wastewaters, ion
exchange is  used  extensively  in  that  industry.   As  an
end-of-pipe  treatment,  ion exchange is certainly feasible,
but its greatest value is in recovery applications.   It  is
commonly  used  as  an integrated treatment to recover rinse
water  and  process  chemicals.   At   some   electroplating
facilities  ion  exchange  is used to concentrate and purify
plating baths.

Ion exchange is highly efficient at recovering metal bearing
solutions.   Recovery   of   chromium,   nickel,   phosphate
solutions,  and sulfuric acid from anodizing is commercially
viable.  A chromic acid recovery efficiency of 99.5  percent
has been demonstrated.  Ion exchange systems are reported to
be  installed at three pickling operations, however, none of
these systems were sampled during this study.  Data for  two
plants in the coil coating category are shown below.
                       206                                            \

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             Ion Exchange Performance
Pollutant
All Values
mg/1
Al
Cd
Cr*»
Cr*«
Cu
CN
Au
Fe
Pb
Mn
Ni
Ag
S04
Sn
Zn
Plant
Prior to
Purifi-
cation
5.6
5.7
3.1
7.1
4.5
9.8
—
7.4
-
4.4
6.2
1.5
-
1.7
14.8
A
After
Purifi-
cation
0.20
0.00
0.01
0.01
0.09
0.04
-
0.01
_
0.00
0.00
0.00
-
0.00
0.40
                                     Plant B
                                Prior to  After
                                Purifi-   Purifi-
                                cation    cation
                                 43.0
                                  3.40
                                  2.30

                                  1.70
                                    60
                                    10
                                210.00
                                  1.10
                                            0.10
                                            0.09
                                            0.10

                                            0.01

                                            0.01
                                            0.01
                                            2.00
                                            0.10
Advantages and Limitations
Ion exchange is a versatile technology applicable to a great
many  situations.   This flexibility, along with its compact
                                     exchange  an  effective
                                     However,  the resins in
                                     limiting  factor.   The
                                     generally placed in the
                                     its  use   in   certain
nature and performance,  makes  ion
method  of  wastewater  treatment.
these systems can  prove  to  be  a
thermal  limits of the anion resins
vicinity  of  60°C,  could  prevent
situations.   Similarly,  nitric  acid,  chromic  acid,  and
hydrogen peroxide can all damage the resins  as  will  iron,
manganese,   and   copper   when   present  with  sufficient
concentrations of dissolved oxygen.  Removal of a particular
trace  contaminant  may  be  uneconomical  because  of   the
presence  of  other  ionic  species  that are preferentially
removed.  The regeneration of the resins  presents  its  own
problems.   The  cost  of  the regenerative chemicals can be
high.  In addition, the wastewater streams originating  from
the  regeneration  process  are  extremely high in pollutant
cncentrations,  although  low  in  volume.   These  must  be
further processed for proper disposal.

Operational Factors

a.   Reliability:  With the exception of occasional clogging
     or fouling of the resins,   ion  exchange  is  a  highly
     dependable technology.
                     207
                                                                       ii

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     b.   Maintainability:  Only the normal maintenance of pumps,
          valves,  piping  and  other  hardware   used   in   the
          regeneration process is usually encountered.

     Demonstration Status

     All  of  the  applications  mentioned  in  this  section are
     available for commercial use,  and industry sources  estimate
     the number of units currently in the field at well over 120.
     The  research and development in ion exchange is focusing on
     improving the quality and efficiency of the  resins,   rather
     than  new  applications.   Ion  exchange is used in at least
     three different plants in the  steel  industry.   Also,  ion
     exchange  is  used  in  a  variety  of other metal finishing
     operations.

2.   Reverse Osmosis

     Reverse osmosis (RO) is an operation in  which  pressure  is
     applied  to  a  solution  on the outside of a semi-permeable
     membrane causing a permeate to diffuse through the  membrane
     leaving   behind   concentrated   higher   molecular  weight
     compounds.   The  concentrate  can  be  further  treated  or
     returned  to the original operatiDn for continued use,  while
     the permeate water can be recycled for use as clean water.

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

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

     Spiral-wound  membranes  consist   of   a   porous   backing
     sandwiched between two cellulose acetate membrane sheets and
     bonded  along three edges.   The fourth edge of the composite
     sheet is attached to a large  permeate  collector  tube.    A
     spacer  screen is then placed on top of the membrane sandwich
     and  the entire stack is rolled around the centrally locateu
     tubular  permeate  collector.    The  rolled  up  package  is
     inserted  into  a  pipe able to withstand the high operating
     pressures employed in this process,  up to 55 atm (800  psi).
     When  the system is operating,  the pressurized product  water

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permeates  the  membrane  and  flows  through  the   backing
material  to the central collector tube.  The concentrate is
drained off at the end of the  container  pipe  and  can  be
reprocessed or sent to further treatment facilities.

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

The hollow fiber and spiral-wound modules  have  a  distinct
advantage  over  the  tubular  system in that they contain a
very large membrane  surface  area  in  a  relatively  small
volume.   However,  these  membranes  types  are  much  more
susceptible to fouling than the tubular system, which has  a
larger  flow  channel.   This  characteristic also makes the
tubular membrane easier to clean and regenerate than  either
the spiral-wound or hollow fiber modules.

Application and Performance

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

The closed-loop system described above may  be  supplemented
by  the addition of a vacuum evaporator after the RO unit in
order to  further  reduce  the  volume  of  reverse  osmosis
concentrate.    The  evaporated  vapor  can  be condensed and
returned to the last rinse  tank  or  sent  on  for  further
treatment.
The  largest  application  of reverse osmosis systems is
the recovery of nickel and other metal  solutions.   It  has
been  shown  that  RO  can generally be applied to most acid
metal baths with a high  degree  of  performance,  providing
that  the  membrane  unit is not overtaxed.  The limitations
most  critical  are  the  allowable  pH  range  and  maximum
operating   pressure   for  each  particular  configuration.
                     209

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Adequate  prefiltration  is  also  essential.   Only   three
membrane types are readily available in commercial RO units.
For  the  purpose  of calculating performance predictions of
this technology, a rejection rate of 98 percent was  assumed
for dissolved salts, with 95 percent permeate recovery.

Advantages and Limitations

The   major   advantage  of  reverse  osmosis  for  treating
wastewaters is the ability to concentrate  dilute  solutions
for   recovery   of  salts  and  chemicals  with  low  power
requirements.  No latent heat of vaporization or  fusion  is
required   for   effecting   separations;  the  main  energy
requirement is  for  a  high  pressure  pump.   RO  requires
relatively  little  floor  space  for compact, high capactiy
units, and exhibits high recovery and rejection rates for  a
number  of  typical  process solutions.  A limitation of the           j
reverse osmosis process is the limited temperature range for           •-
satisfactory operation.  For cellulose acetate systems,  the
preferred  limits  are  18  to  30°C  (65  to  85°F); higher
temperatures will increase the rate of  membrane  hydrolysis
and reduce system life, while lower temperatures will result
in decreased fluxes with no damage to the membrane.  Another
limitation  is  the  Inability  to handle certain solutions.
Strong oxidizing agents, strong acidic or  basic  solutions,
solvents,  and other organic compounds can cause dissolution
of the membrane.  Poor rejection of some compounds  such  as
borates   and  low  molecular  weight  organics  is  another
problem.  Fouling of membranes by failures,  and  fouling  of
membranes  by  wastewaters  with  high  levels  of suspended
solids  can  be  a  problem.   A  final  limitation  is  the
inability  to  treat or achieve high concentration with some
solutions.  Some concentrated  solutions  may  have  initial
osmotic  pressures which are so high that they either exceed
available operating pressures or are uneconomical to treat.

Operational Factors

a.   Reliability:  RO  systems  are  reliable  provided  the
     proper precautions are taken to minimize the chances of
     fouling  or degrading the membrane.  Sufficient testing
     of the wastewater stream prior to application of an  RO
     system  will provide the information needed to insure a
     successful application.

b.   Maintainability:  Membrane life is  estimated  to  fall
     between 6 months and 3 years, depending upon the use of
     the  system.   Down time for flushing or cleaning is on
     the order of two hours as often as once  each  week;  a
     substantial  portion  of maintenance time must be spent
     on cleaning  any  prefilters  installed  ahead  of  the
     reverse osmosis unit.
                     210

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     Demonstration Status

     There  are  presently  at  least one hundred reverse osmosis
     wastewater applications in  a  variety  of  industries.   In
     addition to these, thirty to forty units are used to provide
     pure process water for several industries.  Despite the many
     types and configurations of membranes, only the spiral-wound
     cellulose  acetate  membrane  has  had widespread success in
     commercial  applications.   There  are  no  known  RO  units
     presently  in  operation  in  the  steel  'industry  to treat
     wastewaters.

Zero Discharge Technologies

Zero discharge of  process  wastewater  is  achieved  in  several
subcategories  of  the  steel  industry.  The most commmonly used
method is to treat the  wastewater  sufficiently  so  it  can  be
completely  reused in the originating process or to control water
application in semi-wet air pollution control systems so that  no
discharge   results.    This   method   is  used  principally  in
steelmaking.

Another potential means to achieve zero discharge is by  the  use
of  evaporation  technology.  Evaporation systems concentrate the
wastewater constituents and produce a  distillate  quality  water
that can be recycled to the process.  Although this technology is
very  costly  and  energy  intensive,  it  may be the only method
available  to  attain  zero  discharge  in  many  steel  industry
subcategories.

Evaporation

Evaporation is a concentration process.  Water is evaporated from
a  solution,  increasing  the  concentration  of  solute-  in  the
remaining solution.  If the resulting water  vapor  is  condensed
back  to  liquid  water,  the evaporation-condensation process is
called distillation.  However evaporation is used in this  report
to   describe   both  processes.   Both  atmospheric  and  vacuum
evaporation are commonly used  in  industry  today.    Atmospheric
evaporation  could  be accomplished simply by boiling the liquid.
However,  to aid evaporation,  heated  liquid  is  sprayed  on  an
evaporation  surface,  and  air  is  blowr,  over  the surface and
subsequently  released  to  the  atmosphere.   Thus,  evaporation
occurs  by  humidification of the air stream, similar to a drying
process.   Equipment for carrying out atmospheric  evaporation  is
quite  similar  for  most  applications.   The  major  element is
generally  a  packed   column   with   an   accumulator   bottom.
Accumulated  wastewater  is  pumped  from the base of the column,
through a heat exchanger, and back into the top  of  the  column,
where  it  is  sprayed  into  the packing.  At the same time, air
drawn upward through the  packing  by  a  fan  is  heated  as  it
contacts  the  hot  liquid.   The  liquid partially vaporizes and
                          211

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humidifies the air stream.  The fan then blows the hot, humid air
to the outside atmosphere.

Another form of atmospheric evaporator  also  works  on  the  air
humidification  principle,  but the evaporated water is recovered
for reuse by condensation.  These air  humidification  techniques
operate  well  below the boiling point of water and can use waste
process heat to supply some of the energy required.

In vacuum evaporation, the evaporation  pressure  is  lowered  to
cause  the  liquid  to  boil  at reduced temperature.  All of the
water vapor is condensed and, to maintain the  vacuum  condition,
noncondensible  gases (air in particular) are removed by a vacuum
pump.  Vacuum evaporation may be either single or double  effect.
In  double  effect evaporation, two evaporators are used, and the
water vapor from the first evaporator (which  may  be  heated  by
steam)  is  used  to supply heat to the second evaporator.  As it
supplies  heat,  the  water  vapor  from  the  first   evaporator
condenses.   Approximately  equal  quantities  of  wastewater are
evaporated  in  each  unit;  thus,  the  double   effect   system
evaporates  twice the amount of water that a single effect system
does,  at  nearly  the  same  energy  cost.   The  double  effect
technique   is  therB«odynamically  possible  because  the  second
evaporator is maintained at Icwer  pressure  (high  vacuum)  and,
therefore,  lower  evaporation  temperature.   Another  means  of
increasing energy efficiency is vapor recompression  (thermal  or
mechanical),  which  enables  heat  to  be  transferred  from the
condensing water vapor to  the  evaporating  wastewater.   Vacuum
evaporation  equipment  may  be  classified  as sumberged tube or
climbing film evaporation units.

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

The major elements  of  the  climbing  film  evaporator  are  the
evaporator, separator, condenser, and vacuum pump.  Wastewater is
"drawn"  into  the system by the vacuum so that a constant liquid
level  is  maintained  in  the  separator.   Liquid  enters   the
steam-jacketed  evaporator  tubes,  and  part of it evaporates sov
that a mixture of vapor and liquid  enters  the  separator.   The
design  of  the separator is such that the liquid is continuously
circulated from the  separator  to  the  evaporator.   The  vapor
entering  the  separator  flows  out  through  a mesh entrainment
separator to the condenser, where it is  condensed  as  it  flows
                            212

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down through the condenser tubes.  The condensate, along with any
entrained  air, is pumped out of the bottom of the condenser by a
liquid ring  vacuum  pump.   The  liquid  seal  provided  by  the
condensate keeps the vacuum in the system from being broken.

Application and Performance

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

Advantages and Limitations

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

Operational Factors

1.   Reliability:  Proper maintenance will ensure a  high  degree
     of reliability for the system.  Wthout such attention, rapid
     fouling   or   deterioration  of  vacuum  seals  may  occur,
     especially when handling corrosive liquids.

2.   Maintainability:  Operating parameters can be  automatically
     controlled.   Pretreatment  may  be  required,  as  well  as
     periodic cleaning of the  system.   Regular  replacement  of
     seals,   especially  in  a  corrosive  environment,   may  be
     necessary.
                          213

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     Demonstration Status

     Evaporation  is  a  fully   developed,   commercially   available
     wastewater  treatment  technology.   It  is  used  extensively to
     recover plating chemicals in the electroplating  industry  and  a
     pilot  scale unit has been used in connection with phosphating of
     aluminum.  Evaporation technology is not used in  steel  industry
     applications for wastewater treatment.

C.   In-Plant Controls and Process Modifications

     In-plant technology is used in the steel industry  to  reduce  or
     eliminate  the pollutant load requiring end-of-pipe treatment and
     thereby improve the efficiency of existing  wastewater  treatment
     systems   or   to   reduce  the  requirements  of  new  treatment
     facilities.  In-plant  technologies  demonstrated  in  the  steel
     industry    includes    alternate   rinsing   procedures,   water
     conservation, reduction  of  dragout,  automatic  controls,  good
     housekeeping  practices,  recycle of untreated process waters and
     process modifications.

     1.    In-Process Treatment and Controls

          In-process treatment and controls apply to both existing and
          new installations  and  include  existing  technologies  and
          operating  practices.   The  data received from the industry
          indicates that water conservation practices are widely  used
          in  many  subcategories.   Within any particular subcategory
          process wastewater can vary substantially.   In  many  cases,
          these  variations  are  directly related to in-process water
          conservation and control measures.   Although  the  effluent
          limitations  and  standards  do  not regulate flow, they are
          based upon model flow rates demonstrated in  the  respective
          subcategories.

          While  effective  control  ovsr  operating  practices is one
          method of in-plant control,  others  are  more  complex  and
          require  greater  expenditures  of capital.  One of these is
          the  installation  of  cascade   rinsing   (counter-current)
          rinsing   systems.    Cascade   rinsing  is  a  demonstrated
          in-process control for pickling and hot  coating  operations
          and   may   be  implemented  at  other  processes  that  use
          conventional rinsing techniques.

          Another in-process control is the recycle of process  water.
          In   several   steel  industry  processes,   wastewaters  are
          recycled "in- plant" even prior to treatment.  For  example,
          in  the cold rolling process, oil emulsions can be collected
          and returned to the mill in  recirculation  systems  thereby
          reducing the volumes of wastewater discharged.  This control
          method  may not necessarily be used in all processes because
          of the product quality or recycle system problems  that  may
          be encountered.
                                 214

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     Other  simple  in-process controls that can affect discharge
     quality include good housekeeping  practices  and  automatic
     equipment.   For  example, if tight control over the process
     is maintained and spills are controlled,  excessive  "dumps"
     of waste solutions can be averted.  Also, automatic controls
     can  be installed that control applied water rates to insure
     that  water  is  applied  only  when  a  mill  is   actually
     operating.   For  mills  or  lines  that  are  not  operated
     continuously the volume of watar that can be conserved  with
     this practice can be significant.

2.   Process Substitutions

     There are several instances  in  the  steel  industry  where
     process  substitutions  can  be  used to effectively control
     wastewater discharges.  One is  a  cold  rolling  operations
     where   mills  can  be  designed  to  operate  either  in  a
     once-through  or  recycle  mode.   If   those   mills   with
     once-through  systems  operated in a recycle mode, oil usage
     would be reduced and  savings  could  be  achieved  since  a
     smaller treatment system would be required.

     Another  area  where  in-process  substitutions  can achieve
     significant reductions in  wastewater  flows  and  pollutant
     loads is by selecting dry air pollution control systems over
     wet systems.
                                                                           •» *.
                                                                           L

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                                        TABLE VI-1

                               TOXIC ORGANIC CONCENTRATIONS
                                  ACHIEVABLE BY TREATMENT
                                                  Achievable Concentration(pg/l)
No.          Priority Pollutant

003          Acryl emit rile
004          Benzene
009          Rexachlorobencene
011          1,1,1-Trichloroethane
021          2,4,6-Trichlorophenol
022          Parachlorometacretol
023          Chloroform
024          2-Chlorophenol
034          2,4-Dimethylphenol
035          2,4-Dinitrotoluene
036          2,6-Dinitrotoluene
038          Ethylbenzene
039          Fluoranthene
054          Isophorone
055          Naphthalene
057          2-Nitrophenol
060          4,6-Dinitro-o-cre«ol
064          Pentachlorophenol
065          Phenol
066-071      Phthalatet, Total
072          Benzo(a)anthracene
073          Ben£o(a)pyrene
076          Chrysene
077          Acenaphthylene
078          Anthracene
080          Fluorene
084          Pyrene
085          Tetrachlorethylene
086          Toluene
130          Xylene
Carbon Adaorption

     200
     50
     1
     100
     25
     50
     20
     50
     25
     50
     50
     50
     10
     50
     25
     25
     25
     50
     50
     100
     10
     1
     5
     10
     1
     10
     10
     50
     50
     10
Biological Oxidation

       100
       50
       *
       *
       50
       *
       200
       50
       5
       50
       100
       25
       5
       noo
       5
       100
       25
       *
       25
       200
       5
       5
       10
       10
       1
       5
       10
       100
       50
       100
                                                                                        (1)
* No significant removal over influent level.
(1) Two-stage activated aludge lyatem.
                                             216

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                               VOLUME I

                             SECTION VII

                    DEVELOPMENT OF COST ESTIMATES
Introduction

This  section  reviews  the  Agency's  methodology for'developing cost
estimates  for  the  alternative  water  pollution   control   systems
considered  for  each  subcategory.  The economic impacts due to these
costs and to other factors affecting the steel industry  are  reviewed
in the above references report.

Basis of Cost Estimates

Costs  developed  for. the various levels of treatment  (i.e., 3PT, BAT,
NSPS and Pretreatment) are presented in  detail  in  each  subcategory
report  of  the Development Document.  Model costs include investment,
capital depreciation, land rental interest, operating and maintenance,
and energy.  The costs for BPT and BAT are summarized and presented in
Sections VIII and IX of this report.  Costs for PSES are presented  in
Section  XII.   Only model costs are presented for NSPS and PSNS while
total industry costs are presented for the other  levels  of  control.
The  Agency  did  not  include  estimates of capacity addition in this
report.  However, estimates of capacity  additions,  retirements,  and
reworks  are  included  in  Economic Analysis of Effluent Guidelines -
Integrated Iron and Steel Industry.

The Agency developed  model  wastewater  treatment  systems  and  cost
estimates  for those systems.  Industry-wide costs to comply with this
regulation were determined from  application  of  the  costs  for  the
selected  model  treatment  systems  to each plant taking into account
treatment in place as of a reference date.  For each subcategory,  the
model costs were developed as follows:

1.   National annual production and capacity data for each subdivision
     or segment along with the number of plants  in  each  subdivision
     were  determined.   From  these data, an "average" plant size was
     established for each subdivision.

2.   For finishing operations, where more than one mill or line of the
     same operation exists at one plant site, the capacities of  these
     mills  or  lines were summed to develop a site size and costs for
     one wastewater treatment facility were developed as noted  below.
     This  manner  of  sizing  model plants more accurately represents
     actual  wastewater   treatment   practices   in   the   industry.
     Wastewaters  from  all  cold  mills  at  a given site are usually
     treated in central treatment systems.  By using site sizes, where
     appropriate, wastewater treatment within subcategories  was  more
     accurately reflected in the cost estimates.
                               217
                                                                              L

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S.   If different product types or steel types  within  a  subcategory
     were  found to have different average sizes, separate cost models
     were developed to more accurately  define  the  costs  for  these
     groupings.

4.   Applied model process flow rates were established based upon data
     obtained  from  questionnaires  and  accumulated   during   field
     sampling  visits.   The  model  flows  are  expressed in 1/kkg or
     gal/ton of product.

5.   A treatment process model and flow diagram was developed for each
     subcategory based upon appropriate subcategory treatment  systems
     and  effluent  flow  rates  representative  of the application of
     established water pollution control practices.

6.   Finally, a detailed cost estimate was made on the basis  of  each
     alternative  treatment system.  All cost estimated were developed
     in July  1978 dollars.

Total annual costs were  developed  by  summing  the  operating  costs
(including  those  for  chemicals, maintenance, labor, and energy) and
capital recovery costs.  Capital recovery costs were calculated  using
a  capital  recovery  factor  (CRF) derived specifically for the steel
industry.  Separate CRF's were derived for capital investments and for
land costs.  An explanation of the  derivation  of  these  factors  is
provided below.

The  purpose  of  a  capital  recovery  factor is to annualize capital
investment costs over  the  useful  life  of  an  asset.   Annualizing
capital  investment  costs  using  a capital recovery factor procedure
should  be  distinguished  from  using  a  depreciation  schedule   to
calculate  depreciation  expense for accounting purposes.  The purpose
of a depreciation schedule is to match the historic cost or book value
of an investment with accounting revenues occurring  over  the  useful
life  of the asset.  A capital recovery factor indicates the magnitude
of a series of periodic cash flows which, over the useful life of  the
asset,  will  have  a discounted present value equal to the discounted
present value of the investment.  The discounted present value  of  an
investment  is  generally  not  the  same as its book value due to the
impact of investment tax  credits,  tax-deductible  non-cash  expenses
such  as  depreciation, and tax-deductible investment-related expenses
such as interest and property taxes.

Assumption Underlying Capital Recovery Factors

For purposes of this study, it  was  assumed  that  pollution  control
capital  expenditures  would  be financed 20 percent by non-tax exempt
corporate debt and 80 percent by tax-exempt industrial revenue  bonds.
The  interest  rate  on  the corporate debt was determined by adding a
premium of 2.7 percent to the inflation rate assumed  for  the  period
1981-1982.   The tax-exempt interest rate was assumed to be two-thirds
of the non-exempt interest rate.  A marginal income tax rate  of  50.1
percent  was  assumed,  based on a marginal federal rate of 46 percent
                                218

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and a tax-deductible average state  tax  rate  of  7.55  percent.   An
investment  tax  credit  of  10  percent  and  the  five-year "capital
recovery"  tax  depreciation  factors  were  assumed   to   apply   to
investments  in pollution control equipment associated with steel mill
equipment.  A property tax rate of 2.38 percent of net book value  was
also  assumed,  based  on  14-year  straightline depreciation for book      §
purposes.                                        •                           I
                                                                            I
The capital recovery factor used by  the  Agency  in  this  report  is
different  from  and  more  appropriate than that used in the Lecember
1980 Development Document.  This formula is  more  appropriate  as  it
accounts for the tax effects of the industry's investment in capital.

Calculation of Capital Recovery Factors

Given  the  assumption  listed  above,  the Q.4 percent inflation rate
projection for 1981  implies  a  weighted  average  interest  rate  on
pollution control debt of 8.91  percent:

     (9.4 + 2.7)* .2 + .67*(9.4 + 2.7)* .8 « 8.91%

Using  the  discount  rate  to  calculate  the present value of a $1.0
million investment in pollution control equipment yields an  estimated
present  value  of  -$351,020.   Annualizing this outlay over a 14-year
period at the assumed rate of  interest  results  in  a  level  annual
payment  of  $44,854  after  taxes, which implies an outlay of $89,889
before taxes.   Normalizing  the  before-tax  outlay  by  the  initial
investment  of $1.0 million results in the capital recovery factor for
pollution control equipment of  0.0899.

The calculation of an annualized charge for land is slightly  diferent
because  land does not qualify for an investment tax credit and is not
a  depreciable  wasting  asset.    Instead,   land   investments   are
characterized by capital appreciation which is recovered at the and of
the investment period.  For purposes of this study, the Agency assumed
that  property taxes would be based on an assessed value rising at the
average rate of inflation over  the period,   and  that  a  recovery  or
reversion  of  the  appreciated  land  would  occur  at the end of the
14-year period.  Based upon this assumption, a $1.0 million investment
in land financed at  the  weighted  average  interest  rate  used  for
pollution  control  equipment would have a present value of -$247,340.
Recovery of this cost over a 14-year period would require receiving an
annual rent after-tax of $31,660 per  year.   This  corresponds  to  a
before-tax imputed rental of $63,340.   Normalizing this imputed rental
by  the initial investment of $1.0 million yields the required capital
recovery factor for land of 0.0634.

Basis for Direct Costs

Construction costs are highly variable and in order to determine these
costs  in  a  consistent  manner,   the   following   parameters   were
established  as  the  basis  of estimates.   The cost estimates reflect
average costs.  .
                                219

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                                                                           N
!     1.   The treatment facilities are contained within a   "battery   limit
|          site  location  and  are  erected  on a  "green field" site.  Site
j          clearance costs have  been  estimated  based  upon  average site
|          conditions   with   no   allowances   for  equipment  relocation.
]          Equipment  relocation  costs  could  not  be   included   because
1          equipment  relocation  is  highly  site  specific and in fact not
i          required at most facilities.

     2.   Equipment costs for  most  components  are  based  upon  specific
          effluent water rates and pollutant loads.  A change in water flow
          rates  will affect costs.  For vacuum filters, costs are based on
          the square feet (ft2) of surface area of the filter  which  is  a
          function of the amount of solid waste to be dewatered.  Costs for
          rinse  reduction  technology  (i.e., cascade rinse) is based upon
          production  capacity.   For  these  two  components,  costs  are
          affected more by these variables than by flow.

     3.   The treatment facilities are assumed to be located in  reasonable
          proximity  to  the  wastewater  source.  Piping and other utility
          costs  for  interconnecting  utility  runs  from  the  production
          facility  to  the  battery  limits  of the treatment facility are
          based upon a linear distance estimate of 2500 feet.   TI.e   Agency
          considers 2500 ft to be generous for most applications.  The cost
          of return piping is included in recycle system costs.

     4.   Land  acquisition  costs  are  included  in  the  cost  estimates
          prepared  for  this  study.  An average  land cost of $38,000/acre
          (1978 dollars) is used to estimate land cost requirements for the
          model treatment components.  Total land costs were then  adjusted
          to represent an annual charge to be incurred over the life  or the
          treatment  system  by  applying  the  land  cost capital recovery
          factor explained above.

     5.   Costs for  all  nessary  instrumentation  to  operate  the  model
          wastewater   treatment  facilities  have  been  included  in  the
          Agency's cost estimates,  including  pH  and  ORP  control,  flow
          meters,  level  controls,  and  various  vacuum   instruments,  as
          appropriate.

     6..   The Agency's cost estimates include  costs  for  standard   safety
          items   including   fencing,  walkways,  guard  rails,  telephone
          service, showers, and lighting.

     7.   The Agency's cost estimates are based upon  delivered  prices  of
          the  water  pollution  control  equipment and related items, thus
          freight charges are included  in  the  Agency's  cost  estimates.         i
          However,  because  of the highly variable nature of sales and use         j
          taxes imposed by state, regional, country, and local governments,         1
          the Agency did not include such taxes in its cost estimates.  •            {
                                                                                    I
     8.   Control  and  treatment  system   buildings   are   prefabricated         !
          buildings; not of brick or block construction.                            ]
                                     220                                           j
                                                                                   i

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In general, the cost estimates reflect an on-site installed cost for a
treatment  plant with electrical substation and equipment for powering
the  facilities,  all  necessary   pumps,   essential   controls   and
instrumentations,  treatment  plant  interconnecting  feed pipe lines,
chemical feed and treatment facilities, foundations, structural steel,
and a control  house.   Access  roadways  within  battery  limits  are
included  in  estimates based upon 3.65 cm (1.5 inch) thick bituminous
wearing course and 10 cm (4 inch) thick sub-base with sealer,  binder,
and gravel surfacing.  A nine gauge chain link fence with three strand
barb  wire  and  one  truck  gate were included for fencing.  The cost
estimates  also  include  a  15%  contingency  fee,  10%  contractor's
overhead and profit allowance, and engineering fees of 15%.

Sources  of  cost  data for wastewater treatment system components and
other direct cost items include vendor  quotations  and  cost  manuals
commonly  used  for  estimating  construction  costs.   These  manuals
include:
     b -
The  Richardson  Rapid  System,  Process  Plant
Estimating    Standards;   1978-1979   Edition;
Engineering Services, Inc.
Building Construction Cost Data;  1978;  Robert
Company, Inc.
Contruction
 Richardson

Snow  Means
Basis for Indirect Costs

In   addition   to   developing  estimates  for  individual  treatment
components, the Agency has also included indirect costs in  its  total
cost  estimates for water pollution control equipment.  Indirert costs
cover  such  items  as  engineering  expenses,  taxes  and  insurance,
contractor's  fees  and  overheads  and  other miscellaneous expenses.
Normally, these indirect costs are represented by three broad  expense
categories: engineering, overhead and profit, and contingencies.

Cost  manuals,  vendor  quotes and actual installation costs generally
show a range for total indirect costs of between 15% and 40% of  total
direct  costs    The  Agency's estimates contain indirect cost factors
which total 45% of the total direct costs.  The factors  used  by  the
Agency  and  an  example  of  how they are applied to direct costs are
shown below:
                                 Incremental
                                 Cost.5 ($)
                                        Total Cost ($)
Total Direct Cost
  Contingency a> 15%
  Overhead and Profit a> 10%
  Engineering 3) 15%
Total Indirect Costs
                       1,OOC,000        1,000,000
                         150,000        1,150,000
                         115,000        1,265,100
                         189,750        1,454,750
                         454,750 (45.5% of direct costs)
Cost comparisons  made  between  the  Agency's  estimates  and  actual
installation  costs  have  demonstrated that the Agency's methodology,
                               221

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including its method of applying indirect costs, is proper and can  be
used to accurately estimate industry-wide costs.

BPT, BAT. NSPS, PSES and PSNS Cost Estimates

Two  cost estimates were made for this study for the BPT, BAT and PSES
levels of treatment.  The first deals with the capital costs  for  the
systems  already  installed  and  the  second accounts for the capital
costs for the treatment components still required  at  each  of  these
levels.   Additionally,  both  in-place and required annual costs were
calculated  and  these  costs  are  included  in  all  cost  summaries
presented in this document.

Because  DCP  responses  were received from all major steel operations
and almost all minor steel facilities,  the  data  base  on  installed
treatment  components  (as  of  January  1, 1978)^ was fairly complete.
Additionally, the Agency updated  the  information  to  July 1,  1981,
based upon personal knowledge of EPA Staff, NPDES records, and conjtact
with  the  industry  during  the. public comment period on the proposed
regulation.  Using this data  base,  a  plant-by-plant  inventory  was
completed which tabulated the treatment components presently installed
and those components which are required to bring the systems up to the
BPT,  BAT  and  PSES  treatment levels.  Hence, an estimate of capital
cost requirements was made for each plant and subcategory  by  scaling
individual plants to the developed treatment model and factoring costs
based  upon production by the "six-tenth factor".  By this method, the
Agency estimated the expenditures already made by the steel  industry.
These  data  were  summarized  earlier  in  Section  II  and  are also
summarized in' each subcategory report.

For NSPS and PSNS, total industry costs have  not  been  presented  in
this report since predictions of future expansion in the industry were
not made as part of this study.
                               222

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                               VOLUME I

                             SECTION VIII

                     EFFLUENT QUALITY ATTAINABLE
           THROUGH THE APPLICATION OF THE BEST PRACTICABLE
                CONTROL TECHNOLOGY CURRENTLY AVAILABLE
Introduction

Best  Practicable  Control  Technology  Currently  Available  (BPT) is
generally based upon the average of the best existing performances  at
plants   of  various  sizes,  ages,  and  unit  processes  within  the
industrial subcategory.  This average is not based upon a broad  range
of  mills within the subcategory, but is based upon performance levels
achieved at plants known to  be  equipped  with  the  best  wastewater
treatment facilities.

The Agency also considered the following factors:

1.   Tho size and age of equipment and facilities involved.

2.   The processes employed.

3.   Non-water  quality  environmental   impacts   (including   sludge
     generation and energy requirements).

4.   The engineering-aspects of  the applications of various  types  of
     control techniques.

5.   Process changes.

6.   The total cost of application of technology in  relation  to  the
     effluent reduction benefits to be achieved from such application.

BPT  emphasizes  treatment  facilities  at   the end of  a manufacturing
process but can also  include control  technologies within  the  process
itself  when  they  are  considered   to  be  normal practice within the
industry.

The Agency also considered  the   degree  of   economic  and  engineering
reliability  in  order to determine whether  a  technology is "currently
available." As a result of  demonstrations, projects, pilot plants  and
general  use,  the Agency must have a high degree of confidence  in the
engineering and economic practicability of the technology at th<   time
of  commencement  of   construction  or  installation  of   the  c^.itrol
facilities.
                                223

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Identification of BPT

For the most part, the proposed BPT limitations are the same as  those
contained in prior steel industry water pollution control regulations.
The  Agency  proposed  less  stringent  limitations  where  the  prior
limitations were not being achieved in the industry,  or  more  recent
and complete data indicated the prior limitations were not appropriate
because  of  changes  in  subcategorization or the absence of specific
limited pollutants in the respective wastewaters.
The major changes between  the  proposed  BPT  limitations
contained in the prior regulation are summarized below:
                                       and  those
Subcategory

A.   Cokemaking
B.   Sintering
D.   Steelmaking
H.   Scale Removal
I.   Acid Pickling
J.   Cold Rolling
Change; Prior Regulations co Proposed Regulation

    The suspended solids limitation for coke-
    making operations was increased.

    All of the limitations for sintering opera-
    tions were increased based upon increased
    model treatment system flow rates.

    Segments were added for BOF wet-suppressed
    combustion operations.

    For scale removal operations, the dissolved
    chromium limitations were changed to total
    chromium limitations; and, for Kolene®
    operations, the cyanide limitations were
    deleted.

    For combination acid pickling operations,
    limitations for dissolved chromium and nickel
    were changed to total chromium and total
    nickel.

    Separate zero discharge limitations for cold
    worked pipe and tube operations were proposed.
    These operations had been included in the
    subdivision for hot worked pipe and tube
    operations in prior regulations.
K.   Alkaline Cleaning
L.   Hot Coating
    Limitations for dissolved iron, dissolved
    chromium, and dissolved nickel were deleted
    for alkaline cleaning operations.

    Separr-te limitations were proposed for
    galvai izing hot coating operations of wire
    products and fasteners and all hot coating
    operations using metals other than zinc and
    terne metal.   These operations were not
    regulated separately in the prior regulation.
                               224

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Other  than  the changes noted above, the Agency proposed the same BPT
limitations that were contained in the prior regulations, even  though
in many instances, more stringent limitations might be justified.  The
Agency chose this course of action for the following reasons:

     1.   The technological bases of the prior regulations were upheld
          by the Court in A IS I-1 and AISI-II and the-  Agency  believes       f|
          the limitations and standards are appropriate.                     ||
                                                                             «l
     2.   For virtually every subcategory, the Agency proposed BAT and       ,|?
          BCT  limitations  more  stringent  than  the  proposed   BPT       .fss
          limitations.   Thus,  upon  promulgation,  the  BAT  and BCT
          limitations would become the operative limitations for NPDES
          permits and, in most cases, the BPT limitations  would  have
          little or no impact on the permitting process.

Based  upon  comments  received on the proposed regulation, the Agency
has made some substantial changes to the BPT  limitations  from  tnose
that  were  proposed,  particularly  for  the  forming  and  finishing
operations.  In  some  cases,  more  stringent  BPT  limitations  were
promulgated.   In  other  cases,  leas  stringent BPT limitations were
promulgated.  For  the  basic  steelmaking  operations,  most  of  the
proposed BPT limitations were promulgated.  In all cases, however, the
Agency used the same basic model treatment technologies to develop the
proposed  BPT  limitations  as  were  used  to  develop  the final BPT
limitations.

The public comments caused the Agency to re-examine the subdivision of
each subcategory, in terms of whether or not  model  treatment  system
flows  based  upon  product  type  or  operating mode are appropriate,
whether or not in-process of end-of-pipe flow  reduction  systems  are
appropriate,  and,  the  performance of the model treatment systems in
achieving the desired effluent quality.   For  the  basic  steelmaking
operations,  the  response to public comments did not cause the Agency
to substantially alter its conclusions regarding  the  appropriateness
of  the  proposed  BAY  limitations.    Thus, upon promulgation of more        .-,
stringent BAT limitations for these  operations,  the  Agency  saw  no        J
reason  to  alter  the  proposed  BPT  limitations except where public        s
comments provided compelling evidence that  they  are  too  stringent.        m
For  many  of  the  forming  and finishing operations,  the response to        .«S
public  comments  caused  the  Agency  to  substantially   alter   the        sf
subdivision  of  the subcategories,  change model treatment system flow
rates and, reevaluate the performance of the model treatment  systems.
Also,  the  Agency  found  that  substantial  flow  reduction  systems
included in many of the BAT alternatives are not warranted.  Thus, for
these operations, the Agency believes that revised BPT limitations are
appropriate.  Alternatively, the Agency  could  have  promulgated  the
proposed BPT limitations and more stringent BAT limitations, but chose
not  to  do  so  because no additional technology would bs required to
achieve the more stringent BAT limitations; and, the Regulation  would
be  confusing  and  not  in  accordance  with  the  Agency's policy of
co-treatment of compatible wastewaters.

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The Agency revised the BPT limitations for the forming  and  finishing
operations for the following reasons:

     1.   Based upon  data  and  comments  received  on  the  proposed
          regulation,  the  Agency  decided  not  to  promulgate  more
          stringent BAT  limitations  in  several  subcategories  (Hot
          Forming,  Salt Bath Descaling (formerly Scale Removal), Cold
          Rolling, Acid Pickling, Alkaline Cleaning, and part  of  Hot
          Coating).     Because    additional   wastewater   treatment
          technology beyond that used to develop the  BPT  limitations
          would not be required, the Agency believes it is appropriate
          to  limit  those  toxic  pollutants found in the wastewaters
          from the respective subcategories at the BPT level.

     2.   In some cases, the Agency's response to comments involved  a
          complete  reevaluation  of  the new and previously available
          data for particular subcategories.  For some operations, the
          data  demonstrate  that  the  model  treatment  technologies
          perform  substantially better than indicated by data used to
          develop the prior regulations (Hot Forming,   Acid  Pickling,
          Hot   Coating).   In  the  absence  of  more  stringent  BAT
          limitations for these operations, the Agency believes it  is
          appropriate  that  the  BPT limitations are based upon these
          data.   For  other  operations,    the   Agency   found   the
          subdivision   of  certain  subcategories  contained  in  the
          proposed regulation is not appropriate (Salt Bath  Descaling
          (formerly  Scale  Removal),  Acid  Pickling,  Cold  Forming,
          Alkaline   Cleaning).    Revised   subdivision   of    these
          subcategories   based  upon  product-related  process  water
          requirements or mode of operation was provided.

     3.   The selection of limited pollutants was modified in  several
          instances   to   facilitate   co-treatment   of   compatible
          wastewaters not possible with the proposed BPT  limitations;
          (Salt   Bath   Descaling   (formerly  Scale  Removal),  Acid
          Pickling, Cold Rolliing, hot Coating).

The bases for all of these  changes  is  set  out  in  detail  in  the
subcategory  reports presented in the development document.  A summary
is provided below:

Subcategcry         Change-Proposed Regulation to Final Regulation

A.   Cokemaking          The suspended solids limitations were
                         increased further based upon additional
                         data.  A separate segment was provided
                         for merchant cokemaking operations.

B.   Sintering           All of the sintering limitations were
                         increased further based upon an increase
                         in the model treatment system flow rate.

D.   Steelmaking         The Open hearth Semi-Wet segment was deleted.
                               226

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     Hot Forming
Less stringent limitations were promulgated
for BOF Wet-Open Combustion and Wet Electric
Arc Furnace operations based upon changes in
respective model treatment system flow rates.

The limitations for all hot forming operations
were revised to reflect actual performance
of the model treatment system.
H.   Salt Bath Descaling The Salt Bath Descaling subcategory (formerly
                         Scale Removal) was subdivided differently to
                         take into account product-related process
                         water requirements and modes of operation
                         (batch and continuus).  Performance data
                         submitted by the industry were used as a
                         basis for the limitations.
I.   Acid Pickling
J.   Cold Forming
k.   Alkaline Cleaning
L.   Hot Coating
The Acid Pickling subcategory was treated in
the same fashion as the Scale Removal
Subcategory.  Fume scrubber operations
are limited separately on a daily mass basis
not related to production rate.

Separate limitations were promulgated for
Single Stand Recirculation and Direct
Application Cold Rolling Mills.  Limitations
for two toxic organic pollutants were
promulgated for all cold rolling operations.

The Alkaline Cleaning subcategory has been
subdivided to take into account higher
process water requirements for both batch
and continuous operations.

Limitations for the Hot Coating subcate-
gory were made consistent with those for
acid pickling and cold rolling operations to
facilitate co-treatment.
Development of BPT Limitations

Model Treatment Systems

As noted above, the Agency used the same model  treatment  systems  to
develop  the  promulgated  BPT limitations as were used to develop the
prior and proposed BPT limitations.  These technologies are  installed
throughout   the  industry  and  are  well  demonstrated.   The  model
treatment systems are described in detail in the  subcategory  reports
of this development document.
                                227

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Model Treatment System Flow Rates

The Agency's approach to developing the BPT limitations based upon the
model  treatment  systems  includes specification of a model treatment
system effluent flow rate and performance standards  for  the  limited
pollutants.   The  model  treatment system flow rates have either been
retained from the proposed or prior regulations; or, in several  cases
revised  based  upon  some of the factors noted above.  The Agency has
established model treatment system effluent flow rates based upon  the
best  performing  plants in each subcategory rather than upon averages
of all plants or upon statistically derived flows because, to a  large
extent, flow rates are within the control of the operator.

For  the  basic  steelmaking operations where recycle of air pollution
control system wastewaters or process wastewaters is an integral  part
of  the  model  treatment  systems, the "average of the best" blowdown
rates or recycle rates formed the basis for the model treatment system
effluent flow rates used to develop  the  BPT  limitations.   The  hot
forming operations were evaluated in much the same fashion in that the
primary  scale  pit  recycle rates and thus the model treatment system
effluent flow rate for  each  subcategory  were  determined  from  the
average of the best or most appropriate recycle rates.

For the other finishing operations, the Agency used two approaches for
developing the model treatment system effluent flow rates.  Production
weighted  flow rates were developed by product for Salt Bath Descaling
and  Acid  Pickling  operations.    As   noted   above,   the   Agency
substantially  revised  the subdivision of these subcategories to take
into account product related rinsewater flow requirements.   In  doing
so, the Agency believes that production weighted flows are appropriate
because  it  could  not  develop discreet groups of the best plants in
each segment.  Thus, the production weighted flow  provides  the  best
measure  of  a  model plant.  For Cold Rolling, Alkaline Cleaning, and
Hot Coating operations, the average of the best discharge  flows  were
used  to  establish  the  model  BPT  effluent flow rates.  The Agency
believes the "average of the best"  flows  for  these  operations  are
appropriate  because it could identify the best plants.  In any event,
in all but a few cases, the production weighted average flow rates for
these operations are about the same as, or less than, the "average  of
the best" flow rates.

The development of the respective model treatment system flow rates is
set out in detail in each subcategory report.

Model Treatment System Effluent Quality

The  Agency  used  the  model treatment system effluent flow rates and
performance standards for the limited pollutants to  develop  the  BPT
limitations.   The  development  of  the performance standards for the
limited pollutants is presented in  Appendix  A.   In  several  cases,
particularly  in the forming and finishing operations, the Agency used
data  from  central  treatment  facilities   that   treat   compatible
wastewaters  to  establish  and  demonstrate  compliance  with the BPT
                                228

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limitations.  The Agency believes use of central treatment plant  data
for  these  purposes  is appropriate because it is consistent with the
manner in which the Agency structured the Regulation with  respect  to
co-treatment  of compatible wastewaters and is consistent with current
treatment practices in the industry.

BPT Effluent Limitations

Table 1-2 summarizes the 1974 and 1976 BPT limitations, along with the
changes that have been made and the requirements  of  the  promulgated
regulation.   Where no changes are noted, the limi'tations are the same
as the  original  limitations.   The  guidelines  are  based  on  mass
limitations  in kilograms per 1000 kilograms (lbs/1000 Ibs) except for
fume scrubbers at acid pickling and hot coating operations  where  the
limitations  are  in  kg  per  day.   As  noted  earlier,  these  mass
limitations do not require the attainment of any particular  discharge
flow  or  effluent  concentration.   There  are  virtually an infinite
number of combinations of flow and concentration that can be  used  to
achieve  the  appropriate  limitations.  This is illustrated in Figure
VIII-1 which shows the BPT limitation for  suspended  solids  for  the
Blast  Furnace  subcategory.   Also  shown  on  this  figure,  are the
relative positions of  the  sampled  plants,  some  of  which  are  in
compliance  and  some  of  which  did not achieve the limitations.  As
shown by this diagram, those plants that do not presently achieve  the
discharge  limitation could do so by reducing either discharge flow or
effluent concentration, or a combination of the two.

Costs to Achieve the BPT Limitations
Based  upon  the  cost  estimates  developed  by   the   Agency,   the
industry-wide investment costs to achieve full compliance with the BPT     j
limitations  is  approximately $1.7 billion (in July 1, 1978 dollars).
The Agency estimates that as of July 1, 1981,  about $0.21  billion  of     j
this  amount  remained  to be spent by the industry.  The total annual
cost associated with the BPT regulation is  about  $0.20  billion.   A
breakdown  of  these  BPT  costs  by subcategory is presented in Table
VIII-1.  The Agency believes  that  the  effluent  reduction  benefits     j
resulting  from  compliance  with  the  BPT  limitations  justify  the     !
associated costs.                                                          >

These  costs  are  different  than~ those  presented  in   the   Draft
Development Document.  As noted earlier, the Agency updated the status
of  the industry with respect to the installation of pollution control
facilities from January 1978 to July 1981.  Also,  the  installed  and
required  costs  for production facilities shut down during the mid to
late 1970's were deleted.  These facilities were included in the  data
base  for the proposed regulation.  The above estimates do not include
costs for treatment facilities installed by the industry which are not
required to achieve the BPT limitations or  for  facilities  installed
which  provide  treatment  more stringent than required to achieve the
BPT and BAT limitations (e.g. cascade rinse and acid recovery  systems
for  acid  pickling  operations;  high  rate  recycle  for hot forming
operations).                                                                ;
                               229
I

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                                    TABLE VIII-1

                                  BPT COST SUMMARY
                               IROH  AND STEEL INDUSTRY
Subcategory/Subdivision

A. Cokemaking
   1. US - Biological
   2. l&S - Physical-Chemical
   3. Merchant - Biological
   4. Merchant - Physical-Chemical
   5. Beehive

*Cokemaking Total

B. Sintering

C. Ironmaking

D. Steelmaking
   1. BOF: Semi-Wet
   2. BOF: Wet-SC
   3. BOF: Wet-OC
   4. Open Hearth
   5. EAF: Semi-Wet
   6. EAF: Wet

*Steelmaking Total

E. Vacuum Degassing

F. Continuous Casting

G. Hot Forming
   1. Primary C w/s
   2. Primary C wo/s
   3. Primary 3 w/8
   4. Primary S wo/s
   5. Section Carbon
   6. Section Spec
   7. Flat C HS&S
   8. Flat S HS&S
   9. Flat C Plate
  10. Flat S Plate
  11. Pipe & Tube-Carbon
  12. Pipe & Tube-Spec

*Hot Forming Total
                                           Capital
       Annual
In-place
96.98
1.84
19.43
2.69
0.78
121.72
58.82
412.34
2.70
15.81
57.20
17.78
0.79
14.48
108.76
20.43
59.55
76.45
34.15
6.74
6.49
88.95
13.28
102.04
5.05
13.66
3.01
12.76
3.68
366.26
Required
41.50
3.70
2.45
0.00
0.00
47.65
5.07
22.40
1.61
0.00
1.42
0.00
0.22
0.00
3.25
7.47
4.84
20.78
9.85
0.00
0.76
19.05
4.17
23.26
0.14
6.49
0.18
9.35
0.00
94.03
In-Place
25.45
0.55
4.08
0.59
0.13
30.80
12.10
52.53
0.41
4.22
13.30
3.75
0.13
2.82
24.63
2.99
8.62
-29.62
-5.29
-0.75
-0.15
-0.96
-0.15
-4.83
0.23
-1.23
0.07
1.42
0.27
Required
9.51
0.88
0.54
0.00
0.00
10.93
1.34
2.74
0.24
0.00
0.34
0.00
0.03
0.00
0.61
1.11
0.76
2.66
1.32
0.00
0.00
2.48
0.30
3.06
0.02
0.87
0.02
1.23
0.00
-40.99
               11.98
                                               230

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  TABIE  VHI-1
  EPT  COST SUMMARY
  IRON AN0 STEEL  INDUSTRY
  PAGE 2
  Subcategory/Subdivision

  H. Salt Bath Descaling
     1. Oxidizing - B S/P
     2. Oxidizing - B R/W/B
     3. Oxidizing - B P/T
     4. Oxidizing - Conl
     5. Reducing - Batch
     6. Reducing - Conl

  *Salt Bach  Descaling Total

  I. Acid Pickling
     1.  Sulfuric-R/W/C-Neut
    2.  Sulfuric-S/S/?-Neut
    3.  Sulfuric-B/B/B-Neut
    4.  Sulfuric-P/T/0-Neut
    5.  Sulfuric-S/S/P Au
    6.  Sulfuric-R/W/C Au
    7.  Sulfuric-B/B/B Au
    8.  Sulfuric-P/T Au
    9. Hydrochloric-R/V'C
   10. Hydrochloric-S/S/V
   11. Hydrochloric-P/T
   12. Hydrochloric-S/S/P Ar
   13. Combination-R/W/C
   14. Conbination-B S/S/P
   15. Coobination-C S/S/P
   16. Coobination-B/B/B
   17. Coobinalion-P/T

 *Acid Pickling  Total
   Cold Forming
   1. CR-Recirc Single
   2. CR-Recirc Multi
      CR-Combination
      CR-DA Singla
      CR-DA Multi
      CW Pipe&Tube Water
      CW Pipe & Tube Oil
*Cold Forming Total
In-place
  0.58
  0.86
  0.76
  1.53
  0.61
  0.20

  4.54
                                              Capital
                                     144.65
0.20
0.02
0.00
0.16
0.00
0.00

0.38
                                                     5.38
                           In-Place
 0.08
 0.13
 0.11
 0.23
 0.09
J).Q3

 0.67
                                                                         Annual
                                                                 51.16
0.03
0.00
0.00
0.02
0.00
o.qo

0.05
0.51
1.86
0.00
0.42
0.00
0.00
0.00
0.00
0.15
1.65
0.10
0.00
0.14
0.03
0.08
0.00
0.44
3.37
13.13
2.93
1.92
0.54
0.58
0.00
0.12
0.75
22.87
0.19
-4.87
1.54
0.74
'6.54
0.20
0.61
0.13
1.23
0.00
0.08
0.00
0.00
0.00
0.00
0.02
1.46
0.01
O.C.
0.02
0.00
0.02
0.00
0.08
                                                                                3.05
                                     28.98
                                                    5.87
                                                                 3.62
                                                                               0.95
                                            231

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NOTES:  Co*L* are in million* of 7/1/78 dollar*.
Basia:  Facilities in-place as of 7/1/81.
                                               21L
Industry Total                    1,491.49        205.96       168.73         35.27
                                                                                                     !
TABLE VIII-1
BPT COST SUMMARY
IRON AND STEEL INDUSTRY
PACE 3	
                                    	Capital	     	Annual	
Subcategory/Subdivision             In-place       Required     In-Place      Required                ! »
                                                                                                     ; j

K. All-aline Cleaning                                                                                 ' •
   1. Batch                           1.67          0.31         0.21          0.04                    {X
   2. Continuoua                     10.01          0.27         1.39          0.04                    |

*Alk«line Cleaning Total             11.68          0.58         1.60          0.08                    j
                                                                                                       "t
1. Hot Coating                                                                                         |
   1. Calv. SS wo/a                   9.87          1.47         1.48          0.26                    {
   2. Calv. SS w/a                    9.80          0.44         1.55          0.08
   3. Calv. Wire wo/a                 5.44          0.66         0.69          0.10                    1  /
   4. Calv. Wire w/s                  1.10          0.66         0.17          0.10                    ',
   5. Terne wo/a                      0.52          0.05         0.07          0.01                    >
   6. Terne w/a                       1.32          0.32         0.20          0.05                    i
   7. Other SS wo/a                   0.73          1.00         0.11          0.16        .            !
   8. Other SS w/s                       -                                                             !
   9. Other Wire wo/s                 0.31          0.00         0.04          0.00                    j
  10. Other Wire w/s      ,            0.74          0.00         0.00          0.00

*Hot Coating Total                   29.83

Total                             1,367.56

Confidential Plants                  39.83

Costs for Component* Installed
  Beyond BPT                         84.10          0.00        11.TJ^          0.00
                                                                                                     I

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                             FIGURE  Vlll-l
                     POTENTIAL  FOR   ACHIEVING
                     AN  EFFLUENT  LIMITATION
   800


   480 H
e  400
o
   S80-

.§ 800
3  too
u.

jg  £00


I  I8°
O
   100 H
    so
                       EXAMPLE
                       SUBCATEOORY! IRONMAKINO
                       POLLUTANT:  TSS XT THE BPT LEVEL
 (PLANT

(PLAN? N)
                                (PLANT
                                             •(PLANT tt)
           IO  SO   SO  4O   6O  «O   TO  SO   90   IOO  IIO

                  TSS EFFLUENT  CONCENTRATION (mg/l)
                                                                 -r*-
                                         I2O  ISO ITO
       	: SOLID LINE  REPRESENTS TBS LIMIT OP 0.02i kfl/kkg(IM/tOOO lb«)
       NOTE:  PLANTS ABOVE THE SOLID LINE DO NOT MEET TBS LIMITATIONS.
              HOWEVER, THEY COULD ATTAIN THE APPROPRIATE LOAD BY EITHER
              REDUCING THEIR PLOW Oft EFFLUENT CONCENTRATION AS SHOWN
              BY THE DASHED ARROWS OR ANT COMBINATION OF THE TWO.
                                233

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                               GENERAL

                              SECTION IX

                 AFFLUENT QUALITY ATTAINABLE THROUGH
           THE APPLICATION OF THE BEST AVAILABLE TECHNOLOGY
                       ECONOMICALLY ACHIEVABLE
Introduction

The effluent limitations which must be achieved by July 1, 1984 are to
specify the  degree  of  effluent  reduction  attainable  through  the
application  of the best available technology economically achievable.
Best available technology is not based upon an "average of  the  best"
performance  within  an  industrial  category,  but  is  determined by
identifying the best  control  and  treatment  technology  used  by  a
specific  point source within the industrial subcategory.  Also, where
a technology is readily transferable from  one  industry  to  another,
such technology may be identified as BAT technology.

Consideration was also given to:

1.   The size and age of equipment and facilities involved.

2.   The processes employed.

3.   Non-water  quality   environmental   impact   (including   energy
     requirements).

4.   The engineering aspects of the application of  various  types  of
     control techniques.

5.   Process changes.

6.   The cost of  achieving  the  effluent  reduction  resulting  from
     application of BAT technology.

Best  available  technology  may  be  the  highest  degree  of control
technology that has been achieved  or  has  been  demonstrated  to  be
capable  of  being  designed  for  plant  scale  operation  up  to and
including "no discharge" of pollutants.  Although economic factors are
considered in the development, the level of control is intended to  be
the top-of-the-line current technology, subject to limitations imposed
by  economic  and engineering feasibility.  However, this level may be
characterized by some technical risk with respect to  performance  and
with respect to certainty of costs.
                                 235
Preceding page blank

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Development of. BAT Effluent Limitations                                    j

Model Treatment Systems

The  Agency  considered  from  two  to  five BAT alternative treatment
systems for each of the twelve steel  industry  subcategories.   These     j
alternatives  are  designed  to  oe  compatible  with  the  BPT  model     j
treatment  systems  in  each  subcategory  from  the   standpoint   of     j
retrofitting  the  necessary  water pollution control facilities.  For     \
those  operations  where  BAT  limitations  more  stringent  than  the     i
respective  BPT  limitations have been promulgated, the required water     f
pollution control facilities  can  be  installed / without  significant
retrofit   costs.   For  most  subcategories  (Sintering,  Ironmaking,
Steelmaking,  Vacuum  Degassing,  and   Continuous   Casting),   flows
amounting to only a few percent of the model BPT treatment system flow
rates  require  treatment  in  the  BAT  model treatment systems.  For
cokemaking operations, additional biological treatment compatible with
the BPT model biological treatment system is the model BAT technology.
The BAT alternative treatment systems are reviewed in  detail  in  the
respective subcategory reports of the development documents.

Model Treatment System Flow Rates

The  Agency's  selection of model BAT flow rates is highly subcategory
specific.  In every case the Agency sought to determine the best  flow
rate  that  could  be  achieved  on a subcategory wide basis.  In some
cases, the model BAT flow rates for the alternative treatment  systems
are  significantly more restrictive than the respective model BPT flow
rates.  However, for most forming and finishing operations, where more
stringent BAT limitations were not promulgated,  the  model  BAT  flow
rates are the same as the model BPT flow rates.  The Agency considered
zero discharge alternatives based upon evaporative technologies in all
subcategories.  These technologies were rejected because of energy and
cost considerations.

A  summary  of  the  model  BPT  and BAT effluent flow rates for those
operations where more stringent BAT limitations  were  promulgated  is
presented below:

                            Model BPT       Model BAT
  Subcateqory               Flow Rate       Flow Rate

A.  Cokemaking
     Iron and Steel         225 gal/ton      153 gal/ton
     Merchant               240              170

b.  Sintering               120              120                           j

C.  Ironmaking              125               70

D.  Steelmaking
     BOF, semi-wet            0                0
     EOF, wet-supp. comb.    50               50
                                236

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     BOF, wet-open comb.    110              110
     Open Hearth, wet       110              110
     EAF, semi-wet            0                0
     EAF, wet               110              110

E.   Vacuum Degassing        25               25

F.   Continuous Casting     125               25

L.   Hot Coating
   .  Fume Scrubbers         100 gpm           15gpm

The  lower  BAT  model  flow rates for cokemaking operations are based
upon recycle of barometric condenser cooling water, or replacement  of
the barometric condenser with a surface condensor.  The ironmaking BAT
model  flow  was set at 70 gal/ton based upon demonstrated performance
at plants in this subcategory.  The BAT model flow rate for continuous
casting operations  was  set  at  25  gal/ton  based  upon  widespread
demonstration  of  flows  of  25 gal/ton and less in that subcategory.
Finally, the hot coating fume scrubber BAT model flow  of  15  gpm  is
based  upon recycle of fume scrubber wastewaters, a common practice in
the industry.  The Agency did not set more restrictive BAT model  flow
rates  for  the other operations listed above because it does not have
sufficient information and data at this time to demonstrate that  more
restrictive  flow  rates  are  achievable on a subcategory-wide basis.
Reference is made to the respective subcategory reports for additional
information on the selection of the BAT model  treatment  system  flow
rates.

Model Treatment System Effluent Quality

The  performance  standards  for  the model BAT treatment systems were
determined in the same .fashion as described in Section  VIII  for  the
BPT   limitations.    Where   more   stringent  BAT  limitations  were
promulgated, the Agency based the limitations upon the best performing
representative plant or plants in the subcategory;  upon  pilot  scale
demonstration  studies at plants within the subcategory; or upon pilot
scale demonstration  studies  at  plants  with  similar,  more  highly
contaminated  wastewaters.  In all cases, however, the BAT limitations
are achieved on a full scale basis in the industry.

Summary of_ Changes From Proposed Regulation

Based upon comments  on  the  proposed  regulation,  the  Agency  made
several changes in promulgating the final BAT effluent limitations.

For  the  most  part, BAT effluent limitations more stringent than the
BPT limitations were promulgated for the basic steelmaking  operations
and  BAT  limitations  no more stringent than the BPT limittaions were
promulgated for the forming and finishing operations.   These  changes
are summarized below:
                               237

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Subcateqory

A.   Cokemaking
B.   Sintering
C.   Ironmaking
D.   Steelmaking
E.   Vacuum Degassing
F.   Continuous Casting
G.   Hot Forming
H.   Salt Bath Descaling
Changes from Proposed to Promulgated Regulation

     While the model BAT treatment systems have
     not changed substantially, slightly less
     stringent limitations for all pollutants
     were promulgated based upon analysis
     of additional data received for the best
     treatment facilities.

     The selected model technology was changed
     from alkaline chlorination to filtration.
     Limitations for ammonia-N, total
     cyanide, and phenols (4AAP) were provided
     for sintering operations with wastewaters
     that ate co-treated with ironmaking
     wastewaters.

     Less stringent ammonia-N limitations
     were promulgated on the basis of comments
     and data received on the proposed limit-
     ations.

     The selected mode' technology was changed
     to delete post filtration of the lime
     precipitation effluent.  Slightly less
     stringent limitations for lead and zinc
     were promulgated and the limitations
     for chromium were deleted.

     The model treatment technology was
     changed to lime precipitation and
     sedimentation from filtration.
     Less stringent limitations for
     lead and zinc were promulgated
     and the limitation for chromium was
     deleted.  The limitations for these
     operations are now consistent with
     those for Steelmaking operations.

     High rate recycle of hot forming
     wastewaters was not selected as the
     model BAT treatment technology.
     Thus, BAT limitations for hot
     forming operations were not
     promulgated.

     Filtration of the BPT model
     treatment system effluent was
     not selected as the model BAT
     treatment system.  Thus, BAT
     limitations no more stringent
     than the BPT limitations were
     promulgated.
                                23G

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I.   Acid Pickling
J.   Cold Forming
K.   Alkaline Cleaning
L.   Hot Coating
                              Cascade rinsing of acid pickling
                              rinsewaters was not selected as
                              the BAT model treatment system.  Thus,
                              BAT limitations no more stringent than
                              the BPT limitations were promulgated.

                              BAT limitations no more stringent than
                              the BPT limitations were promulgated.

                              BAT limitations wete not proposed
                              and not promulgated.

                              Cascade rinsing of hot coating
                              rinsewaters was not selected as the
                              model BAT treatment technology.
                              BAT limitations no more stringent
                              than the BPT limitations were
                              promulgated for those hot coating
                              operations without fume scrubbers.
                              More stringent BAT limitations were
                              promulgated for those hot coating
                              operations with fume scrubbers.

Best Available Technology Effluent Limitations and Associated Costs
..*
Based  upon  the  information contained in Sections II through VI11 of
this report and upon data  presented  in  the  respective  subcategory
reports,  various  treatment systems were considered for the BAT level
of treatment.  A short description of the model BAT treatment  systems
is  presented  in  Table  1-15.   The  BAT  effluent  limitations  are
summarized in Table 1-4.  The costs  associated  with  the  model  BAT
systems are summarized in Table IX-14 by subcategory.  As with the BPT
effluent  limitations,  the  Agency  has  concluded  that the effluent
reduction  benefits  associated  with  the  selected  BAT  limitations
justify   the  costs  and  non-water  quality  environmental  impacts,
including energy consumption, water consumption,  air  pollution,  and
solid waste generation.

Co-Treatment with Non-Steel Industry Finishing frastewaters
The  steel
coated with
This  regulation  contains
hot coating processes (i.e.
baths of zinc,  terne metal,
does  not  include specific
            industry  produces  a number of finished products that are
            various metals  for  protective  or  decorative  purposes.
                            effluent limitations and standards for the
                           ,  coating of steel by immersion  in  molten
                            or other metals).  However, the regulation
                            limitations for cadmium, copper, chromium,
nickel, tin, and zinc electroplating operations found  at  many  steel
plants.  It is common practice in the industry to co-treat wastewaters
from  these  operations  with  wastewaters  from  acid  pickling, cold
rolling,  alkaline  cleaning,  and  hot  coating  operations.   Often,
pretreatment  of  wastestreams  with  high  levels  of  cyanide  or  a
particular metal  is  practiced  prior  to  final  neutralization  and
settling   (i.e.,   reduction   of   hexavalent   chromium;   separate

-------
neutralization  and  settling  for  zinc).    The  model  BPT  and  BAT
treatment   systems   for  steel  industry  finishing  operations  are
installed at many co-treatment plants and,  effluent data from some  of
the co-treatment systems were considered in developing the limitations
and standards in this regulation.

     Application  of  the  limitations and standards contained in this
regulation  to  plants  with  electroplating  operations  without  any
allowance  for  those operations will present problems, both to permit
writers and to the industry.  The following guidance  is  provided  to
permit  writers  to develop plant specific NPDES permit conditions for
these facilities:

     a.   Treatment Plants with BPT/BAT Treatment Facilities In-Place
          1)   Determine   the   plant   specific   BPT/BAT   effluent
               limitations   for   those   steel   industry  finishing
               operations included in this  regulation.   Compare  the
               mass  loadings  to current performance of the treatment
               facility in question for  periods  of  relatively  high
               production.
          2)   If the applicable effluent limitations  fcr  the  steel
               operations  included  in this regulation are determined
               not to be achievable considering appropriate historical
               performance data, alternate BAT limitations  should  be
               developed for those plants with well operated treatment
               facilities.   These treatment facilities should include
               all of the BPT/BAT treatment components and not include
               a substantial amount of cooling waters, surface runoff,
               or process wastewaters from hot forming or any  of  the
               basic  steelmaking  operations.   These  alternate mass
               effluent limitations should be based upon  the  current
               performance  of  the  treatment  facility  on a concen-
               tration basis,  and treatment system  flow  rates  which
               take  into  account those finishing operations included
               in this regulation and flows  from  the  electroplating
               operations.   In  some cases, in-process flow reduction
               including  recycle  of  fume  scrubbers,  reduction  in
               rinsewater  flows,   etc.,   may  ce  required to further
               reduce the discharge from current levels.  In  general,
               the  concentrations  determined from actual performance
               data  should  be  in  the  immediate  range  of   those
               concentrations  presented  in  the Development Document
               used to develop the BPT and BAT effluent limitations.

     b.   Treatment Plants Without BPT/BAT  Treatment  Facilities  In-
          Place
          1)   Determine   the   plant   specific   BPT/BAT   effluent
               limitations   for   those   steel   industry  finishing
               operations included in this  regulation.
          2)   Determine   an   allowance   for   the   electroplating
               operations based upon the process flow rates from those
               operations  (after   appropriate flow minimization steps
               are implemented i.e.,  fume scrubber recycle),   and  the
                                240
' W
  e>.
 m
 '&
 •&
 I

-------
•                    performance  data presented in the Development Document
;                    for similar co-treatment systems.
i
i     Technical assistance for permit  writers  may  be  obtained  from  the
i     Effluent  Guidelines Division for developing limitations for treatment
|     systems  that  treat  wastewaters  from  operations  covered  by  this        J
     regulation and wastewaters from other operations.                             '•

}                                                             •                      i-
                                                                                   I »
                                                                                   ii
                                    241

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                               TABLE  IX-1
                             BAT  COST SUMMARY
                         IRON AND STEEL INDUSTRY
Capital
Subcategory/Subdi vision
A. Cokeauking
1. US - Biological
2. US - Physical-Chemical
3. Merchant - Biological
4. Merchant - Physical-Chemical
•Cokemaking Total
B. Sintering
C* Ironmaking
D. SCeelmaking
1. BOF: Semi-Wet
2. BOF.' Wet-SC
3. BOF: Wet-OC
4. Open Hearth
S. EAF: Semi-Wet
6. EAF: Wet
*Steelm*king Total
E. Vacuum Degassing
F. Continuous Casting
L. Bot Coating
1. Galv. SS wo/s
2. Galv. SS w/s
3. Galv. Wire wo/s
4. Galv. Wire w/s
5. Terne wo/s
6. Terne w/s
7. Other SS wo/s
8. Other SS w/s
9. Other Wire wo/s
10. Other Wire w/s
*Hot Coating Total
Total
Confidential Plants
Industry Total
In- pi ace

4.83
3.74
0.39
2.16
11.12
0.51
7.63

-
1.20
0.56
0.33
-
0.46
2.55
0.20
0.82

-
0.31
-
0.04
-
0.00
-
-
-
0.10
0.45
23.28
0.80
24.08
Required

28.62
0.00
4.33
0.00
32.95
5.51
23.20

-
0.34
5.32
1.44
-
1.09
8.19
2.82
2.23

-
0.32
-
0.03
-
0.16
-
-
-
0.00
0.51
75.41
1.94
77.35
Annual
la-Place

0.92
1.62
0.07
0.98
3.59
0.05
2.27

-
0.16
0.08
0.05
-
0.06
0.35
0.03
0.11

~
0.04
-
0.01
-
0.00
-
-
_
0.00
0.05
6.45
0.18
6.63
Required

6.96
0.00
0.94
0.00
7.90
0.74
6.77

-
0.06
0.78
0.23
-
0.17
1.24
0.39
0.31

-
0.04
-
0.00
-
0.02
-
-
_
0.00
0.06
17.41
0.43
17.84
NOTES: Costs are in Billions of 7/1/78 dollars.
Basis: Facilities in-place as of 7/1/81.
:   BAT limitations  equal  to  BPT are being promulgated in the
   other subcalegories/aubdivisions.  There is no additional
   costs in these subcategories/subdivisions.
                             242

-------
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                                           243

-------
                               VOLUME I

                              SECTION X

            BEST CONVENTIONAL POLLUTANT CONTROL TECHNOLOGY
Introduction

The   1977   Amendments   added   Section  301(b)(2)(E)  to  the  Act,
establishing "best conventional pollutant  control  technology"  (BCT)
for  discharges  of  conventional  pollutants from existing industrial
point sources.  Conventional pollutants are those defined  in  Section
304(a)(4)  [biochemical  oxygen  demanding  pollutants  (BOB$),  total
suspended solids (TSS), fecal coliform, and pH],  and  any  additional
pollutants  defined  by  the  Administrator as "conventional" (oil and
grease, 44 FR 44501, July 30, 1979).

BCT is not an additional limitation but replaces BAT for  the  control
of conventional pollutants.  In addition to other factors specified in
Section  304{b)(4)(B),  the  Act  requires  that  BCT  limitations  be
assessed in light of a two part "cost-reasonableness" test.   American
Paper Institute v. EPA, 660 F. 2d 954 (4th Cir. 1981).  The first test
compares  the  cost  for  private  industry to reduce its conventional
pollutants with the  costs  at  publicly  owned  treatment  works  for
similar  levels  of  reduction in their discharge of these pollutants.
The  second  test  examines  the  cost-effectiveness   of   additional
industrial  treatment  beyond BPT.  EPA must find that limitations are
"reasonable" under both tests before establisning them as BCT.  In  no
case may BAT be less stringent than BPT.

Because of the remand in American Paper Institute v. EPA (No. 79-115),
the  regulation  does  not  contain  BCT  limitations except for those
operations for which the BAT limitations are not more  stringent  than
the respective BPT limitations.
                                245
                                                        Preceding page blank

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                               VOLUME I

                              SECTION XI

               EFFLUENT QUALITY ATTAINABLE THROUGH THE
           APPLICATION OF NEW SOURCE PERFORMANCE STANDARDS
Introduction

NSPS  are  to  specify  the  degree  of  effluent reduction achievable
through the application of the  best  available  demonstrated  control
technology,  processes,  operating  methods,  or  other  alternatives,
including, where applicable, a  standard  requiring  no  discharge  of
pollutants.

For new source plants, a zero discharge of pollutants limit was sought
for   each   subcategory.    There  are  several  facilities  in  some
subcategories that demonstrate zero discharge.   However,  the  Agency
determined  that for most of these subcategories zero discharge is not
attainable for all new sources without the use of  costly  evaporative
technologies.   For  these wastewater operations, treatment systems at
lowest achievable flow rates have been considered.

Because new  plants  can  be  designed  with  water  conservation  and
innovative  technology in mind, costs can be minimized by treating the
lowest possible wastewater flows.  No considerations had to  be  given
to  the  "add-on"  approach that was characteristic of the BPT and BAT
systems  and  therefore  the  NSPS  Alternatives  consider  the   most
efficient   treatment   components  and  systems.   NSPS  systems  are
generally the same as the BAT systems; however, in some subcategories,
alternate treatment components are included.

Identification of NSPS

The alternative treatment systems considered for NSPS are the same  as
the  alternatives  considered for BAT with minor exceptions.  However,
as noted above,  in  many  subcategories  lower  discharge  flows  are
considered  for NSPS.  Since the criteria for NSPS is to consider only
the very best systems, the lowest demonstrated flow could be  used  to
develop  NSPS  standards.  Table XI-I lists the treatment systems used
as models for NSPS.  The standards  associated  with  the  model  NSPS
systems  are  summarized  in  Table  1-15.   Additional details on the
development  of  NSPS  are  provided  in  the  individual  subcategory
reports.  All of the NSPS are demonstrated in the steel industry.

NSPS Costs

The  Agency  did  not  estimate  the number of new source plants to be
built.  However,  the  Agency  did  consider  the  potential  economic
impacts  of  NSPS  in  Economic  Analysis  of  Effluent  Guidelines  -
                                247
Preceding page blank

-------
Integrated Iron and Steel Industry.  Model costs for the NSPS  systems
are detailed in the individual subcategory reports.
                                24C

-------
                               VOLUME I

                             SECTION XII

            PRETREATMENT STANDARDS FOR PLANTS DISCHARGING
                  TO PUBLICLY OWNED TREATMENT WORKS
Introduction

The  industry discharges untreated or partially treated wastewaters to
publicly owned treatment works (POTWs) from operations in nearly every
subcategory.  Table XII-1 lists all plants which  reported  discharges
to  POTWs.   In  the  individual  subcategory  reports, two classes of
discharges to POTWs were addressed:  existing sources and new sources.       jj
Also, the  national  pretreatment  standards  developed  for  indirect       j
discharges  fall  into  two  separate  groups:  prohibited discharges,       )
covering  all  POTW  users,  and  categorical  standards  applying  to       j
specific industrial subcategories.

As  was  done  for  BAT,  BCT  and NSPS, various alternative treatment
systems  were  considered  for  pretreatment  standards.   Up  to  six       j
alternatives were considered for each subcategory.                           f

National Pretreatment Standards                                              I

The  Agency  has  developed  national standards that apply to all POTW       j
discharges.  For detailed information  on  the  Agency's  approach  to
Pretreatment   Standards   refer  to  46  FR  9404  et  seq,  "General
Pretreatment Regulations for Existing and New  Sources  of  Pollution,
(January 28,  1981).   See  also  47  FR  4518 (February 1, 1982).  In
particular, Part  403,  Section  403.5  et.  seq.  describes  national
standards,  prohibited  discharges  and  categorical  standards,  POTW
pretreatment programs, and a national pretreatment strategy.                 j
                                                                             1
Categorical Pretreatment Standards

The Agency based the categorical pretreatment standards for the  steel
industry  on  the  minimization of pass through of toxic pollutants at
POTWs.   For each subcategory, the Agency compared  the  removal  rates
for  each  toxic pollutant limited by the PSES to the removal rate for
that pollutant at well operated POTWs.  The POTW  removal  rates  were
determined  through an extensive study conducted by the Agency at over
forty POTWs.  The POTW removal rates are presented below:

               Toxic Pollutant   POTW Removal Rate

                 Cadmium                    38%
                 Chromium                   65%
                 Copper                     58%
                 Lead                 '      48%
                 Nickel                     19%
                               249
I
a

-------
                 Silver                     66%
                 Zinc                       65%
                 Cyanide                    52%

As shown in  the  respective  subcategory  reports,  the  pretreatment
alternatives   selected  by  the  Agency  in  all  cases  provide  for
significantly more removal of toxic pollutants  than  would  occur  if
steel  industry wastewaters were discharged to POTWs untreated.  Thus,
the pass through of these  pollutants  at  POTWs  will  be  minimized.
Except  for  the  Cokemaking  subcategory,   all selected PSES and PSNS
alternatives are the same as the respective BAT and NSPS alternatives.
For cokemaking operations, the Agency's selected PSES  alternative  is
based  upon  the  same  physical/chemical  pretreatment  the  industry
provides for its on-site coke plant biological treatment systems.

The PSES and PSNS are set out in Tables  1-8  and  1-6,  respectively.
The associated industry-wide PSES costs are presented in Table XI1-14.
PSNS  model  treatment  system  costs  are presented in the respective
subcategory reports.
                              250

-------
                                TABLE  Xll-l
       LIST OF  PLANTS WITH  INDIRECT  DISCHARGES TO POTW SYSTEMS
PLANT
 00208
 0020C
 0024A
 0048D
 0048F
 0060
 00606
 0060H
 00601
 0060L
 0060M
 0060R
 OQ60S
 0068
 0088
 00886
 OII2F
 01 120
 01121
 01368
 OI36C
 OI76C
 OI76D
 0180
 0212
 0248A
 O256A
 0256K
 0256N
 OZ64
 O264A
 0264 C
 0264D
 0280B
 0320
 0380
 0384A
 0396A
 0396C
 0396D
 0432B
 0432E
 0432 J
 0432L
                                   251


-------
TABLE  Xll-l
LIST OF POTW (XSCHAR6ER8
PAGE  2
0440A
0444
0448A
0460A
O4608
0460C
0460F
04600
O460H
O464B
0464C
0526
O548B
0580
05808
0560C
0580 E
0580F
05800
05848
0636
064OA
06408
0648
06 56 A
06728
0684 H
0684 K
0684 Z
0696A
0740A
0760
0776C
07T60
0776J
0792A
0792C
0810
0856F
0860H
0884E
0936
0946A
0948B
0948C
TOTAL
(90 SUM)









X
X








X




X

X










X




X

X
18













































1


























X


















2


























X












X





2













































0







































X





1













































0

X

X

























X
K








X





7

























X
X












X





6
X

*

X.
















X




X












X


X


9


X




































X





3


























X


















1
X










X

































2













































1





X
X
X
X



X
X

X




X






X



X

X


X

X




X

29


X










X
X
X
X
X



























9
X











X
X




X

X

X
X



X




x;

X
X




X




18























X





















3








































X




3


X





X


X
X
X
X

X

X

X










X
X
X











16


X


X
X
X
X









X



X
X




X.






X





X



20




























































































                                        252

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                                     TABLE XII-2
                              PJtETREATWKT COST SUMMARY
                               IRON AND STEEL INDUSTRY
Subcategory/Subdivision

A. Cok«tMking
   1. US - Planes
   2. Merchant - Plants

*Coke*aking Total

B. Sintering

C. Ironauking

D. SteelBaking
   1. BOF: Seat-Wet
   2. BOPi Wet-SC
   3. BOF: Wet-OC
   4. Open Hearth
   5. EAT: Srai-Wet
   6. EAT: Wet

*Steelauking Total

E. Vacuum1 Degassing

F. Continuous Canting

C. Hot Forning
   1. Primary C w/s
   2. Primary C wo/s
   3. Primary S «/s
   4. Primary S wo/s
   5. Section Carbon
   6. Section Spec
   7. Plat C HS&S
   8. Plat S HS&S
   9. Flat C Plate
  10. Flat S Plate
  11. Pipe & Tube*Carbon
  li. Pipe & Tube-Spec

•Hot Forming Total
Capital

In-placc Required
28.21
2.66
30.87
3.23
13.21
3.06
5.73
2.90
11.69
9.01
3.93
5.6*
0.67
11.47
0.05
3.39
2.81
1.16
7.52
7.41
14.93
0.36
0.65
0.00
0.00
0.00
0.00
0.34
0.43
0.00
0.30
2.66
0.00
0.00
0.00
0.00

In-Place
7.04
0.?6
7.60
0.78
2.26
0.82
1.30
0.55
2.67
1.34
-1.08
-0.29
-0.08
0.00
-0.01
-0.33
0.07
0.14
Annual
Required
1.12
1.45
2.57
0,05
0.18
0.00
0.00
0.00
0.00
0.05
0.05
0.00
0.04
0.18
0.00
0.00
0.00
0.00
29.12
               3.39
                           -1.58
                                                                               0.27
                                        253
                                    I  /

-------
TABU XI1-2
PRmtZATKEKT COST SUMMARY
IROM AXO STEEL IKDUSTRY
PACE 2	
SubcattKorT/Subdivision.

H. Salt Bath Descaling
   1. Oxidizing - B S/P
   2. Oxidizing - B R/W/B
   3. Oxidizing - B P/T
   4. Oxidizing - Cont
   5. Reducing - Batch
   6. Reducing - Cont

*S«H Bath Descaling Total

I. Acid Pickling
   1. Sulfuric-R/U/C-Heut
   2. Sulfuric-S/S/P-Neut
   3. Sulfuric-B/B/6-Neut
   4. Sulfuric-P/T/0-Neut
   5. Sulfuric-S/S/P Au
   6. Sulfuric-R/W/C Au
   7. SuHuric-8/B/B Au
   8. Sulfuric-P/T Au
   9. Hydrochlorir-R/W/C
  10. Hydrochloric-S/S/P
  11. Hydrochloric-P/T
  12. Hydrochloric-S/S/P Ar
  13. Co»bination-R/W/C
  14. Coebination-B S/S/P
  IS. Covbination-C S/S/tf
  16. Coobination-B/B/B
  17. Cocbination-P/T

•Acid Pickling Total

J. Cold Foraing
   1. CR-Rftcirc Single
   2. CR-Recirc Hulti
   J. Cft-Co«biuation
   4. CR-DA  Single
   5. CR-DA  Multi
   6. CW Pipe&Tube Water
   7. CW PipeiTubc Oil

•Cold Forming Total
                                            Capital
In-place
  0.0?

  0.09
  0.04
  0.20
  3.05
  1.11
  0.53
  1.42
  1.18
  1.74
  0.01

  1.28
 11.03
  0.00
  0.00
  0.09
  0.09
0.20

0.72
0.08
 1.00
 3.82
 1.44
 1.18
 0.64
 3.52 .
 0.02
 0.02

 1.93

 0.33
 0.11
 0.85

13.86
 0.03
 0.03
                                                                       Annual
                                                               In-Place
0.01

0.01
0.01
                             0.03
1.05
0.80
0.23
0.41
0.40
1.59
0.00

0.39

0.00
0.15
0.07

5.09
0.00
0.00
                                         Required
0.03

0.11
0.01
                            0.15
1.16
0.79
0.42
0.20
0.75
0.01
0.00

0.48

0.12
0.03
0.21

4.17
0.00
0.00
                                             254

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TABLE XI1-2
PUTREAiHEirr COST SOTtoARY
IKON AND STEEL 1NDUSTIY
PACE 3

Subcatetory/Subdiviaion

K. Alkaline Cleaning
   1. Batch
   2. Continuous

*AHc«Hn« Cleaning Total

L. Mot Coating
   1. Calv. SS wo/e
   2. Calv. SS »/e
   3. Calv. Wir« wo/»
   4. Calv. Wire «/a
   5. Ttrn« wo/a
   6. Tern* «/•
   7. Other SS wo/a
   8. Other SS w/e
   9. Other Wire vo/a
  10. Other Wire w/a

•Hot Coating Total

Total

Confidential Planta

Coata for Coaponente tnatalled
  Beyond PSES

Induatry Total
                                            Capital
                                   Annual
In-place
  0.00
  0.47

  0.47
  0.27
  0.14
  0.92
  1.24
  0.01
  0.07
NOTES:  Coata in aillions of 7/1/76 dollars.
Basin  Facilitiea ir.-place aa of 7/1/81.
                                      255
                0.00
0.75
0.00
0.37
0.70
0.0)
0.43
                           In-Plaee
             0.00
             0.06

             0.06
0.04
0.02
0.13
0.18
0.00
0.01
              0.00
              0.00

              0.00
0.10
0.00
0.0}
0.11
0.01
0.06
2.6S
111.57
2.14
18. 27
131.98
2.30
36.89
4.02
_ 0.00
40.91
0.38
18.64
0.70
2.75
22.09
0.33
7.77
0.85
0.00
8.62

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                               VOLUME  I

                             SECTION XIII

                           ACKNOWLEDGEMENTS
The field sampling and analysis  for  this  project  and  the   initial
drafts of this report were prepared under Contracts No. 68-01-4730 and
68-01-5827  by  the  Cyrus  Wm. Rice Division of NUS Corporation.  Th*-
final report has been revised substantially by and at the direction of
EPA personnel

The preparation and writing of the initial drafts of this document was
accomplished through the efforts  of  Mr.  Thomas  J.  Centi,   Project
Manager,  Mr.  J. Steven Paquette, Deputy Project Manager, Mr.  Joseph
A. Boros  Mr. Patrick C. Falvey, Mr. Edward D.  Maruhnich,  Mr.  Wayne
M.  Neeley,  Mr.  William D. Wall, Mr. David E. Soltis, Mr. Michael C.
Runatz, Ms. Debra M. Wroblewski, Ms. Joan 0. Knapp, and Mr. Joseph  J.
Tarantino.

The Cyrus W. Rice Field and sampling programs were conducted under the
leadership of Mr. Richard C. Rice, Mr. Robert J. Ondof and Mr.  Matthew
J.  Walsh.  Laboratory and analytical servies were conducted under the
guidance of Miss C. Ellen Gonter, Mrs. Linda A. Deans and Mr.   Gary A.
Burns.  The drawings contained within and general engineering services
were  provided  by the RICE drafting room under the supervision of Mr.
Albert M. Finke.  Computer services and data analysis  were  conducted
under the supervision of Mr. Henry K. Hess.

The  project was conducted by the Environmental Protection Agency, Mr.
Ernst P. Hall, P.E. Chief, Metals  and  Machinery  Branch,  OWWH,  Mr.
Edward L. Dulaney, P.E., Senior Project Officer; Mr. Gary A. Amendoia,
P.E.,  Senior  Iron  and  Steel Specialist, Mr. Terry N. Oda, National
Steel Industry Expert, Messers. Sidney C.  Jackson,  Dwight  Hlustick,
Michael  Hart,  John  k'lliams, Dr. Robert W. Hardy, and Dennis Ruddy,
Assistant Project Officers, and Messers. J.  Daniel  Berry  and Barry
Malter,   Office   of  General  Counsel.   The  contributions   of
              Mr.
Walter J. Hunt, former Branch Chief, are also acknowledged.
The cooperation of the American Iron and  Steel  Institute,  and  more
specifically, the individual steel companies whose plants were sampled
and  who submitted detailed information in response to questionnaires,
is gratefully appreciated.  The operations and plants visited were the
property  of  the  following  companies:   Jones  &   Laughlin   Steel
Corporation,   Armco   Inc.,  Ford  Motor  Company,  Lone  Star  Steel
Corporation, Bethlehem Steel Corporation, Inland Steel Company, Donner
Hanna Coke Corporation, Interlake, Inc., Wisconsin Ste?l  Division  of
Envirodyne  Company, Jewell Smokeless Coal Corporation, National Steel
Corporation,   United   States   Steel   Corporation,   Kaiser   Steel
Corporation,  Shenango,  Inc.,  Koppers  Company, Eastmet Corporation,
Northwestern Steel and Wire Company, CF&I Steel Corporation, Allegheny
                               257
frececfing page Wank

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Ludlum  Steel  Corporation,  Wheeling-Pittsburgh  Steel   Corporation,
Republic  Steel  Corporation,  Lukens  Steel  Company,  Laclede  Steel
Company, Plymouth Tube Co., The  Stanley  Steel  Division,  Youngstown
Sheet & Tube Co., McLouth Steel Corp., Carpenter Technology, Universal
Cyclops,  Joslyn  Steel,  Crucible  Inc.,  Babcock  &  Wilcox Company,
Washington Steel, and Jessop Steel.

Acknowledgement and appreciation is  also  givenf to  the  secretarial
staff  of  the RICE Division, of NUS (Ms. Rane Wagner, Ms. Donna Guter
and Ms. Lee Lewis) and to the word processing staff  of  the  Effluent
Guidelines Division (Ms. Kaye Storey, Ms. Pearl Smith, Ms. Carol Swann
and  Ms.  Glenda  Clarke)  for  their efforts in the typing of drafts,
necessary revisions,  and  preparation  of  this  effluent  guidelines
document.
                               258

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                               VOLUME I

                             SECTION XIV

                              REFERENCES
1.   Adams, C.E., Jr., "Treatment of  a  High  Strength  Phenolic  and
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                                     B?Pi
                                            ^

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                                 260

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26.  "Clean System Quenches Coke", Iron Age. 211 (14), p.   25   (April
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27.  "Controlling Quenching Emissions", Iron and  Steel  Engineer,  53
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28.  Cook,  W.R.  and  Rankin,  L.V.,  "Polymers  Solve  Waste   Water
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29.  Cooper,  R.L.,  "Methods  of  Approach  to  Coke  Oven   Effluent
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30.  Cooper, R.L. and Catchpole, J.R., "The  Biological  Treatment  of
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31.  Cooper,  R.L.  and  Catchpole,  J.R.,  "Biological  Treatment  of
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32.  Cousins, W.G. and Mindler,   A.B.,  "Tertiary  Treatment  of  Weak
     Ammonia Liquor", JWPCF. 44, 4 607-618 (April, 1972).

33.  Cruver, J.E. and Nusbaum, I., "Application of Reverse Osmosis  to
     Wastewater  Treatment," Journal WPCF, Volume 45, No. 2, February,
     1974.

34.  Davis, R.F.,  Jr.  and  Cekela,  V.W.,  Jr.,  "Pipeline  Charging
     Preheated  Coal  to  Coke  Ovens",  Ironmaking  Proceedings,  The
     Metallurgical Socitry  of  A.I.M.E.,   Toronto,   34,  pp.  339-349
     (1975).

35.  Decaigny, Roger A., "Blast Furnace Gas Washer  Removes  Cyanides,
     Ammonia,  Iron,  and  Phenol", Proceedings, 25th Industrial Waste
     Conference, Purdue University, pp. 512-517 (1970).

35.  DeFalco, A.J., "Biological Treatment of Coke Plant  Waste",  Iron
     and Steel Engineer, pp. 39-41 (June,  1976).

37.  DeJohn, P.B., Adams, A.D.,  "Treatment of Oil Refinery Wastewaters
     with Granular and Powdered Activated Carbon",  Purdue  Industrial
     Waste Conference.

S8.  Directory of Iron and Steel Plants, Steel Publications, Inc..

39.  Directory of_ the  Iron  and  Steel  Works  of.  the  World,  Metal
     Bulletins Books, Ltd., London, 5th edition.

40.  Donovan, E.J.,  Jr.,  Treatment  of  Wastewater  for  Steel  Cold
     Finishing Mills, Water and Wastes Engineering,  November, 1970.
                                261

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41.  DuMond, T.C., "Mag-Coke Creates  Big  Stir  in  Desulfurization",
     Iron Age, 211 (24), pp. 75-77 (June 14, 1973).

42.  Dunlap, R.W. and McMichael, F.C., "Reducing Coke Plant Effluent",
     Environmental Science and Technology,  10 (7), pp.  654-657 (July,
     1976).

43.  Duvel, W.A. and Helfgott, T., "Removal of Wastewater Organics  by
     Reverse Osmosis," Journal WPCF, Volume 47, No.  1_, January, 1975.

44.  Edgar, W.D. and Muller, J.M., "The Status of Coke Oven  Pollution
     Control", AIME, Cleveland, Ohio  (April, 1973).

45.  Effect of Geographical Variation on Performance of  Recirculating
     Cooling Ponds, EPA-660/2-74-085.

46.  Eisenhauer, Hugh R.,  "The Ozonation of Phenolic Wastes",  Journal
     of  the  Water  Pollution  Control Federation, p. 1887 (November,
     1968).

47.  Elder, R.G., "Zinc Control in a  Blast  Furnace  Gas  Wash  Water
     Recircuiation  System",  Presented  at  the U.S. EPA Symposium on
     Iron and Steel Pollution Abatement Technology for  1981,  October
     1981 .

48.  Elliott, J.F., "Direct Reduction of Iron  Ores  -  Processes  and
     Products",  Ironmaking  Proceedings, The Metallurgical Society of
     A.I.M.E., Toronto, 34, pp. 216-227 (1975).

49.  Environmental Protection  Agency,  "Analytical  Methods  for  the
     Verification  Phase  of  the  BAT  Review",  Office  of_ Water, and
     Hazardous Materials (June, 1977).

50.  Environmental Protection Agency, "Biological  Removal  of  Carbon
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     Research and Monitoring, Washington, D.C. (April, 1973).

51.  Environmental Protection Agency, Draft Development  Document  for
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     Alloy  and Stainless Steel Industry, Datagraphics, _I_n.c_._ (January,
     1974).

52.  Environmental Protection Agency, "Industry Profile Study on Blast
     Furnace and Basic Steel  Products  ,"  C.W.  Rice  Division  -NUS
     Corporation for EPA,  Washington, D.C.  (December, 1971).

53.  Environmental Protection  Agency,  "Pollution  Control  of  Blast
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     and Monitoring, Washington, D.C. (Project No.  12010EDY).

54.  Environmental   Protection   Agency,   "Sampling   and   Analysis
     Procedures  for  Screening  of   Industrial Effluents for Priority
                                262

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     Pollutants", Environmental  Monitoring  and  Support  Laboratory,
     Cincinnati, Ohio (March, 1977 revised April, 1977).
                                                                             j
55.  Environmental Protection Agency, "Steel  Making  Segment  of  the       !
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     Water and Hazardous Materials, Washington, D.C.  (June, 1974).          j

56.  Environmental  Protection  Agency,   "Water   Pollution   Control       |
     Practices  in  the  Carbon  and  Alloy  Steel  Industries",  EPA,       j
     Washington, D.C.  (September 1, 1972).                                 ||
                                                                            i I
57.  Environmental  Protection  Agency,   "Water   Pollution   Control       ;
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     No. R800625).                                                           j

58.  Environmental Steel, The Council of_ Economic Priorities.                }

59.  Fair,  G.M.,  Geyer,  I.C.,  Okum,  D.P.,  Water  and  Wastewater       '
     Engineering, Volume J_, Water Spray and Wastewater Removal.              '•

60.  Flynn, B.P.,  "A  Model  for  the  Powdered  Activated  Carbon  -
     Activated   Sludge  Treatment  System;  Purdue  Industrial  Waste
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61.  Foltz, V.W., Thompson, R.J., "Armco Develops Cold Mill Waste  Oil
     Treatment Process", Water and Wastes Engineering, March 1970.

62.  Ford, D.L., "Putting Activated  Carbon  in  Perspective  in  1983
     Guidelines,"  National  Conference  on  Treatment and Disposal of
     Industrial Waste Waters and Residues, April 26-28, 1977.

63.  Ford, D.L., Elton,  Richard L., "Removal of Oil  and  Grease  From
     Industrial Wastewaters", Chemical Engineering, Oct.  17, 1977.

64.  Fraust, C.L., "Modifying A Conventional Chemical Waste  Treatment
     Plant to Handle Fluoride and Ammonia Wastes", Plating and Surface
     Finishing, p. 1048-1052 (November, 1975.)

65.  Gelb, B.A., "The Cost of Complying with Federal  Water  Pollution
     Law",  Industrial  Water Engineering, 12 (6), pp.  6-9 (December,
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66.  George, H.D. and Boardman,  E.B.,  "IMS  -  Grangcold  Pelletizing
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67.  Goldstein,  M.,   "2.  Economics  of  Treating  Cyanide   Wastes",
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86.  Gordon,  C.K.,   "Continuous  Coking  Process",  Iron  and   Steel
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                                263

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69.   Gordon,  C.K.  and Droughton,  T.A.,  "Continuous  Coking  Process",
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70.   Gould, J.P.  and  Weber,  W.J,,  Jr.,   "Oxidation  of  Phenols  by
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71.   Grieve,   C.G.,   Stenstron,   M.K.,   "Powdered   Carbon   Improves
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72.   Grosick, H.A.,  "Ammonia Disposal - Coke  Plants",  Blast  Furnace
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73.   Haqer, D.G.,  "Waste Treatment Advances:   Waste  Water  Treatment
     Via  Activated   Carbon,"  Chemical Engineering Progress, 72  (10),
     pp. 57-60 (October, 1976).

74.   Hall,  S.A.,  Brantner,  K.A.,   Kubarewicz,  J.W.,  Sullivan,  M.D.,
     "Pilot Evaluation of Alkaline Chlorination Alternatives for Blast
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     and Steel Pollution Abatement Technology for 1981, October 1981.

75.   Hall,  D.A. and   Nellis,  G.R.,  "Phenolic  Effluents  Treatment,"
     Chemical Trade  Journal  (Brit.), 156,  p. 786 (1965).

76.   Hansen,  L.G., Oleson,  K.A.,  "Comparison of Evaporative Losses  in
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77.   Harold,  D.S., "Development of a  Deduing  Process  for  Recycling
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78.   Hoffman,  D.C.,  "Oxidation  of  Cyanides  Adsorbed  on  Granular
     Activated Carbon", Plating,  60, pp. 157-161 (February, 1973).

75.   Hutton,   W.C.  and  LaRocca,  S.A.,  "Biological   Treatment   of
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80.   lammartino,  N.R., "Formed Coke:  A 1980's Boom  for  the  World's
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82.   Jola,  M., "Destruction  of  Cyanides  by  the  Cyan-Cat  Process,"
     Plating and Surface Finishing, pp. 42-44 (September, 1976).
                                26-1

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83.   Kemmetmueller, R., "Dry  Coke  Quenching  -  Proved,  Profitable,
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84.   Kiang, ¥., "Liquid Waste Disposal System",  Chemical  Engineering      j
     Progress, 72 (1), pp. 71-77 (January, 1976).                           |

85.   Kibbel, W.H., "Peroxide Treatment For Industrial Waste Problems",      [
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86.   Kolflat, T.D., Aschoff, A.F., Baschiere,  R.S.,  "Cooling  Towers
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87.   Kohlmann, H.J., Hot stein, H., "Minimizing Water Blow downs  from
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88.   Knopp, P.V., Gifchel, W.B., Zimpro, Inc.,  "Wastewater  Treatment
     with   Powdered   Activated   Carbon  Regenerated  with  Wet  Air
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89.   Kostenbader, Paul D.,  and  Flecksteinet,  John  W.,  "Biological
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90.   Kremen, S.S., "Reverse Osmosis Makes  High  Quality  Water  Now",
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91.   Kreye, W.C., King, P.H. and Randall, C.W., "Biological  Treatment
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92.   Kreye, W.C., King, P.H. and Randall,  C.W.,  "Kinetic  Parameters
     and  Operation  Problems  in  the  Biological  Oxidation  of High
     Thiosulfate Industrial  Wastewaters",  Proceedings  of  the  29th
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93.   Labine,  R.A.,  "Unusual  Refinery  Unit  Produces  Phenol-  Free
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94.   Lanouette, K. H., "Heavy Metals Removal,"  Chemical  Engineering,
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95.   Lanyon, R. Lue-Hing,  C.  "Reduction  of  Wastes  Discharged  from
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                                265

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96.   Lawson,  C.T.,  Hovious, J.C., "Realistic Performance Criteria  for
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97.   Laufhuette,  D., "Hydrogen Sulfide/Ammonia Removal From Coke  Oven
     Gas",   I^ronmaking  Proceedings,  The  Metallurgical  Society  of
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98.   Linsky,   B.,   Littlepage,  J.,  Johannes,  A.,  Nekooi,  R.   and
     Lincoln,  P.,   "Dry  Coke  Quenching, Air Pollution and Energy: a
     Status Report", Journal of the Air Pollution Control Association,
     25 (9),  pp.  918-924 (September, 1975TT

99.   Lisanti, A.F., "Ultrafiltration Oil  Reclamation  Process,"  Iron
     and Steel Engineer, (March, 1977).

100. Ludberg, James E., and Nicks, Donald G., "Phenols and Thiocyanate
     Removed from Coke Plant Effluents", Water and Sewage Worksf  116,
     pp. 10-13 (November, 1969).

101. Makridakas,   S.,  Wheelwright,  S.,   "Interactive   Forecasting,
     Holden-Day Inc., San Francisco, Cal., 1978.

102. Maloy, J., "Developments in  Cokemaking  Plant",  Proceedings  of_
     Coke  in Ironmaking Conference, Iron and Steel Institute, London,
     pp. 89-97 (December, 1969).

103. Marting, D.G.  and Balch, G.E., "Charging Preheated Coal  to  Coke
     Ovens",  Blast  Furnace and Steel Plant, p. 326 (May, 1970).

104. Maruyama, T.  et al., "Metal  Removed  by  Physical  and  Chemical
     Treatment Process," Journal WPCF,  Volume 47, No. 5, (May, 1975).

105. McBride,  T.J.  and  Taylor,  D.M.,  "Joint  Municipal-Industrial
     Wastewater  Treatment  Based on Pilot Plant Studies," Proceedings
     of the 28th  Industrial Waste Conference, Purdue  University,  pp.
     832-840 (1973T

106. McKee, J.E.  and Wolfe, H.W.,  "Water  Quality  Criteria",  Second
     Edition,  State   Water   Quality   Control  Board,  Sacramento,
     California,  Publication No. 3-A.

107. McManus, G.J., "Mini  Mill  Approaches  Continuous  Steelmaking",
     Iron Age, 211  (16), pp. 62-63 (April  19, 1973).

108. McManus, G.J., "One-Step Steelmaking Takes  Another  Step  Toward
     Reality", Iron Age, p. 41 (May 10, 1973).

109. McManus, G.J., "U.S. Examines Soviet Dry  Coke  Quenching",  Iron
     Age,  pp. 47-48 (May 31, 1973).
                                 26G

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110.  McMichael,  Francis C.,  Maruhnich,  Edward D.,  and Samples, William
     R.,  "Recycle Water Quality From a Blast Furnace", Journal of  the
     Water Pollution Control Federation, £3, pp.  595-603 (19?"lT7

111.  McMorris,  C.E., "Inland's Experience  in  Reducing  Cyanides  and
     Phenols  in  the  Plant  Water  Outfall", Blast Furnace and Steel
     Plant, pp.  43-47 (January, 1968).

112.  McMorris,  C.E., "Inland's Preheat - Pipeline  Charged  Coke  Oven
     Battery",   Ironmaking  Proceedings^  The Metallurgical Society of
     A.I.M.E..  Toronto, pp.  330-338 (1975).

113.  Medwith,   B.W.,  Lefei   Hoce,  J.F.,   "Single-stage   Biological
     Treatment   of  Coke  Plant  Wastewaters  with  a Hybrid Suspended
     Growth-fixed  firm  Reactor",  presented  at  the   36th   Purdue
     Industrial  Waste Conference,  May 1981.

114.  Minor,  P.S.,  "Organic   Chemical   Industry's   Waste   Waters"
     Environmental  Science   and Technology, § (7), pp. 620-625 (July,
     1974).

115.  "More Pollution Control", Iron Age, 217 (22),  p.   11  (May  31,
     1976).

116.  Muller, J.M. and Coventry, F.L.,  "Disposal of Coke Plant Waste in
     the Sanitary Water System," Blast Furnace and  Steel  Plant,  pp.
     400-406 (May, 1968).

117.  Nasco, A.C. and Schroeder, J.W.,  "A New Method of  Treating  Coke
     Plant  Waste  Waters",   Ironmaking Proceedings, The Metallurgical
     Society of  A.I.M.E., Atlantic City. 33, pp. 121-141 (1974).

118.  Nemec, F.A., "How Much  Environmental Protection -What  Should  Be
     The  Federal Role?", Iron and Steel Engineer, 53 (10), pp.  35-37
     (October,  1976).

119.  Negmeth,   R.L.,  Wxsniewski,   L.D.,  "Minimizing  Recycled  Water
     Slowdown  from  Blast Furnace Gas Cleaning Systems", presented at
     the U.S.  EPA Symposium  on  Iron  and  Steel  Pollution  Abatement
     Technology for 1981, October 1981.

120,  Nilles, P.E. and Dauby, P.H., "Control of the OBM/Q-BOP Process",
     Iron and Steel  Engineer,  pp.  42-47 (March, 1976).

121.  Osantowski, R., Geinpolos, A.,  Rollinger,  G.  "Physical/Chemical
     Treatment   of  Coke  Plant  Wastewater",  U.S.  EPA 600/S2-ED-107
     April  1981.

122.  Patterson,  J.W., et al,  "Heavy  Metal  Treatment  via  Carbonate
     Precipitation,"  30th  Ind.  Wastes  Conf., Purdue Univ., pg. 132
     (May, 1975).
                                 267

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Patton, R.S., "Hooded  Coke  Quenching  System  For  Air  Quality
Control",  Ironmakinq  Proceedings,  The Metallurgical Society of.
A.I.M.E. . Atlantic City, 33., pp. 209-219 (1974).

Pearce, A.S. and Punt,  S.E.,  "Biological  Treatment  of  Liquid
Toxic  Wastes-Part  1", Effluent and Water Treatment Journal. 15,
pp. 32-39 (January, 1975T

Pearce, A.S. and Punt,  S.E.,  "Biological  Treatment  of  Liquid
Toxic  Wastes-Conclusion,"  Effluent and Water Treatment Journal,
15, pp. 87-95 (February, 1975).

Pearce, J., "Q-BOP Facility Planning  and  Economics,"  Iron  and
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Pearce, J., "Q-BOP  Steelmaking  Developments,
Engineer, pp. 29-38 (February, 1975).
         Iron  and  Steel
Pengidore, D.A., "Application of Deep Bed Filtration  to  Improve
Slab  Caster  Recirculated Spray Water", Iron and Steel Engineer,
52. (7), pp. 42-45 (July, 1975).

Perry, J.H., Chemical Engineering Handbook, 4th edition.

"Pollution Control at Inland, A Long, Hard, and Costly Climb", 33_
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Potter, N.M. and Hunt, J.W., "The Biological  Treatment  of  Coke
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Industry, Special Report No^ 61, pp. 207-218 (1958).

Price, J.G., Berg, T.A. and  Stratman,  J.,  "Coke  Oven  Pushing
Emissions  Control and Continuous Wet Coke Quenching," Ironmaking
Proceedings, The  Metallurgical  Society  of  A.I.M.E.T  Atlantic
City. 33. pp. 220-232 (1974).
"Process  Design  Manual  for  Carbon
Technology Transfer, (October, 1973).
Adsorption,"   U.S.   EPA
Raef, S.F., Characklis, W.G., Kessick, M.A. ami Ward, O.H., "Fate
of Cyanide and Related Compounds in Industrial Waste  Treatment",
Proceedings  of  the  29th  Industrial  Waste  Conference, Purdue
University, pp. 832-840 (1974).

Research  on  Dry  Type  Cooling  Towers  for  Thermal   Electric
Generation   -   Part   I,   Environmental   Protection   Agency,
16130EE511/70.

Rexnord, Inc., Environmental Research Center", Treatment of Steel
Plant Wastewaters to BATEA levels using Mobile Treatment  Units",
prepared for U.S. EPA, Research Triangle Park, June 26,1979.
                                268

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136.


138.



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140.


141.



142.


143.
     Rizzo, J.L., "Granular Carbon for  Wastewater  Treatment,"  Water
     and Sewage Works, Volume 118, pp. 238-240, (April, 1971).

     Rosfjord, R.E., Trattner, R.E. and Cheremisinoff, P.N.,  "Phenols
     -  A  Water Pollution Control Assessment,"Water and Sewage Works,
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     Rouse, J.V., "Removal of Heavy Metals from Industrial Effluents,"
     Journal of the Environmental Engineering  Division..,  V  102,  No.
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     Savage, E.S., "Deep-Bed  Filtration  of  Steel  Mill
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     Sludge,"Industrial Wastes - Pgs. 34-39, (July- August, 1979).

     Skubak, J., NewfeJd,  R.D.,  "A Mass Balance Model  for  Rinsewater
     in  'a Continuous Strip Halogen Electrolytic Tinning Operation for
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     presented at  the U.S. EPA Symposium on Iron and  Steel  Pollution
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144.  Smith, John M.,  Masse, A.N.,   Feige,  W.A.   and  Kamphake,  L.J.,
     "Nitrogen   Removal   From  Municipal  Waste  Water  by  Columnar
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145.  "Coke in the  Iron and Steel Industry New Methods in  Conventional
     Processes" Steel Times,  193,  pp. 551-556 (October 21, 1966).

146.  Sugeno, T., Shimokawa, K.  and Tsuruoka, K., "Nuclear  Steelmaking
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     (November, 1976).

147;  Symons, C.R.,  "Treatment of Cold Mill  Wastewater  by  Ultra-High
     Rate   Filtration,"   ."ournal  of  the  Water  Pollution  Control
     Federation. (November, 1971).

148.  Technical and  Economic Evaluation  of  Cooling  Systems  Slowdown
     Control  Technologies, Environmental Protection Agency, Office of
     Research and  Development,  EPA-660/2-73-026.

149.  Terril, M.E.,  Neufeld, R.D.,  "Investigation  of  Reverse  Osmosis
     for  the  Treatment  of   Recycled  Blast-Furnace scrubber Water",
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     Abatement Technology  for 1981, October 1981.
                                                                              A
                                                                              1
                               269

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150.  Traubert,  P.M.,  "Weirton Steel Div. - Brown's Island Coke Plant",
     Iron and Steel  Engineer,  5_4 (1 ),  pp.  61-64 (January, 1977).

151.  U.S. Department of the  Interior,  "The  Cost  of  Clean  Water",
     Volume III - Industrial Wastes, Profile No.  K

152.  United States Steel,  The Making,  Shaping, and Treating of_  Steel,
     Harold  E.  McGannon  ed.,   Harlicek  and  Hill,  Pittsburgh, 9th
     Edition, (1971).
                                                 «
153.  Voelker, F.C.,  Jr.,   "A  Contemporary  Survey  of  Coke-Oven  Air
     Emissions   Abatement",   Iron  and  Steel  Engineer,  pp.  57-64
     (February, 1975).

154.  Voice, E.W.  and Ridigion, J.M., "Changes In Ironmaking Technology
     In Relation To the Availability of Coking Coals", Ironmaking  and
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155.  Wahl,  J.R.,  Hayes, T.C.,  et al, "Ultra:iltration For Today's Oily
     Wastewaters:  A  Survey  of  Current  Ultrafiltration   Systems."
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     (May,  1979).

156.  Wagener, D., "Characteristics  of  High  -  Capacity  Coke  Ovens",
     Iron and Steel  Engineer,  pp.  35-41 (October, 1974).

157.  Wallace, De Yarman,   "Blast  Furnace  Gas  Washer  Water  Recycle
     System," Iron and Steel Engineer  Yearbook, pp.  231-235 (1970).

158.  "Waste Water Treatment Facility at U.S. Steel's Fairfield Works",
     Iron and Steel  Engineer,  p. 65 (June, 1976).                              ,

159.  "Weirton Steel  Gets It All  Together at New Coke Plant on  Brown's         I
     Island," 33 Magazine,  11  (1),  pp. 27-30 (January, 1973).

160.  Wilson,  L.W., Bucchianeri,  B.A.,  Tracy, K.D.,  "Assessment of  the
     Biological  Treatment  of coke-Plant Wastewaters with addition of
     Powdered Activated Carbon  (PAC)",  presented  at  the  US.S  EPA
     Symposium  on  Iron  and Steel Pollution Abatement Technology for
     1/81,  October 1981.

161.  Woodson, R.D.,  "Cooling  Towers,"  Scientific  American.  224(5).
     70-78, (May, 1971).

162.  Woodson, R.D.,  "Cooling Alternatives  for  Power  Plants,"  paper
     presented  to  the  Minnesota  Pollution Control Agency, (November
     30,  1972).

163.  "World-Wide Oxygen Steelmaking Capacity - 1974", Iron  and  Steel
     Engineer,  p. 90 (April, 1975).

164.  "Worldwide Oxygen Steelmaking  Capacity - 1975",  Iroj-i  and  Steel
     Engineer,  p. 89 (April, 1976).
                               27 C.

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165.  "World Steel Statistics - 1975",
     57-58 (August, 1976).
Iron  and  Steel  Engineer  pp.
166.  Zabban, Walter and  Jewett,  H.W.,  "The  Treatment  of  Fluoride
     Wastes,"  Engineering  Bu1 letin of Purdue University, Proceedings
     of the 22nd Industrial Waste Conference, 196?, p.  706.

167.  Zahka, Pinto,  S.D., Abcor, Inc. Ultrafiltration of Cleaner  Baths
     Using Abcor Tuoular Membranes.
                                                                                "M
                                                                                V
                                                                                y^

                                                                                -'I

                                                                                ^3

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                               VOLUME I

                              APPENDIX A

              STATISTICAL METHODOLOGY AND DATA ANALYSIS
Introduction

Statistical Methodology

This  section1 provides an overview of the statistical methodology used
by the Agency to develop effluent limitations for the steel  industry.
The  methodology consists essentially of determining long term average
pollutant  discharges  expected  fro®  well  designed   and   operated
treatment  systems,  and  multiplying  these  long  term  averages  by
variability factors designed  to  allow  for  random  fluctuations  in
treatment  system  performance.   The  resulting  products yield daily
maximum and 30-day average concentrations  for  each  pollutant.   The
daily maximum and 30-day average concentrations were then multipled by
an  appropriate  conversion factor and the respective treatment system
model effluent flow rate to determine  mass  limitations.   A  general
description  of  the  methods  employed  to derive long term averages,
variability factors, and the resulting  concentrations  follows.   The
development  of the model treatment system flow rates are presented in
each subcategory report.

Determination of Long Term Average

For  each  wastewater  treatment  facility,   an   average   pollutant
concentration  was calculated from the daily observations.  The median
of the plant averages for a pollutant was then used as the  long  term
average  for  the  industry.  The long term average was determined for
each pollutant to be limited and  used  to  obtain  the  corresponding
limitations for that pollutant.

The  long  term  average  (LTA)  is  defined as the expected discharge
concentration  (in  mg/1)  of  a  pollutant  from  a  well   designed,
maintained,  and  operated treatment system.  The long-term average is
not a limitation, but rather a design value which the treatment system
should be designed to attain over the long term.

Determination of Variability Factors

Fluctuations in the pollutant concentrations discharged occur at  well
designed  and properly operated treatment systems.  These fluctuations
may reflect temporary imbalances in the  treatment  systes  caused  by
fluctuations  in  flow,   raw  waste  load  of  a particular pollutant,
chemical feed,  mixing flows  within  tanks,  or  a  variety  of  other
factors.
                               273
                                                         Preceding page blank

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Allowance  for  the  day-to-day  variability in the concentration of a
pollutant discharged from  a  well  designed  and  operated  treatment
system  is accounted for in the standards by the use of a "variability
factor." Under certain assumptions discussed below, application  of  a
variability  factor  allows  the calculation of an upper bound for the
concentration of a particular pollutant.  On the average  a  specified
percent  of  the randomly observed daily values from treatment systems
discharging this pollutant at a  known  mean  concentration  would  be
expected  to fall below this bound.  The 99th percentile for the daily
maximum value is a commonly used and accepted level in the  steel  and
other industrial categories.  Also, this percentile has been chosen to
provide  a  balance  between  appropriate considerations of day-to-day
variation in a properly operating plant and the  necessity  to  insure
that a plant is operating properly.

The  derivation of the variability factor for plants with more than 10
but less than 100 observations is based upon the assumption  that  the
daily  pollutant concentrations follow a lognormal distribution.  This
assumption  is  supported  by  plots  of  the  empirical  distribution
function  of  observed  concentrations for various pollutants (Figures
A-l to A-4).  The plots of these data on lognormal  probability  paper
approximated  straight  lines  as  would  be  expected of data that is
lognormally distributed.  It is also  assumed  that  monitoring  at  a
given plant was conducted responsibly and in such a way that resulting
measurements  can  be  considered independent and amenable to standard
statistical  procedures.   A  final  assumption  is   that   treatment
facilities   and  monitoring  techniques  had  remained  substantially
constant throughout the monitoring period.

The daily maximum variability factor  is  estimated  by  the  equation
(derived   in   Appendix   XII-A1  of  the  Development  Document  for
Electroplating  Pretreatment  Standards,  EPA  440/1-79/003,   August,
1979),

     In (VF) * Z(Sigma) - .5(Sigma)z        (1)

where

     VF is the variability factor

     Z  is  2.33, which is the 99th percentile for the standard normal
     distribution, and

     Sigma is the standard deviation of the natural logarithm  of  the
     concentrations.

For  plants  with  100 or more observations for a pollutant, there are
enough data to use nonparametric statistics  to  calculate  the  daily
maximum  variability  factor.  For these cases, the variability factor
was calculated by  dividing  the  empirical  99th  percentile  by  the
pollutant  average.  The empirical 99th percentile is that observation
whose percentile is nearest 0.99.
                               274

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The  estimated  single-day  variability  factor  for  each   pollutant
discharged  from  a well designed and operated plant was calculated in
the following manner:

1.   For each plant with 10 or more but less  than  TOO  observations,
     Sigma  was  calculated  according  to  the  standard  statistical
     formula14and was then substituted into Equation (1) to  find  the
     VF.

2.   For those plants with over 100 observations, the VF was estimated
     directly by dividing the 99th percentile of the  observed  sample
     values by their average.

3.   The medir.n of the plant variability factors was  then  calculated
     for each pollutant.

The  variability factor for the average of a random sample of 30 daily
observations about the mean value of a  pollutant  discharged  from  a
well designed and operated treatment system was obtained by use of the
Central  Limit  Theorem.   This  theorem  states that the average of a
sufficiently large sample of independent and  identically  distributed
observations  from  any  of  a large class of population distributions
will  be  approximately  normally  distributed.   This   approximation
improves  as  the  size  of the sample, n, increases.  It is generally
accepted that a sample size of 25 or 30 is sufficient for  the  normal
distribution  to adequately approximate the distribution of the sample
average.  For many populations, sample sizes as small as 10 to 15  are
sufficient.


The  30-day average variability factor, VF*, allows the calculation of
an upper bound for the concentration of a particular pollutant.  Under
the same assumptions stated  above,  it  would  be  expected  that  95
percent  of  the  randomly  observed  30-day  average  values  from  a
treatment  system  discharging  the  pollutant   at   a   known   mean
concentration will fall below this bound.  Thus, a well operated plant
would  be  expected,  on  the  average,  to  incur  approximately  one
violation of the 30-day average limitation during a 20  month  period.
The 95th percentile was chosen in a manner analogous to that explained
previously in the discussion of the daily variability factor.
»ME(xi - x)*/(n-l )]»'*

where

     x_i   is the In of observation i
     x    is the average of observations
     n    is the number of observations
                               275

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The  30-day  average variability factor was estimated by the following
equation  (based  on  the   Central   Limit   Theorem   and   previous
assumptions),

      (VF*> « 1.0 * 7. (S*/A)       (2)

where

     VF*  is the 30-day average variability factor;

     Z    is 1.64, which is the 95th percentile of the standard normal
          distribution;

     S*   is the estimated standard deviation of the 30-day  averages,
          obtained by dividing the estimated standard deviation of the
          daily  pollutant  concentrations  by  the square root of 30;
          and,

     A    is the average pollutant concentration.

In the case of biological treatment  of  cokemaking  wastewaters,  the
Agency   determined   that  , the  general  assumption  of  statistical
independence between successive observations, which is a basis "of  the
general  formula,  is not valid.  The other assumptions underlying the
application of the Central Limits Theorem valid.  An analysis  of  the
data for the biological treatment system at Plant 0868A indicated that
sample  measurements  made  over  a  number  of succesive days are not
independent.   As  a  result,  the  Agency  modified  its  method  for
calculating  the  30-day  average  concentrations  to account for this
correlation.  It  should  bo  noted  that  the  Agency  did  not  find
correlations   of   any   significance   between   successive   sample
measurements made at physical-chemical treatment systems used to treat
other steel industry wastewaters.

The application of the Central Limit Theorem to the effluent data from
biological treatment of cokemaking wastewaters remains  valid.   Thus,
the  variability  factors,  VF*, for the 30-day average concentrations
are calculated using equation (2) above.  However, to account for  the
statistical   dependence   of   the  effluent  data,  the  correlation
(Covariance) terms are included in the  calculation  of  the  standard
deviation of the 30-day averages, S*, as shown in Table A-51.


The  effect  of the dependency of the effluent data is to increase the
standard  deviation,  and,   thus,   increase   the   30-day   average
concentrations.   The  30-day  average  concentration  bases for total
suspended solids, ammonia-N and total cyanide for the BAT (biological)
limitations and NSPS for the cokemaking subcategory were calculated on
this basis.  The phenols (4AAP) concentration was determined using the
original method since the Agency determined that the dependency of the
effluent data for phenols (4AAP) are not significant.
                                276

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Determination of Limitations

Daily  maximum  and  30-day  average   concentrations   (L   and   L*,
respectively)  were  calculated  for each pollutant from the long term
average (LTA), the daily  variability  factor  (VF),  and  the  30-day
average  variability  factor  (VF*) for that polluant by the following
equations:

     L   - VF  X LTA          (3)
     L*  « VF* x LTA          (4)

The  above  concentrations  were  multiplied  by  the  effluent   flow
(gal/ton)  developed for each treatment subcategory and an appropriate
conversion factor to obtain mass limitations and standards in units of
kg/1,000 kg of product.

The daily maximum limitation calculated for each pollutant is a  value
which is not to be exceeded on any one day by a plant discharging that
pollutant.   The 30-day average maximum limitation is a value which is
not to be exceeded by the average of up to 30  consecutive  single-day
observations for the regulated pollutant.  Long term data analyses are
presented in Tables A-2 through A-50.

Analysis of Data From Filtration and Clarification Treatment Systems

The  observations used to derive daily maximum and 30-day average con-
centrations include both long term data obtained from the  D-DCPs  and          \
agency requests, and short term data obtained through sampling visits.
Engineering judgment15 was used to delete 'some data from the long term
data  sets  analyzed;.   Generally those data deleted indicate possible
upsets, lack of proper operation of treatment facilities, or bypasses.
These values typically could be considered effluent  violations  under
the  NPDES permit system.  The number of observations deleted for each
pollutant is identified in Tables A-9 to A-50.  Table A-l  presents  a
key  to  the  long-term  data summaries for all plants included in the
analyses.  A  discussion  of  the  analyses  for  filtration  and  for
clarification treatment systems follows.

Filtration Treatment System

Table  A-2 presents average concentrations and variability factors for
total suspended solids for those plants1* with long term effluent data
for filtration treatment systems.  Detailed descriptive statistics for
all relevant pollutants sampled  at  these  plants  are  presented  in
15The Agency's justification for using engineering judgment to  delete
values  from  monitoring  data  sets was upheld in U.S. Steel Corp. v.
Train, 556 F.2d 822 (7th Cir. 1977).
16Plant 920N was not included in this long term data analysis.  Visits
to this plant by EPA personnel have demonstrated  that  the  treatment
system was not properly operated.                                              j
                               277

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Tables  A-9  to  A-18.   The  median  of  the  long  term  averages is
multiplied by the apporpriate median variability factor to obtain  the
daily  maximum  and 30-day average concentrations for TSS as presented
in Table A-2.  Table A-3 presents,  in  a  similar  manner,  averages,
variability   factors  and  daily  maximum  and  30-day  average  con-
centations for oil and grease.

The average concentrations for five toxic  metals  (chromium,  copper,
lead,  nickel  and  zinc) calculated from long and short term data are
presented with the  respective  medians  in  Table  A-4.   Variability
factors,  presented  in  Table  A-5,  were calculated for those plants
having  long  term  toxic  metals  data.   The  median  daily  maximum
variability  factors  for  the  metals  range  "from 2.0 to 4.5 and the
30-day variability factor for all of the toxic metals is  1.2.   These
values  are  similar  to those obtained for TSS and oil and grease, in
which case the daily maximum variability factors are 3.9 and  4.2  for
TSS,  and  oil  and  grease,  respectively;  and  the  30-day  average
variability  factor  is  1.3  for  both   pollutants.    Since   these
variability  factors  were  calculated  from  a  larger data base, the
Agency  decided  to  use  the  average  of  these  to  represent   the
variability  of  the  toxic metals.  Therefore, variability factors of
4.0 and 1.3 were used to obtain the daily maximum and  30-day  average
concentrations, respectively.  The results are presented in Table A-5.
The daily maximum and 30-day average concentrations were rounded up to
0.3 and 0.1 mg/1, respectively, for all toxic metals except zinc.  For
zinc  the daily maximum and 30-day average concentrations were rounded
to 0.45 and 0.15  mg/1,  respectively.   These  values  were  used  to
calculate  the  toxic  metals mass limitations for filtration systems,
where applicable.

Clarification/Sedimentation Treatment System

Tables A-6 and A-7 present the average  concentrations  of  long  term
data,  the variability factors and the calculations used to derive the
daily maximum and 30-day average concentrations for TSS  and  oil  and
grease,  respectively.   The long term effluent data and the resultant
concentrations   apply   to   clarifacation/sedimentation   wastewater
treatment  systems.   Detailed  descriptive statistics of these plants
are presented in Tables A-18 to  A-37  and  A-50.   For  Plants  0112,
0684F,  and  0684H,  long term data were provided for several parallel
treatment  systems  in  one  central  treatment  facility.   In  these
situations  the  data  from the clarifier providing the best treatment
were used.

Screening and verification data were used  to  calculate  the  average
concentrations  for  toxic  metals  removal by clarification treatment
systems treating wastewaters  from  carbon  steel  operations.   These     |
average  concentrations  are  presented  in  Table  A-8.   Variability     ]
factors of 3.0 and 1.2 were used to calculate the  daily  maximum  and     ]
30-day  average concentrations (shown in Table A-8),  respectively, for     j
all the metals.  The above variability factors were based upon:            j
                                270

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1.   the variability factors for TSS and oil and grease in Tables  A-6
     and A-7; and,

2.   the variability factors17 derived from  toxic  metals  discharged
     from   clarification  treatment  systems  in  .the  electroplating
     category.

The daily maximum and 30-day average concentrations  were  rounded  to
0.3  and  0.1  mg/1,  respectively for chromium, copper, and zinc, and
0.45 and 0.2 mg/i for nickel, and 0.30 and 0.15 mg/1 for lead.   These
concentrations   were   used   to  establish  the  toxic  metals  mass
limitations  for  all  forming  and  finishing  operations,  with  the
exception  of  combination  acid  pickling  and  salt  bath  descaling
operations.

For combination acid pickling and salt bath descaling operations, both
of which process speciality steels, the Agency  relied  on  long  term
effluent data from a clarification treatment facility located at Plant
0060B.  This treatment facility treated wastewaters from both of these
specialty  steel  operations.   The  descriptive  statistical data are
presented in Table A-34.  The daily maximum  and  the  30-day  average
concentrations  used  to  establish  the mass effluent limitations for
chromium are 1.0 mg/1 and 0.4 mg/1, respectively; and for  nickel  0.7
mg/1 and 0.3 mg/1, respectively.
17Daily maximum variability  factors  presented  in  the  "Development
Document  for Electro- plating Pretreatment Standards"; are: Cu - 3.2,
Cr - 3.9, Ni - 2.9, Zn - 3.0, Pb - 2.9.
                                279

-------
                                         TABLE A-l

                              KEY TO LONG-TERM DATA SUMMARIES
                                   IRON & STEEL INDUSTRY

Table No.

  A-9
  A-10
  A-ll
  A-U
  A-l 3
  A-14
  A-l 5
  A-16
  A-l 7
  A-18
  A-19
  A-20
  A-21
  A-22
  A-23
  A-24
  t 25
  ,.-26
  A-27
  A-28
  A-29
  A-30
  A-31
  A-32
  A-33
  A-34
  A-35
  A-36
  A-37
  A-38
  A-39
  A-40
  A-41
  A-42
  A-43
  A-44
  A-45
  A-46
  A-47
  A-48
  A-49
  A-50
Reference Code

0112B-SA
0112C-011
0112C-122
0112C-334
OU2C-617
OU2I-5A
0384A-JE
0384A-4L
0684H-EF
06B4F-4I
0112-5B
0112A-5A
0112H-5A
0320-5A
0384A-5E
0384A-5F
0584A-5F
0584B-5F
0684F-5B
0684F-5E
0684H-5C
0856N-5B
0860B
0920C->A
0060B
0060B
0860B
0584E
0856D
08603
0012A-5F
0060A
0868A
0684 F
0684 F
0060
0060
0060
06)2
0612
0612
0948C
      Subcategory
                                                                        Treatment
Hoi Fonsing
Hoi Forming
Hot Forming
Hoi Forming
Hoi Forming
Pickling/Al. Cleaning
Cent. Casting
Conl. Casting
Pipe & Tube
Hoi Forming
Ironmaking
Sintering
Comb. Acid Pickling
Hot Forming
Ironmaking
Steelmaking (BOF)
Hot Forming
Hot Forming
Ironmaking
Ironmaking
Ironmaking
Hot Forming
Ironmaking
Cold Rolling
Comb. Acid Pickling
Comb. Acid Pickling
Forming & Finishing
Mile. Finishing Operations
Forming & Finishing
Ironmaking
CokemaUing
Cokemaking
Cokemaking
Cokemaking
Cold Rolling
Sintering
Sintering
Sintering
Steelmaking - EAF
Sleelmaking - EAF
Steelmaking - EAF
Misc. Finishing Operations
Filtration
Filtration
Filtration
Filtration
Filtration
Filtration
Filtration
Filtration
Filtration
Lagoons/Filtration
Polymer/Clarifier
Thickener
C1arifier/Lagoons
Lagoona
Thickener
Thickener/Clarifier
Settling Basin
Lagoons
Clarifier
Clarifier
Clarifier
Settling Basin
Clarifier
Clarifier
Lirae/Lagoons
Lioe/Clarifier
Chem. Addition/Clarifiers
Chem. Addition/Clarifiers
Chem. Addition/Clarifiers
A. Chlorination/Filtration
Single-Stage Biological
Single-stage Biological
2-Slage Biological
Phys-Chem (Carbon Columns)
Cat Flotation
Filtration (Pilot)
Lime/Clarifier (Pilot)
Lime/Clar/Filter (Pilot)
Filter (Pilot)
Hydroxide/Clarifier (Pilot)
Lime/Filter (Pilot)
Chem. Addition/Clarifierfc
                                        2CO

-------
                                         TABLE  A-2

                                  LONG-TERM DATA ANALYSIS
                                    FILTRATION SYSTEMS
                                   TOTAL SUSPENDED  SOLIDS
Plata

0112C-33A
0112I-5A
0112C-617
0684H-EF
OI12C-01I
0112B-5A
0384A-4L
0112C-122
0384A-3E
0684F-4I
Average (pg/1)

     2.3
     3.6
     4.8
     6.0
     8.9
    10.6
    10.8
    13.3
    17.4
    22.2
  Variability Factor*
 rage            Maxioua*
1.4
1.5
1.3
1.3
1.3
1.1
1.3
1.3
1.2
1.2
Median Value*                                    9.8              1.3

30-Day Average Concentration Baei* • (9.8 mg/1)  (1.3)  • 12.7 ng/l

Daily MaxiouB Concentration Ba«it • (9.8 ag/1) (3.9) " 38.2 ag/1
Note:  For the purpoae* of developing effluent limitation* and itandarda,
       the following value* were uaed for total *u*pended tolid*.

       Average -15 «g/l
       Maxima* - 40 og/l

* For plant* with »ore than 100 observational

                              99th Percentile
  Daily Variability Factor •
                                   Average
                                       281
6.8
8.9
5.4
5.3
3.5
2.3
3.0
4.0
2.5
3.7
                                         3.9

-------
                                         TABU A-3

                                  LONG-TERM DATA ANALYSIS
                                    FILTRATION SYSTEMS
                                       Oil. AND CIEASE
Plant

0112B-SA
0112C-334
0112C-617
0112C-122
0684H-EF
0112C-OI1
0384A-4L
Average (•>/!)

    1.1
    1.3
    1.3
    2.0
    3.4
    6.7
    6.7
                                                                    Variability Pactora
                                                                   raee            Maxinua*
1.1
1.4
1.4
1.3
1.4
1.3
1.2
2.9
5.3
4.5
5.3
3.8
5.1
3.4
Median Value*                                   2.0               1.3

30-Day Avtt«|« Concentration Kati* • (2.0 •»/!) (1.3) » 2.6 •»/!

Daily Haxi«m Conccntratioa B««i*  • (2.0 aj/l) (4.5) • 9.0 •»/!
                                         4.5
Not*:  A atxiaua valu* of 10 •»/! haa been u»«d to develop
       effluent liatitatioa* and atandardi for oil and greaae.

* For planta with more than 100 obaervatiooat

                              99th Percentile
  Daily Variability Factor •
                                   Average
                                        2C2

-------
                                          TABLE  A-4

                                        DATA ANALYSIS
                                     FILTRATION SYSTEMS
                                RECgLATED  METALLIC POLLUTANTS
 PUnt

 A.  Chroaiu*

     OI12I-5A
     0684 F-41
     0684H
     0584E
     0496
     0612

 MEDIAN
NIB her of
 ple Pointi
  61
  II
  3
  3
  3
  3
Average
 (mg/1)
 0.02
 0.03
 0.03
 0.03
 0.03
 0.04

 0.03
 B.   Copper

     0584F
     0684 F-41
     0684H
     0612
     0496
     0112I-5A
     08688

MEDIAN
  3
  11
  3
  3
  3
  60
  3
 0.015
 0.02
 0.02
 0.03
 0.05
 O.OS
 0.25

 •-.03
C.  U«d
    0684P-4I
    0684H
    0496
    01121
    0612
    0868B
MEDIAN
  11
  3
  3
  3
  3
  3
0.03
0.05
0.05
0.07
0.18
0.32

0.06

-------
TABLE A-4
DATA ANALYSIS
PILTKATION SYSTEMS
RCGDLATCD METALLIC POLLOUURS
PACE 2                	
                                                  ef
    0684 H
    0612
    0496
    OU2I-5A
    0684F-*I
3
3
3
27
11
MEDIAN
0.02
0.025
O.C4
0.07
0.09

O.Oi
E.  line
    06&4H
    OSME
    0496
    0112I-5A
    0612
    0684 P
    0868B
3
3
3
>8
3
43
3
MEDIAN
0.02
0.02
0.02
0.10
0.12
0.39
1.6

0.10
                                       2S4

-------
                                         TA»t* A-5

                   DERIVATION Of VARIABILITY FACTORS AlfO PROPOSED LIMITS
                                     FILTRATION SYSTEMS
                               REGULATED MBTALLIC POLLUTANTS
Parameter

A.  Qiromivam

    0112I-SA
    0684F-*I
MEDIAN
B.  Copper

    0112I-5A
    0684 f-4 1

MEDIAN
C.
    0684 F-* I
ibility Fcetor*
No. of
Staple Point*
61
a

60
tl

n
27
11

58
45

Averai
1.2
1.2
1.2
1.2
1.1
1.2
1.1
1.2
1.2
1.2
1.2
1.2
Variability Factor*
t* MaitiwJ*
2.9
3.6
3.3
5.1
2.7
3.9
2.0
3.3
5.6
4.5
3.0
4.2
D.  Nicktl

    0112I-5A
    06S4F-4I

MEDIAN
E.  Zinc

    01..T-5A
    U684P-4I

VDIAN
Hotct  n** for «ll regulated cietal*
       A»«r*gc Variability Factor • 1.3
       Kaxiamai Variability Factor • 4.0
                                                              1.2
                                                                                      3.6
                                         285
                                                                                                               \

-------
TABLE A-)
DERIVATION OF V AS LABILITY FACTORS AMD PROPOSED LIMIT*
flLTXATIOtt SYSTEMS
REGULATED METALLIC fOLLutAXTS
PACE 2                         	
Derivation ef Concentration Value*

A.  ChroeniB*
    30-Day Average Concentration B**(*
    Daily Maxima Concentration Batii
B.  Copper
    }0-D*jr Average Concentration B*»i*
    Daily MaxiauB Concentration Baiii
C.  Lead
    30-Day Average Concentration Bail*
    Daily KaiiauB Concentration Baat*
D  Nickel
    30-Day Average Concentration Baila
    Daily KaxiiiuB Concentration Baaia
(O.OJK1.J, • 0.0*
(0.03X4.0) • 0.12
(0.03)U.3) • 0.0*
(C.03X4.0) • O.U
<0.06)(!.3) • O.OC
(0.06X4.0) - 0.24
(0.04XJ.3) . O.OJ
(0.04X4.0) - 0.16
C.  Zinc
    30-Day Average Concentration Batia
    Daily KaxiBua Concentration Be«ti
(0.10X1.3)
(0.10)(4.0>
 0.13
" 0.40
Hotel  For th« purpoae* of developing effluent limitation*
       and *Candarda, the following value* were uaed for all •••tali except tinci
             * • 0.10 •«/!
       Maxiaua - 0.30 ag/1

       For line, the following valuci have been oaedl

       Average » 0.15 »R/1
       H«xiauB » 0.4) ag/l

       All concentraticm value* «re in mgjl.
                                                              1
                                                                                                        •J
                                                                                                       ".**
-------
                                         TABLE A-6
                                  LONG-TERM DATA ANALYSIS
                            CLARIFICATION/SEDIMENTATION SYSTEMS
                                  TOTAL SUSPENDED SOLIDS
Nuaber
of
SMkpie
Pointa
853
102
291
49
24
151
97
74
24
380
98
195
101
383
101
17
175
528


Average Variability
(mt/l) Average
5.2 1.1
8.9 1.1
9.9 1.3
11.7
14.5
15.8
16.1
19.0
23.1
24.5
24.6
25.0
25.4
26.7
32.1
33.1
35.7
45.5
.2
.2
.2
.1
.2
.1
.1
.1
.2
.1
.2
.2
.2
.2
.0


Factor*
Maximum*
2.3
2.3
4.0
3.2
5.3
2.3
2.8
5.4
2.5
2.4
2.3
3.1
1.8
2.5
3.2
3.4
2.5
3.6
Plant

0584E
08608
0112-5B
0112H-5A
0060B
0320-5A
0384A-5F
0684R-5C
0060B
0684F-5B
0584B-5F
0920G-5A
0584A-5F
0384A-5E
0856N-5B
0856D
0112A-SA
0684F-5E

Median Value*                                23.8                 1.2

30-Day Average Concentration Baaia • (23.8 •*/!) (1.2) - 28.6 mg/1

Daily Maxi*u» Concentration Baaia  • (23.8 »g/l) (2.7) • 64.3 mg/1
2.7
Note:  For the purpoaea of developing effluent Imitation* and standards,
       the following valuea were used for total suspended solids:

       Average • 30 ng/1
       Ma*i»ia • 70 »g/l

*: For plants vith aiore than 100 observation*:

   Daily Variability Factor -  99th Perctntile
       '           *               Average
                                      287

-------
                                         TABLE A-7

                            CLARIFICATION/OIL SKIMMING SYSTEMS
                            	OIL AND GREASE	
Plant

0320-5A
0584 E
0684F-5E
OS56D
0860B
OS84A-SF
0856N-5B
0584B-5F

MEDIAN VALUES
                   Ifisiber of
                 Staple Point«

                     35
                     853
                     5
                     17
                     260
                     98
                     103
                     58
Average
 (ng/1)

  0.1
  1.6
  2.8
  4.0
  4.8
  5.9
  7.0
  8.4

  4.4
                                                                    Variability Factors
                                                                   rage            Maximum*
1.2
1.2
 .1
 .1
 .1
 .2
 .1
 .2

1.2
 4.0
 3.7
"2.3
 1.7
 3.3
 6.7
 2.0
 2.9

 3.1
30-Day Average Concentration Baaia "(4.4 mg/l)(1.2). • 5.3 ng/1
Daily Maxima*. Concentration Basia  " (4.4 ng/l)(3.1) • i3.6 mg/1
Rote:  For the purpoaea of developing effluent limitations and standards,
       the following valuea were used for oil and grease:

       Average • 10 mg/1
       Maxiaim • 30 »g/1
* For plants with more than 100 observations:

                              99th Percentile
                                   Average
Daily Variability Factor -
                                        238

-------
                                                                  TABLE A-8

                                                                DATA ANALYSIS
                                                     CLARIFICATION/SEDIMENTATION SYSTEMS
                                                        REGULATE'  METALLIC POLLUTANTS
                         Plant

                         A.  Chromium

                             0856D
                             0948C
                             NN-2
                             04 76 A
                             0528
                             0584E
                             0948C
                             0396A
                             0920E
                             0424-01

                         MEDIAN
Subeategory
Forming & Finishing Wastes
Pickling
Galvanizing
Pickling
Pickling
Finishing Wastes
Finishing Wastes
Pickling
Galvanizing
Pickling
                         30-Day Average Concentration Basis • (0.04 mg/1)(1.2)
                         Daily Maximum Concentration Basis  - (0.04 rag/l)(3.0)
                         B.  Copper

                             0948C
                             0476A
                             OS28
                             0920E
                             0424-01
                             0396A

                         MEDIAN
Pickling
Pickling
Pickling
Galvanizing
Pickling
Pickling
                         30-Day Average Concentration Basis • (0.04 mg/l)(1.2)
                         Daily Maximum Concentration Basis  " (0.04 mg/l)(3.0)
                         C.  Lead

                             0856D
                             0948C
                             04 76 A
                             0528
                             0396A
                             0920E

                         MEDIAN
Forming & Finishing Wastes
Pickling
Pickling
Pickling
Pickling
Galvanizing
                         30-Day Average Concentration Basis
                         Daily Maximum Concentration Basis
          (0.10 mg/l)(1.2)
          (0.10 mg/l)(3.0)
  Number of
Sample Points
      17
      3
      3
      3
      3
      853
      236
      3
      3
      3
                             0.05 rng/1
                             0.12 mg/1
                             0.05 mg/1
                             0.12 mg/1
      17
      3
      3
      3
      3
      3
 0.12 mg/1
 0.30 mg/1
0.02
0.02
0.03
0.03
0.03
0.04
0.04
0.08
0.27
1.32

0.04
                              0.02
                              0.03
                              0.03
                              0.04
                              0.08
                              0.17

                              0.04
0.02
0.05
0.10
0.10
0.57
0.60

0.10
                                                                289
L  .

-------
                  TABLE  A-8
                  DATA ANALYSIS
                  CLARIFICATION/SEDIMENTATION  SYSTEMS
                  REGULATED  METALLIC  POLLUTANTS
                  PAGE 2	

                                                                          Number of                 Average
                  Plant                      Subeategory                 Sample Point*                «y/l

                  D.   Nickel

                      0948C                  Pickling                          3                       0.03
                      0476A                  Pickling                        .  3                       0.03
                      0528                  Pickling                          3                       0.03
                      0396A                  Pickling                          3                       0.27
                      0424-01                Pickling                          3                       2.50
                      0920E                  Galvanizing                       3                       2.90

                  MEDIAN                                                                              0.15

                  30-Day Average  Concentration Baai* •  (0.15 mg/l)(1.2) • 0.18 mg/1
                  Daily  Maxima Concentration  Bacii  •  (0.15 ag/l)(3.0) • 0.45 mg/l

                  E.   Zinc

                      0528                  Pickling                          3                       0.02
                      0424-01                Pickling                          3                       0.035
                      0584E                  Finishing  Waate*                  853                     0.04
                      0476A                  Pickling                          3                       0.05
                      0948C                  Finishing  Wastes                  236                     0.05
                      0948C                  Pickling                          3                       0.07
                      0856D                  Forming &  Finishing Wastes        17                      0.13
                      0396A                  Pickling                          3                       0.24
                      0920E                  Galvanizing                       3                       6.7

                  MEDIAN                                                                              0.05

                  30-Day Average  Concentration Basis •  (0.05 mg/DO.2) • 0.06 og/1
                  Daily  Maxinum Concentration  Basis  •  (0.05 mg/l)(3.0) • 0.15 mg/l
                  Note:  For the purposes of developing effluent  limitations  and  standards,
                         the following values were used:

                         For chromium, copper and zinc:

                         Average • 0.10 og/1
                         Maximum - 0.30 mg/1

                         For nickel:

                         Average " 0.20 mg/1
                         Maximum • 0.60 mg/1

                         For lead:

                         Average "0.15 mg/1
                         Maximum • 0.45 mg/1
                                                        290
„.-- x-
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-------
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                                TABLE A-51

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-------
           VOLUME I
          APPENDIX B
IRON AND STEEL PLANT INVENTORY
               3-41


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     30-
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u                            z    o    •-
w>   o   o   o    *        <
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     _j_l-l   —    -iUZZ
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      —    X    *   <   *   _
                                        o   o
                                        ZZ
                                                       388

-------
      VOLUME I





     APPENDIX C





SUBCATEGORY SUMMARIES
          38'J

-------
                    o
                    Q.
bJCO N
GZ
OUJ
    LU
    e>

    s
MISCELLANEOUS
PROCESS
WASTES

WASTE
AMMONIA
LIQUOR
BENZOL
PLANT
WASTES

FINAL
OOLER
BLOWDOWN


CRYSTALLIZER 1
BLOWOOWN J
                                     391
                                                             Preceding page blank

-------
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Air — 'BIOLOGICAL
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CINAL
COOLER
RI nwnnww

h-li— fa . *
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1 	 Blowdown replaces u" to 50GPT A
of dilution woter. T
— — — -^Encess blowdown lo
quench station
R -Free Still and Small Equalization To
prior to still not included in cost estin
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                         392

-------
                                            SUBCATECORY SUMMARY DATA
                                              BASIS 7/1/78 DOLLARS
SUBCATECOtY:
           :
By-Product Cokemaking
Iron an«< Steel Plants
MODEL SIZE (TPD):  4700
OPER. DAYS/YEAR :   365
TURNS/DAY       :     3
RAH HASTE FLOWS
Model PUnl
15 Direct Dischargers
13 To Quenching Operations
8 Indirect Dischargers
3 Zero Dischargers
39 Active Plants
0.8 MCD
11.6 MOD
9.9 MOD
6.1 MGD
0.8 MOD
28.2 HGD
MODEL COSTS ($X10"3)

Investment

Annuj1

$/Ton of Production
              Biological
              Physical-Chenical
              Biological
              Physical-Chemical
              Biological
              Physical-Chemical
PSES-l

4021
-
1049
-
0.61
-
PSES-2
BPT
5232
4117
1379
1063
0.80
0.62
PSES-3
BAT-1
141 »
37i6
327
1557
0.19
0.91
PSES-4
BAT- 2
1927
4274
398
1831
0.23
1.07
PSES-5
BAT- 3
1988
-
623
-
0.36
-
PSES-6
BAT-4
1672
3919
359
1583
0.21
0.92
WASTEWATER
CHARACTERISTICS
     Flow (CPT)
     pH (SU)
     Anaonia-N
     Oil and Crease
     Phenolic Compounds (4-AAP)
     Sulfide
     Vhiocyanale
     Total Suspended Solids

   3  Acrylonitrile
   4  Benzene*
 21  2,4,6,-Trichlorophenol
 22  Parachloroaetacresol
 23  Chloroform*
RAW PSES-l PSES-2 PSES-3 PSES-4 PSES-5
WASTE BPT BAT-1 BAT-2 BAT-3
162
7-10
600
75
300
150
480
50
1.2
35
0.1
0.6
0.3
103
6-9
(75)60
225(1)(2) 15j(l)(3) 15J(1
6-9 6-9 6-9
(97)75 (15)7 (15)7
(25)15 (11.6)8 (10)5 (8)4
(50)36
50
180
(120)100
0.25
10
0.05
0.15
0.2
(1.6)0.5 (0.05)0.02 (0.05)0.02
1 0.4 0.4
2 0.3 0.3
(80)66 (80)66 (20)15
0.05 0.02 0.02
0.3 (0.05)0.04 (0.05)0.04
0.02 0.005 0.005
0.05 0.005 0.005
0.2 0.2 0.1
)(4) 153(1)
6-9
(10)5
(5)2
(0.025)0.01
0.3
0.2
(20)15
0.01
(0.04)0.03
<0.005
<0.005
0.05
PSES-6
BAT-40'
0
-
-
-
-
-
_
-
-
-
-
                                                         393

-------
SVBCATECORY SUHKARY DATA
BY-PRODUCT COKEMAKING
PACE 2	
UASTEUATER
CHARACTERISTICS
34
35
36
38
39
54
55
60
64
65
66-71
72
73
76
77
80
84
86
114
115
121
125
128
130
2,4-Dimethylphenol
2,4-Dinitrotoluene
2,6-Dinitrotoluene
Ethylbenzeoe*
Fluoranlhen**
Isophorone
Naphthalene*
4,6-Dinitro-o-cresol
Pentachlorophenol
Phenol*
Total Phthalatee*
Benxo (a) Anthracene
Benio (a) Pyrene*
Chrysene*
Acenaphthylene*
Fluorene*
Pyren«*
Toluene*
Ant imony*
Artenic
Cyanide*
Selenium*
Zinc*
Xylene*
RAW
WASTE
5
0.2
O.I
3
0.8
O.S
10
0.12
0.12
27S
5
0.3
0.1
0.4
3.5
0.6
0.6
25
0.2
2
50
0.2
0.2
12
PSES-1

1
0.1
0.05
0.3
0.2
0.3
5
0.08
0.08
30
2
0.2
0.05
0.2
1.0
0.2
0.2
5
0.1
1
(20)16
0.2
0.2
3
PSES-2
BIT
0.02
0.02
0.02
0.05
0.05
0.1
0.05 (0
0.01
0.01
0.3
1
0.05
0.05 (0
0.05
0.08
0.05
0.1
0.3
0.1
0.4
(23)5
0.1
0.1
0.2
PSES-3
BAT-1
0.005
0.01
0.01
0.03
0.02
0.01
.01)0.005
0.005
0.005
0.005
0.2
0.01
.02)0.01
0.01
0.02
0.02
0.03
0.05
0.1
0.4
(3)2.5
0.1
0.1
0.02
FSES-4
BAT-2
0.005
0.01
0.01
0.03
0.02
0.01
(0.01)0.005
0.005
0.005
0.005
0.2
0.01
(0.02)0.01
0.01
0.02
0.02
0.03
0.05
0.05
0.25
(3)2.5
0.05
0.05
0.02
PSES-5
BAT-3
<0.005
0.005
0.005
0.02
0.01
0.005
(0.01)<0.005
<0.005
<0.005
<0.005
0.1
0.005
(0.01)0.005
0.005
0.01
0.01
0.02
0.04
0.04
0.25
(2.5)2
0.05
0.05
0.01
PSES-6
BAT-4
_
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
.
-
-
-
-
Mote*!  All concentrations are in »g/l unless otherwise noted.
      :  BAT and PSES-3 through PSES-6 com are incremental over BPT/PSES-2 coitt.
      t  Values in parentheses represent the concenrrations used to develop the
        limitations/standards for the various levels of treatment.  All other values
        represent long ten* average values or ptedicted average performance levels.

*   Toxic pollutant found in all rev waste sample* analyzed.
(1) Plow includes up to 50 CPT of dilution water to optimize conditions for bio-oxidation.
    Part of this dilution water e>ay be replsced with blovdown* from air pollution control
    scrubbers froai pushing operations.
(2) For physical-chemical plants, flow basis is 175 CPT, and limitations are as foltowai
    Ammonia-N 125 mg/1; Oil t Crease 15 mg/l| Phenolic Compounds 2 mg/l| TSS 100 Bg/1)
    and Cyanides 30 ny/l.
(3) For physical-chemical plants, flow basis is 103 CPT, and limitations are as follows:
    Ammonia-N 75 mx/1; Phenolic Compounds 0.1 mg/1 Beniene 0.05 mg/l| Naphthalene 0.01 mg/ll
    and Benco(a)pyrene 0.02 mf/l.
(4) For physical-chemical plants, flow basis is 103 CPT. and limitation' are as follows!
    Amnonia-N 15 mg/1; Phenolic Compouads 0.05 mg/1; Benxene 0.05 mg/lf Naphthalene 0.01 mg/1;
    and Benxo(a)pyrene 0.02 •«/!.
(5) For physical-chemical plants, this alternative is BAT-3.
                                                          394

-------
                                                                                                                      IZJ
                                           SUBCATECORY SUKttRY DATA
                                             BASIS 7/1/78 DOLLARS
SUBCATECORY:
By-Product CokemaVing
Merchant Coke Producer*
                MODEL SIZE (TPD):
                OPER. DAYS/YEAR  1
                TURKS/DAY        I
                                  ALL
                                  OTHERS
                                  1690
                                    365
                                     3
RAW WASTE FLOWS
Model Plant
     Indirect Discharger      0.2 MOD
     All Other*               0.3 MOD
 7   Direct Di*ch«rger«       2.1 HOT
 2   To Quenching Operation*   0.6 MOT
 8   Indirect Diacharger*     1.3 MOT
 2   Zero Discharger*         C.3 MOD
19   Active Plant*            4.3 HGD
MODEL COSTS (SXlp"3)	

Inve*uunt
     Indirect Discharger*
     Other Discharg*r*-Biolcgical
     Other Di*charger*-Phy*ical-Che*ucal
Annul1
     Indirect Diacharger*
     Other Di*charger*-Biological
     Other Di*ch*rg<>r*-Phy*ic*l-Ch««ucal
5/Ton of Production
     'indirect Discharger*
     Other Di*charger*-Biological
     Other Disch*rger»-Phy»ic*l-Chc«ic*l
                                         PSES-1
                                         PSNS-1
                                         1630
                                         336
                                         1.00
      BPT
      BCT
      PSES-2
      PSNS-2
      2180
      3097
      2455

      442
      688
      538

      1.32
      1.12
      0.8?
     BAT-1
     PSES-3
     PSHS-3
     506
     721
     2104

     99.0
     152
     907

     0.29
     0.25
     1.47
                 BAT-3
                 PSES-5
                 PSNS-5
                                                                                    672
                                                                                    959
                                                                                    169
                                                                                    271
                                                                                    0.50
                                                                                    0.44
               BAT-4
               PSES-6
               PSNS-6
                           610
                           870
                           2225

                           112
                           170
                           «22

                           0.33
                           0.28
                           1.49
Invettaenl

Annua1

J/Ton of Production
                                                   1.59
                                                             1.64
WASTEWATER
CHARACTERISTICS
     Flow CCPT)
     pH (SU)
     AoBonia-N
     Oil and Cr*a*e
     Phenolic Coapound* (4AAP)
     Sulfides
     Thioc'/anat«s
     Total Su«p«n2.0
 (1.6)0.5 (0.05)0.02 (0.05)0.02 (0.025)0.01
      1          0.4        0.4         0.3
      2          0.3        0.3         0.2
                               50   (140)100  (140)66   (140)66
                                                                    (20)15
                                                                                (20)15
                                                           39:
                                                                                                             t

-------
                                                                                                                          7?
                                                                                                                           ; »
SUBCATECORY SUMMARY DATA
BY-PRODUCT COKEMAKINC
PA3F 2
UASTEUATER
CHARACTERISTICS
3
4
21
22
23
34
35
36
38
39
54
55
60
64
65
66-71
72
73
76
77
80
84
86
114
115
121
125
128
130
Acrylonitrile
Benzene*
2,4,6-Trichlorophenol
Parachloromeiacresol
Chloroform*
2, 4-Dimelhyl phenol
2,4-Dinilrotoluene
2,6-Dinitrotoluene
Elhylbenzene*
Fluoranthene*
Isophorone
Naphthalene*
4,6-Dinitro-o-cresol
Pent ach loi ophenol
Phenol*
Total Phthalates*
Benzo (a) Anthracene
Benzo (a) Pyrene*
Chrysene*
Acenaphihylene*
Fluorene*
Pyrene*
Toluene*
Antimony*
Arsenic*
Cyanide*
Seleniua*
Zinc*
Xylene*
Notes: All concentrations are in mg/l


: BAT, PSES-3 through PSES-6 and
; Value* in parentheses represeni
RAW
WASTE

1.2
35
0.1
0.6
0.3
5
0.2
0.1
3
0.8
0.5
30
0.12
0.12
275
5
0.3
0.1
0.4
3.5
0.6
0.6
25
0.2
2
50
0.2
0.2
12
BPT BAT-1 BAT-2 BAT-3
BCT NSPS-1 NSPS-2 HSPS-3
PSES-1 PSES-2 PSES-3 PSES-4 PSES-5
PSNS-1 PSNS-2 PSNS-3 PSNS-4 PSNS-5

0.25
10
0.05
0.15
0.2
1
0.1
0.05
0.8
0.2
0.3
5
0.08
0.08
30
2
0.2
C.05
0.2
1
0.2
0.2
5
0.1
1
(20)16
0.2
0.2
3

0.05
0.3
0.02
0.05
0.2
0.02
0.02
0.02
0.05
0.05
O.I
0.05
0.01
0.01
0.3
1
0.05
0.05
0.05
0.08
0.05
0.1
0.3
0.!
0.4
(23)5
0.1
0.1
0.2

0.02
(0.05)0.04
0.005
0.005
0.2
0.005
0.01
0.01
0.03
0.02
0.01
(0,0550.005
0.005
0.005
0.005
0.2
0.01
(0.05)0.01
0.01
0.02
0.02
0.03
0.05
0.1
0.4
(5.5)2,75
0.1
0.1
0.02

0.02
(0.05)0.04
0.005
0.005
0.1
0.005
0.01
0.01
0.03
0.02
0.01
(0.05)0.005
0.005
0.005
0.005
0.2
0.01
(0.05)0.01
0.01
0.02
0.0?
0.03
0.05
0.05
0.25
(5.0)2.75
0.05
0.05
0.02

0.01
(0.03)0.02
<0.005
<0.005
0.05
<0.005
0.005
0.005
0.02
0.01
0.005
(0.03X0.005
<0.005
<0.005
<0.005
0.1
0.005
(0.03)0.005
0.005
0.01
0.01
0.02
0.04
0.04
0.25
(5.0)2
0.05
0.05
0.01
1
i
I
BAT-4 '
PSES-6 ',
psws-6 ;
i
-
^ i \
-
-
- ;
-
i
• *
'
„
i
-
_
!
• i
-
-
-
-
-
-
-
-

- ;
-
'
-
-
;
        limitations/standards for the various levels of treatment.  All other values
        represent long ten) average values or predicted average performance  level*.
Toxic pollutant found in all raw waste sample*.
Limit for oil and greaie i* based upon 10 »g/l (maxi
                                                            only).

-------

                               SUMMARY OF EFFLUENT LOADINGS AMD TREATMENT COSTS
                                       BY-PRODUCT COKEMAKINC SDBCATEQORY 	
                                          DIRECT DISCHARGERS
StJECATEGORY LOAD SUMMARY
(TOHS/TEAR)	

Flw (MOD)
    nia (M)
Oil and Greace
Phenolic Compound* (4AAP)
Sulfide
Thiocyanate
Total Cyanide*
Total Suspended Solid*
Total Toxic Hetalt
Total Organic*

SUBCATECORY COST SUMMARY*2'
Investment
RAW
HASTE
25,1
22,947.7
2.858.5
11,473.9
5,736.9
18,358. 3
1,912.2
1,912.2
99.5
4,535.9
_*
-

BPT/BCT
33.3
3,796. S
404.9
25.3
50.7
101.2
253.1
3,846.2
35.4
137.7
168.6
41.61

BAT-1
22.7
242.0
152.1
0.6
13.8
10.4
95.0
2,623.5
24.2
24.7
44.1
11.49

BAT-2
22.7
242.0
152.1
0.6
13.8
10.4
86.4
518.7
13.8
21.2
62.0
14.22

BAT-3
22.7
172.9
69.2
0.3
10.4
6.9
69.2
518.7
13.5
11.3
64.2
20.71


BAT-4
0
-
-
-
-
-
-
-
-

54
12










.6
.77
                                          INDIRECT ( POTWJDIS CHARGERS
SDBCATEGO8Y LOAD SOMMARY
(TOKS/YEAR)	

Flov (MOD)
    aia (N)
Oil and Create
Phenolic Compound* (4AAP)
Sulfide
Thiocyaaate
Total Cyanide*
Total Suspended Solid*
Total Toxic Metal*
Total Organic*  '
SUBCATECORY COST SUMMARY
Investment
Annual
                        (3)
RAW
WASTE
7.4
6,759.1
844.9
3,379.5
1,689.8
5,407.2
563.3
563.3
29.3
1,336.0

-

PSES-1
4.8
434.4
108.6
260.6
361.9
1,303.0
115.8
723.9
10.8
208.1
45.8
10.17

PSES-2
10.3
1,167.3
124.5
7.7
15.6
31.2
77.8
1,182.3
10.9
42.3
52.7
13.10

PSES-3
7.1
74.6
46.9
0.2
4.3
3.2
29.3
809.8
7.4
7.7
13.7
3.61

PSES-4
7.1
74.6
46.9
0.2
4.3
3.2
26.7
159.9
4.3
6.6
18.5
3.73

PSES-5
7.1
53.3
21.3
0.1
3.2
2.2
21.3
159.9
4.1
3.4
19.1
5.74

PSES-6
0
_
.
-
-
-
-
-
.

16.3
3.39
(1)  Individual phenolic compound* (e.g., 2,4-Dinitrophenol, Pentachlorophenol) are not included
     in Toxic Organic*.
(2)  Two confidential plant* have been excluded frov co*t* *hovn.
(3)  The co*t iwnary total* do not include one confidential plant.
                                                       397

-------
                               SUMMARY OF EFFLUENT LOADINGS AND TREATMENT COSTS
                                       BY-PRODUCT COKEMAKING SUBCATEGORY
                                             IRON AND STEEL PLANTS
SUBCATEGORY LOAD SUMMARY
(TONS/YEAR)	

Flov (MOD)

Amonia (N)
Oil and Grease
Phenolic Compounds (4AAP)
Sulfide
Thiocyanale
Tolal Cyanides
Total Suspended Solids
Tolal Toxic Metals
Total Organics
SUBCATEGORY COST SUMMARY
(IX10'6)	
Investment
Annual
SUBCATEGORY LOAD SUMMARY
(TONS/YEAR)	

Flow (MGD)

Amnonia (N)
Oil and Grease
Phenolic Compounds (AAAP)
Sulfide
Thiocyanate
Total Cyanides
Tolal Suspended Solids
Tolal Toxic Metals
Tolal Organics

SUBCATEGORY COST SUMMARY
Investment
Annua1
                        (2)
DIRECT DISCHARGERS
RAW
HASTE
22.1
20,200.5
2,525.1
10,100.3
5,050.1
16,160.5
1,683.3
1,683.3
87.6
3,992.9


INDIRECT
RAW
KASTE
6.1
5,562.7
695.3
2,781.3
1,390.7
4,450.1
463.6
463.6
24.1
1099.6

-

BPT/BCT
29.6
3,380.1
360.5
22.5
45.1
90.1
225.3
3,424.0
31.5
122.6
144.0
36.39

BAT-1
20.1
214.5
134.8
0.6
12.2
9.2
84.2
2,325.1
21.4
21.9
37.2
9.50

BAT-2
20.1
214.5
134.8
0.6
12.2
9.2
76.6
459.7
12.2
18.8
53.0
11.87

BAT-3
20.1
153.2
61.3
0.3
9.2
6.1
61.3
459.7
12.0
10.0
54.9
17.69

BAT-4
0
_
-
-
-
-
-
-
-

46.2
10.64
(POTW) DISCHARGERS

PSES-1
3-9
353.7
88.4
212.2
294.7
1,061.0
94.3
589.5
8.8
169.5
35.7
8.17

PSES-2
8.5
965.7
103.0
6.4
12.9
25.8
64.4
978.6
9.0
35.0
39.7
10.46

PSES-3
5.8
61.3
38.5
0.2
3.5
2.6
24.1
665.1
6.1
6.3
10.7
2.48

PSES-4
5.8
61.3
38.5
0.2
3.5
2.6
21.9
131.3
3.5
5.4
14.6
3.02

PSES-5 PSES-6
5.8 0
43.8
17.5
0.1
2.6
1.8
17.5
131.3
3.4
2.8
15.1 12.7
4.73 2.73
(1)  Individual phenolic compounds (e.g.. 2.4-Dinitrophenol,  Pcntachlorophenol) are not  included
     in Toxic Organics.
(2)  One confidential plant, has been excluded from costs shown.
                                                        398

-------
r
                                                    SUMMARY OF EFFLUENT LOADINGS AND TREATMENT COSTS
                                                           BY-PRODUCT COKEKAKING SUBCATECORY
                                                                     KERCRAKT PLANTS
                    SUBCATEGORY LOAD SUMMARY
                    (TOMS/YEAR)	

                    Flow  (MGD)

                    Ammonia  (N)
                    Oil «nd  Create
                    Phenolic Compounds (4AAP)
                    Sulfide
                    Thiocyanate
                    Total Cyanidea
                    Total Suspended Solida
                    Total Toxic Metals
                    Total Organica1'
                    SDBCATEGORY COST SUMMARY

                    ($X10~*)	
                     Invea taunt
                     Annual
                     SUBCATECORY LOAD SUMMARY
                     (TONS/YEAR)	

                     Flo*  (MOD)

                     Amaonia  (N)
                     Oil and  Create
                     Phenolic Compounds  (4AAP)
                     Sulfide
                     Thiocyanate
                     Total Cyanides
                     Total Suspended Solida
                     Total Toxic Metals
                     Total Organics
                                             (2)
                     SUBCATECORY  COST SUMMARY

                     ($X10~6)	
                     Investment
                     Annual
                                             (3)
DIRECT DISCHARGERS
RAW
WASTE
3.0
2,747.2
343.4
1,373.6
686.8
2,197.8
228.9
228.9
11.9
543.0

—
INDIRECT
RAW
WASTE
1.3
1,196.4
149.6
598.2
299.1
957.1
99.7
99.7
5.2
236.4

-

BPT/BCT
3.7
416.7
44.4
2.8
5.6
11.1
27.8
422.2
3.9
15.1
24.6
5.22

BAT-1
2.6
27.5
17.3
<0.1
1.6
1.2
10.8
298.4
2.8
2.8
6.9
1.99

BAT-2
2.6
27.5
17.3
<0.1
1.6
1.2
9.8
59.0
1.6
2.4
9.0
2.35

BAT-3
2.6
19.7
7.9
<0.05
1.2
0.8
7.9
59.0
1.5
1.3
9.3
3.02

BAT-4
0
_
-
-
-
-
-
-
_

8.4
2.13
(POTW) DISCHARGERS

PSES-1
0.9
30.7
20.2
48.4
67.2
242.0
21.5
134.4
2.0
38.6
10.1
2.00

PSES-2
1.8
201.6
21.5
1.3
2.7
5.4
13.4
203.7
1.9
7.3
13.0
2.64

PSES-3
1.3
13.3
8.4
<0.1
0.8
0.6
5.2
144.7
1.3
1.4
3.0
0.59

PSES-4
1.3
13.3
8.4
<0.05
0.8
0.6
4.8
28.6
0.8
1.2
3.9
0.71

PSES-5 PSES-6
1.3 0
9.5
3.8
<0.05
0.6
0.4
3.8
28.6
0.7
0.6
4.0 3.6
1.01 0.66
                     (1)   Individual  phenolic compound!  (e.g., 2,4-Dinitroph«nol, Pentachlorophenol) are not included
                          in Toxic Organica.
                     (2)   One  confidential  plant has been excluded from costs shown.
                     (3)   The  cost summary  totals do not include confidential plants.

-------
                to
              S3

              II
              10
                Ul
                UJ
                cr
                        o
                        a.
8-
oo
                        LJQ.
                        a
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                        en  -
                         .to
                        HO.
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                        CD 2
L,
                                              401
                                                 Preceding
                                                                                   Page blank

-------
                                                   SUBCATECORY SUMMARY DATA
                                                     BASIS  7/1/78 DOLLARS
SUBCATECORY:  Sintering
ITT, SAT, PSES MODEL SIZE (TFD):   4000
DSPS, PSNS MODEL SIZE (TFD)    :   7000
OPER. DAYS/YEAR                :    365
TURHS/DAY                      :      3
RAH WASTE FLOWS
Model Plant J.8 MOD
15 Direct Discharger. 87.6 MCD
1 Indirect Discharger 5.8 MCD
1 Zero Discharger 5.8 MCD
17 Active Plants 99.2 MCD

MODEL COSTS (SX10~*>
Investment
Annua 1
$/Ton of Production
_^
MODEL COSTS ($X10 )
Investaient
Annua 1
S/Ton of Production


UASTEWATER
CHARACTERISTICS
Flow (CPT)
pH (SU)
Aanonia (N)
Fluoride
Oil and Crease
Phenols (4AAP)
Residual Chlorine (Max. Only)
Total Suspended Solids
39 Fluoranthene
65 Phenol*
76 Chrysene
84 Pyrene*
118 Cadmium*
119 Chromium*
120 Copper*
121 Cyanide (Total)*
122 Lead
124 Nickel*
128 Zinc*

. BAT and PSES— 2 throuKh PSES~6 c
i Values in parentheses represent
levels o£ treatment. All other


BPT BAT-1 BAT-2
PSES-1 PSES-2 PSES-3
3615 401 316
1430 54.0 42.4
0.98 0.037 0.029
HSPS-1 NSPS-2


BAT-3 BAT-4
PSES-4 PSES-5
647 3127
151 473
0.10 0.32
NSPS-3 NSPS-4
PSNS-1 PSHS-2 PSHS-3 PSNS-4 PSNS-5
4822 $362 5219
2299 1399 1380
0.90 0.55 0.54
BAT-1 BAT-2
BPT HSPS-1 NSPS-2
RAW PSES-1 PSES-2 PSES-3
WASTE PSNS-1 PSNS-2 PSKS-3
1460 120 120 120
6-12 6-9 6-9 6-9
6777
6 25 20 20
240 (10)7 (5***)3.5 (10)7
0.2 0.2 0.2 0.2
-
6100 (50)39 (15)10 (25)22
0.10 0.1 0.1 O.I
0.03 0.05 0.05 0.05
0.01 0.01 0.01 0.01
0.01 0.01 0.01 0.01
0.05 0.01 0.01 0.01
0.7 0.6 0.2 0.15
0.1 0.03 0.02 0.02
0.2 0.2 0.2 0.2
0.15 0.12 (0.25)0.02 (0.25)0.02
0.1 0.02 0.01 0.015
1 0.5 (0.3)0.18 (0.3)0.04


the concentrations used to develop the llmita
values represent long term average values or
5594 8524
1462 1842
0.57 0.72
ZAT-3 BAT-4
KSPS-3 NSPS-4
PSES-4 PSES-5
PSNS-4 PSNS-5
120 120
6-9 6-9
(10**)6 (10**)6
20 20
(10)7 (5***)3.5
(0.1**)0.015 (0.1**>0.015
(0.5**)0.05 (0.5**)0.03
(25)22 (15)10
0.1 0.01
0.01 0.01
0.01 0.01
0.01 0.01
0.01 0.01
0.15 0.15
0.02 0.02
(1**)0.03 (1**)0.03
(0.25)0.02 (0.25)0.02
0.015 0.01
(0.3)0.04 (0.3)0.01




BAT-5
PSES-6
4936
1016
0.70
HSPS-5
PSNS-6
11,459
2799
1.10
BAT-S
HSPS-5
PSES-4
PSNS-6
0
.
-
.
-
_
-
-
_
.
_
_
_
_
.
_
.
_
-


t ions/standards for the various
predicted average performance
levels.
* Toxic pollutant found in all raw waste samples.
** When co-treated unh ironaaking wastewaters. These values are based upon the selected BAT alternative in the
Ironmaking Subcategory.
un 10 me/1 (maximum onlv).


                                                           40;

-------
                                                          SUMMARY OF EFFLUENT LOADINGS AND TREATMENT COSTS
                                                                        StHTERIKC SUBCATECORY
SUBCATECORY LOAD SUMMARY
(TONS/YEAR)	
Flow (MGD)
	a (N)
Cyanide (Total)
Fluoride
Oil and Grease
Phenols (4AAP)
Residual Chlorine
Total Suspended Solids
Total Toxic Metjls
Totf.l Organics

SUBCATECORY COST SUMMARY
DIRECT DISCHARCERS
RAW
WASTE
93.4
853.8
28.5
853.8
34,153.3
28.5

BPT
7.2
65.8
2.2
274.1
76.8
2.2

BAT-1
7.2
65.8
2.2
219.3
38.4
2.2

BAT-2
7.2
65.8
2.2
219.3
76.8
2.2
868,064.2    427.6     109.7     241.2
298.8        14.0      4.8       2.8
17.1         1.3       1.3       1.3
(SX10"6)
Investment
Annual

SUBCATECORY LOAD SUMMARY
(TONS/YEAR)
Flow (MGD)
Aavonia (N)
Cyanide (Total)
Fluoride
Oil and Grease
Phenols (4A.-.P)
Total Suspended Solids
Total Toxic Metals
Total Organics
SUBCATECORY COST SUMMARY

Inves tnent
Annual
(1) The raw waste load
are included in the
discharge, it does
waste loads.
(2) Individual phenolic
are not included in

_
~
INDIRECT
RAW
WASTE
5.8
53.4
1.8
53.4
2,134.6
1.8
54,254.0
18.7
1.1


_

and BPT cost contributions
direct discharger data.
not contribute to BAT cost


63.89 6.02 4.98
22.00 0.79 0.64
(POTW) DISCHARCERS

PSES-1 PSES-2 PSES-3
0.5 0.5 0.5
4.4 4.4 4.4
0.1 0.1 0.1
18.3 14.6 14.6
5.1 2.6 5.1
0.1 0.1 0.1
28.5 7.3 16.1
0.9 0.3 0.2
0.09 0.09 0.09


3.23 0.36 0.28
1.28 0.048 0.038
of the zero discharge operation
As this plant has no wastewater
s or to the BPT and BAT effluent

compounds (e.g., 2,4-dinil rophenol, pentachlorophenol)
tolM organics.

                                                                                                               8AT-3

                                                                                                               7.2

                                                                                                               65.8
                                                                                                               0.3
                                                                                                               219.3
                                                                                                               76.8
                                                                                                               0.2
                                                                                                               0.5
                                                                                                               241.2
                                                                                                               2.8
                                                                                                               1.3
                                                                                                                10.33
                                                                                                                2.29
                                                                                                                0.5

                                                                                                                4.4
                                                                                                                0.02
                                                                                                                14.6
                                                                                                                5.1
                                                                                                                0.01
                                                                                                                16.1
                                                                                                                0.2
                                                                                                                0.09
                                                                                                                0.58
                                                                                                                0.14
BAT-4

7.2

65.8
0.3
219.3
38.4
0.2
0.5
109.7
2.4
0.3
47.86
7.15
                                                                                                                                   BAT-5
2.79
0.42
                                                                                                         74.80
                                                                                                         15.40
PSES-5    PSES-6

0.5       0

4.4
0.02
14.6
2.6
0.01
7.3
0.2
0.02
                                                                                                         4.99
                                                                                                         1.04
                                                                                     403
L.

-------
                               I
  CC
  <
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< o
Z O
— z
  Ul
  Ul
      O
      O
      o
      
      4


      Q.
     LO
     0
                                       405
Preceding page blank

-------
                                                SVBCATECORY SUMMARY DATA
                                                  BASIS 7/1/78 COLLARS
SUBCATECORY!  Iron-iking
RAW WASTE FLOWS	

Model Plant
39   Direct Di>ch
MODEL COSTS ($X10'3)
Investment
Annual                  . .
     (with Sinter Plant)"'
     (without Sinter Plant)
S/Ton of Production     . .
     (with Sinter Plant)
     (without Sinter Plant)
Investment
Annua1
                                             trr
                                             PSES-l
                                                  9542
                                             972
                                             2248
                                             0.44
                                             1.03
                                                  HSPS-1
                                                  PSHS-1
                                                  9542
                                BAT-1
                                PSES-2
                                                            172
                                24.2
                                24.2
                                0.011
                                0.011
                                                       HSPS-2
                                                       PSNS-2
                                                            9714
BAT-2
PSES-3
                                                                      286
38.2
38.2
0.017
0.017
                                          KSPS-3
                                          PSNS-3
                                                                      9828
BAT-3
PSES-4
                                                                                   384
BAT-4
PSES-5
                                                                                               784
BAT-5
PSES-6
                                                                                                           3149
                                                                                   9926
                                                                                               10,326
BAT-4
PSES-7
                                                                                                                     4408
58.9
58.9
0.027
0.027
NSPS-4
P5HS-4
234
234
0.11
0.11
NSPS-5
PSNS-5
5*1
541
0.25
0.25
KSPS-4
PSSS-6
900
900
0.41
0.41
NSPS-7
PSNS-7
                                                                                                           12,691     13,950


(with Sinter Plant)* '
(without Sinter Plant)


972
2248
996
2272
1010
2286
1031
2306
1206
2482
1512
2788
1872
3148
$/Ton of Production , ^




(with Sinter Plant)
(without Sinter Plant)


WASTEWATER
CHARACTERISTICS







9
31
34
39
65
73
76
84
114
115
118
119
120
121
122
124
125
128
Flow (CPT)
pH (SU)
Anioonia (N)
Fluoride
Phenols (4AAP)
Residual Chlorine (Max
Total Suspended Solids
Hexachlorobenzene
2,4-Dichlorophenol
2, 4-Dimethyl phenol
Fluoranthene
Phenol*
Benzo (a) pyrene
Chrysene
Pyrene*
Antimony
Arsenic*
Cadmium*
Chromium*
Copper*
Cyanide (Total)*
Lead
Nickel*
Selenium
Zinc*
Notes: All concentrations
* Cost for the BAT— 1 i« — -> — —




RAW
WASTE
3200
6-9
20
15
3
. Only)
1900
0.01
0.01
0.05
0.08
0.65
0.01
0.01
0.05
0.04
0.1
0.1
0.5
0.25
12
5
0.5
0.06
20
are in mg/1 unless
0.44
1.03
BIT
MSPS-1
PSES-l
PSNS-1
125
6-9
(103)60
45
(4)2.3
-
(50)42
0.01
0.03
0.15
0.08
2.1
0.01
0.01
0.05
0.04
0.05
o.:
0.2
0.03
(15)4
0.5
0.1
0.01
0.7
0.45
:.04
BAT-1
KSPS-2
PSES-2
PSSS-2
0
-
0.46
1.04
BAT-2
NSPS-3
PSES-3
PSNS-3
70
6-9
(103)65
-
-
-
-
_
-
-
-
-
-
-
-
-
-
-
-
-
-
40
(4)2.3
-
(15)10
0.01
0.03
0.15
0.08
2.1
0.01
0.01
0.05
0.04
0.05
0.1
0.2
0.03
(5)4
(0.25)0.1
-
-
0.015
0.01
(0.3)0.18
otherwise noted.
: Values in parentheses represent the concentrations used to
standards for the various levels of treatment.

average values or p
redicted average p
erformance
All other
levels.
C.47
1.05
BAT-3
NSPS-4
PSES-4
PSNS-4
70
6-9
(103)45
20
(4)2.3
-
(25)22
0.01
0.03
0.15
0.08
2.1
0.01
0.01
0.05
0.04
0.05
0.01
0.15
0.02
(5)4
(0.25)0.08
0.015
0.01
(0.3)0.08
0.55
1.13
BAT-4
HSPS-5
PSES-5
PSNS-5
70
6-9
(10)6
20
(0.1)0.015
(0.5)0.05
(25)22
0.01
0.02
0.02
0.08
0.01
0.01
0.01
0.05
0.04
0.05
0.01
0.15
0.02
(1)0.03
(0.25)0.08
0.015
0.01
(0.3)0.08
0.69
1.27
BAT- 5
SSPS-6
PSES-6
PSKS-6
70
6-9
(10)6
20
(0.1)0.015
(0.5)0.05
(15)10
C.01
0.02
0.02
0.01
0.01
0.01
0.01
0.01
0.04
0.05
0.01
0.15
0.02
(1)0.03
(0.25)0.08
0.01
0.01
(0.3)0.02
0.85
1.44
BAT-6
HSPS-?
PSES-7
PSNS-7
0
_
-
-
-
-
-
—
.
_
_
_
-
-
_
_
-
_
.
_
-
_
_
_
-

develop the limitations/
values represent long tern





*   Toxic pollutant  found in all raw waste samples.
(1) Wastewaters  from ironmaking operations are disposed of by evaporation on slag.
(2) Credits  for  recovery of ironmaking wastewater sludges are included.
                                                      406

-------
                                    SUMURY OF EFFLUEHT LOADINGS AND TREATMEHT COSTS
                                                            . SUBCATECORY
DIRECT DISCHARGEES
SOBCATECORY LOAD SDtMAJtY
(TOSS/YEAR)
Floy (MUD)
Aaaxroia (M)
Cyanide (Total)
Fluoride
Phenol t (4AAP)
Residual Chlorine
Total Suspended Solid*
Total Toxic Metals
Total Organiea
SOBCATECORY COST SUMMARY* 3>
($XIO~*)
Investswnt
Annual
RAW
KASTE
825.6
25,147. 2
13,088.3
18,860.4
3,772.1
-
2,388,979.8
33,382.8
201.2


_
~

•FT BAT-1
29.2 0
2.672.8 -
178.2
2,004.6 -
102.5
-
1.871.0 -
77.)
7.1


434,74 7.28
55.27'*' 1.02

BAT-2
16.4
1.621.5
99.8
997.8
57.4
-
249.5
18.1
4.0


11.28
1.49

BAT-3
16.4
1,621.5
99.8
498.9
57.4
.
548.8
11.4
4.0


14.80
2.26

(AT-4
16.4
J49.7
0.7
498.9
0.4
1.-4.
548.8
11.4
4.0


30.84
9.04
IHPIRECT (POTW) DISCHARGERS
SUBCATECORY LOAD SUMMARY
(TONS/YEAR)
FlcM (MOD)
As»onia (N)
Cyanide (Total)
Fluoride
Phenol • (4AAP)
Total Suspended Solids
Total Toxic Metals
Total Organics1 '
SOBCATECORY COST SUMMARY
($X10~*>
lnvest»ent
Annual
(1) The raw waste load and BPT
are included in the direct
RAW
BASTE
38.4
1,169.6
701.8
877.2
175.4
111,115.3
1,552.7
9.4


..

cost contribution! of
discharger data. As

KES-1 FSES-2
1.5 0
137.1
9.1
102.8
5.3
95.9
4.0
0.4


12.92 0.23
2.13* ' 0.033
th« xero discharge

FSES-3
0.8
83.2
5.1
51.2
2.9
12.8
0.9
0.2


0.39
0.052
operations

PSES-4
0.8
83.2
5.1
25.6
2.9
28.1
0.6
0.2


0.45
0.064


PSES-5
0.8
7.7
0.04
25.6
0.02
28.1
0.6
0.2


0.95
0.30

these plants hev* no wastewster
     discharge,  they do not  contribute  to  BAT  costs or to the EPT and BAT effluent
     waste loads.
(2)  Individual  phenolic compounds  (e.g.,  2,4-dinilrcpheaol, pentaehlorophenol)
     are not included in total  organics.
(3)  The cost susaury totals do not  include  confidential plants.
(4>  A credit for  recovery of sludges  in sinter  plants has been applied for those
     irorasaking  operations which have  sintering  operations on-site or available
     for use.
                                                                                                        BAT-5

                                                                                                        16.4

                                                                                                        149.7
                                                                                                        0.7
                                                                                                        498.9
                                                                                                        0.4
                                                                                                        1.2
                                                                                                        249.5
                                                                                                        9.7
                                                                                                        1.2
                                                                                                        123.09
                                                                                                        21.03
                                                                                                        FSES-«

                                                                                                        0.8

                                                                                                        7.7
                                                                                                        0.04
                                                                                                        25.6
                                                                                                        0.02
                                                                                                        12.8
                                                                                                        0.5
                                                                                                        0.06
                                                                                                        4.15
                                                                                                        0.71
BAT-6

0
171.64
35.06
                                                                                                                  FSES-7
5.97
1.22
                                                          407

-------
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                            411

-------
                         SUBCATECORY StMUKT DATA
                           BASIS 7/1/7B POUAK5
SUBCATECORY:  Staelaaking
           I  B«»ic Oxygen Furnace
           I  Semi-Wei
HAW WASTE FLOWS	

Model Plant                   1.9 MCD
 8   Direct Diichargert      15.3 MOD
 0   Indirect Diicharger      0.0 MOD
 1   Zero Discharger          0.0 MOD
 9   Active Plant*           15.3 MOD
MODEL SIZE (TPD)t  5300
OPEK. DATS/YEAR :   365
TU8BS/DAT       t     3
MODEL COSTS ($X)0'3)
Investment
Annual
S/Ton of Production
WASTEWATER
CHARACTERISTICS
          BPT/BCT
          BAT/PSES

          590
          100
          0.052
     Flow (GPT)
     pH (SD)
     Fluoride
     Total Suspended Solidt
120  Copper*
122  Lead*
123  Mercury
128  Zinc*
Motet:  All concentrationa are in ng/1 unle*a otherviee noted.
      :  NSPS and PSNS are reserved.

* Toxic pollutant found in all raw waate aaatple*.
                                              415

-------
                                      SUBCATEGORY SUMMARY DATA
                                         BASIS 7/1/78 DOLLARS
   SUBCATEGORY:
              :
              :
Steelmaking
Basic Oxygen Furnace
Vet-Suppressed Combustion
MODEL SIZE (TPD):  7400
OPER. DAYS/YEAR :   365
TURNS/DAY       :     3
   RAW WASTE FLOWS
   Model Plant                 7.4 MGD
v    5   Direct Dischargers    37.0 MGD
    1   Indirect Discharger    7.4 MGD
    6   Active Plan1.:         44.4 MGD


   MODEL COSTS ($X10~3)	

   Investment.
   Annua1
   S/Ton of Production
   Investment
   Annual           %
   $/Ton of Production
   WASTEWATER
   CHARACTERISTICS	

        Flow (GPT)
        pH (SU)
        Fluoride
        Total Suspended Solids

   118  Cadmium
   119  Chromium
   120  Copper*
   122  Lead*
   124  Nickel*
   126  Silver
   128  Zinc*












RAW
WASTE
1000
7-12
15
720
0.06
0.6
0.15
8
0.3
0.02
6.8
BPT
PSES-1
3170
846
0.31

PSNS-1
3122
836
0.31

BPT
PSES-1
PSNS-1
50
6-9
15
BAT-1
PSES-2
247
33.0
0.012
NSPS-1
PSKS-2
3417
879
0.33
BAT-1
NSPS-1
PSES-2
PSSS-2
50
6-9
15
(50)36 (15)10
0.01
0.1
0.15
0.5 (0.
0.3
0.02
0.7 (0.
0.01
0.1
0.1
BAT-2
PSES-3
308
42.9
0.016
NSPS-2
PSNS-3
3478
889
0.33
BAT-:
NSPS-2
PSES-3
PSNS-3
50
6-9
15
(25)22
0.01
0.05
0.05
BAT-3
PSES-4
4082
817
0.30
NSPS-3
PSNS-4
7204
1653
0.61
BAT-3
NSPS-3
PSES-i
PSNS-4
0
-
-
-
_
-
-
5)0.4 (0.3)0.2
0.25
0.02
0.15
0.02
-
-
5)0.4 (0.45)0.4
   Notes:  All concentrations are in mg/1 unless otherwise noted.
        :  BAT and PSES-2 through PSES-4 costs are incremental over BPT/PSES-1 costs.
        :  Values in parentheses represent the concentrations used
           to develop the limitations/standards for the various levels
           of treatment.  All other values represent long term average
           values or predicted average performance levels.

   * Toxic pollutant found in all raw vaste samples.
                                                        416

-------
                                     SUBCATEGOF.Y SUMMARY DATA
                                       BASIS V/l/78 DOLLARS
SUBCATEGORY:  Steelmaking
           :  Basic Oxygen Furnace
           i  Wet-Open Combustion
MODEL SIZE (TPD):  9100
OPER. DAYS/YEAR :   365
TURNS/DAY       :     3
RAW WASTE FLOWS
Model Plant                 10.0 MCD
13   Direct Dischargers    130.1 MGD
 1   Indirect Discharger    10.0 MGD
14   Active Plants         140.1 MGD
MODEL COSTS ($X10~3)

Investment
Annual
$/Ton of Production
Investment
Annual
$/Ton of Production
WASTEWATER
CHARACTERISTICS	

     Flow (CPT)
     pH (SU)
     Fluoride
     Total Suspended Solids
23
115
118
119
120
122
123
124
125
126
127
128
Notes
Chloroform
Arsenic*
Cadmium
Chromium*
Copper*
Lead*
Mercury
Nickel
Selenium
Silver
Thallium
Zinc*
: All conceni
: BAT ar. : PS1












RAW
WASTE
1,100
8-11
20
4,200
0.05
0.06
0.4
5.2
1
3.9
0.02
0.4
0.02
0.08
0.03
14
BPT
PSES-1
4,738
1,102
0.33

PSNS-1
4,617
1,076
0.32

BPT
PSES-1
PSNS-1
110
6-9
20
(50)38
0.05
0.06
0.01
0.1
0.15
0.5 (0
0.001
0.3
0.02
0.01
0.03
0.7 (0
BAT-1
PSES-2
539
74.8
0.023
NSPS-1
PSNS-2
5,277
1,177
0.36
BAT-1
NSPS-1
PSES-2
PSNS-2
110
6-9
20
(15)10
0.05
0.06
0.01
0.1
0.1
.5)0.4 (0
0.001
0.25
0.02
0.01
0.03
.5)0.4 (0.
BAT-2
PSES-3
474
69.6
0.021
NSPS-2
PSNS-3
5,212
1,172
0.35
BAT-2
NSPS-2
PSES-3
PSNS-3
110
6-9
20
(25)22
0.05
0.06
0.01
0.05
0.05
.3)0.2
0.001
0.15
0.02
0.01
0.03
45)0.4
BAT-3
PSES-4
7,549
1,774
0.53
NSPS-3
PSNS-4
12,166
2,850
0.86
BAT-3
NSPS-3
PSES-4
PSNS-4
0
-
-
-
_
-
-
-
-
-
-
-
-
-
-
-
        All concentrations are in mg/1 unless otherwise noted.
                PSES-2 through PSES-4 costs art; incremental over BPT/PSES-1 costs.
     :  Values in parentheses represent the concentrations used
        to develop the limitations/standards for the various levels
        of treatment.  All other values represent long tern average
        values or predicted average performance levels.

  Toxic pollutant found in all raw waste samples.

                                                     417

-------
                                    StmCATECOtT SUMMARY DATA
                                      BASIS 7/1/78 DOLLARS
SUBCATECORY:
              Steeloaking
              Open Hearth
              Wet
MODEL SIZE (17D):  6700
OPER. DAYS/TEAR :   365
TORUS/DAT       I     3
RAW WASTE FLOWS
Model Plant                 11.4 HGD
 4   Direct Discharger!     45.6 MOD
 0   Indirect Discharger     0 0 MGD
 4   Active Plant*          45.6 MGD
MODEL COSTS ($XIO~3)
Investment
Annual
$/Ton of Production
BPT
PSES-1
4531
957
0.39
BAT-1
PSES-2
521
70.8
0.029
BAT-2
PSES-3
452
72.1
0.029
BAT-3
PSES-4
6336
1404
0.57
WASTEWATER
CHARACTERISTICS
     Flou
     pH (SU)
     Fluoride
     Totul Suspended Solids
120  Copper*
122  Lead*
126  Zinc*
RAW
WASTE
1700
3-7
150
1700
1.4
2.8
140
BPT
BAT-1 BAT-2
PSES-1 PSES-2 PSES-3
110
6-9
140
(50)40
0.05
1.5
4.4
110 110
6-9 6-9
140 20
(15)10 (25)22
0.4 0.05
(0.35)0.3 (0.3)0.2
(5.0)4.4 (0.45)0.4
BAT-3
PSES-4
0
-
-
-
_
_
-
Notes:  All concentrations are in ng/1 unless otherwise noted.
      :  BAT and PSES-2 through PSES-4 costs are incremental over BPT and PSES-1 costs.
      t  NSPS and PSNS are reserved.
      t  Values in parentheses represent the concentrations used
        to develop the limitations/standards for the various levels
        of treataent.  All other values represent long Lerm average
        values or predicted average performance levels.

* Toxic pollutant found in all rav waste staple*.
                                                  418


-------
                                            SUBCATEGORY SUMMARY DATA
                                              BASIS 7/1/78 DOLLARS
                SUBCATEGORY:
Steelmaking
Electric Arc Furnace
Semi-Wet
MODEL SIZE (TPD):  3100
OPER. DAYS/YEAR :   365
TURNS/DAY       :     3
                RAW WASTE FLOWS
Model Plant
2 Direct Dischargers
0 Indirect Discharger
1 Zero Discharge
3 Active Plants
0.5 MGD
0.9 MGD
0 MGD
0.5 MGD
1.4 MGD
                MODEL COSTS ($X10~3)
                Investment
                Annual
                $/Ton of Production

                WASTEWATER
                CHARACTERISTICS
                                       BPT/BCT
                                       BAT/PSES

                                       368
                                       79.2
                                       0.070
                      Flow  (GPT)
                      pH  (SU)
                      Fluoride
                      Total Suspended Solids
                 120   Copper*
                 122   Lead*
                 128   Zinc*
                             RAW
                             WASTE

                             150
                             6-9
                             30
                             2200

                             2.4
                             33
                             120
                Notes:  All concentrations are in mg/1 unless otherwise noted.
                      :  NSPS and PSNS are reserved.

                * Toxic pollutant found  in all raw waste samples.
                                                     419
i

-------
                                      SUBCATEGORY SUMMARY DATA
                                        BASflS 7/1/78 DOLLARS
SUBCATEGORY:  Steelmaking
           :  Electric Arc Furnace
           :  Wet
MODEL SIZE (TPD):  1800
OPER. DAYS/YEAR  :   365
TURNS/DAY        :     3
RAW WASTE FLOWS
Model Plant                 3.8 HOT
 6   Direct Dischargers    22.7 MGD
 1   Indirect Discharger    3.8 MOD
 7   Active Plants         26.5 MOD
MODEL COSTS ($X10~3)

Investment
Annual
S/Ton of Production
Investment
Annual
$/Ton of Production
WASTEWATER
CHARACTERISTICS	

     Flow (GPT)
     pH (SU)
     Fluoride
     Total Suspended Solids

 39  Fluoranthene
 58  4-Nitrophenol
 66  Pentachlorophenol
114  Antimony*
115  Arsenic*
118  Cadmium*
119  Chromium*
120  Copper*
122  Lead*
124  Nickel*
126  Silver*
128  Zinc*












RAW
WASTE
2100
6-9
40
3400
0.02
0.01
0.01
0.7
1.2
3.3
4.3
1.3
23
O.OS
0.06
100
BPT
PSES-1
2268
596
0.91

PSNS-1
2268
596
0.91

BPT
PSES-t
PSNS-1
110
6-9
35
(50)47
0.02
0.01
0.01
0.7
0.01
1.5
2
0.15
1.5
0.05
0.06
20
BAT-1
PSES-2
162
21.5
0.033
KSPS-1
PSNS-2
2430
617
0.94
BAT-1
NSPS-1
PSES-2
PSNS-2
110
6-9
35
BAT-2
PSES-3
242
35.5
0.054
NSPS-2
PSNS-3
2510
631
0.96
BAT-2
NSPS-2
PSES-3
PSNS-3
110
6-9
20
BAT-3
PSES-4
2782
512
0.78
NSPS-3
PSNS-4
5049
1107
1.69
BAT-3
NSPS-3
PSES-4
PSNS-4
0
_
.
(15)10 (25)27.
0.02
0.01
0.01
0.7
0 01
l.'j
1.5
c 15
(1)0.95 (0
O.OS
0.06
(20)19 (0.
O.C2
0.01
0.01
0.5
0.01
0.1
1.3
0.1
.3)0.2
0.05
0.06
45)0.4
_
_
_
_
_
-
-
_
-
-
_
-
Notes:  All concentrations are in mg/1 unless otherwise noted.
      :  BAT and PSES-2 through PSES-4 costs are incremental over BPT/PSES-1 costs.
      :  Values in parentheses represent the concentrations used
        to develop the limitations/standards for the various levels
        of treatment.  All other v&lues represent long term average
        values or predicted average Derfo<-mance levels.

* Toxic pollutant found in all raw uaste samples.
                                                    420

-------
                     SUMMARY OF EFFLUENT LOADINGS AND TREATMENT COSTS
                                  STEELMAKING SUBCATEGORY     	
                                DIRECT DISCHARGERS
SOBCATEGORY LOAD SUMMARY
(TONS/YEAR) _

Flow (MGD)

Fluoride
Total Suspended Solids
Total Toxic Metals
Total Organics

SDBCATEGORY COST SUMMARY
(1)
Investment
Annual
RAW
WASTE
252.1
16,894.6
1,121,727.4
20,887.2
11.3
BPT
18.9
1,130.6
1,119.1
116.0
1.1
BAT-1
18.9
1,130.6
239.4
95.4
1.1
BAT-2
18.9
564.9
636.6
29.7
1.1
                      112.00
                      26.28
11.00
1.51
10.74
1.58
                                                             BAT-3
156.60
34.87
                                INDIRECT (POTV) DISCHARGERS

SOBCATEGORY LOAD SUMMARY        RAW
(TOSS/YEAR)	        WASTE         PSES-1       PSES-2       PSES-3       PSES-4

Flow (MGD)                      21.2          1.6          1.6          1.6          0

Fluoride                        704.2         49.6         49.6         45.0
Total Suspended Solids          91,715.8      92.4         23.8         52.5
Total Toxic Metals              1,333.2       11.7         10.0         2.8
Total Organics                  1.0           0.09         0.09         0.09

SUBCATEGORY COST SUMMARY
(SX10"6)	

Investment                      -             11.16        0.00         0.55         0.00
Annual                          -          '   2.79         0.00         0.071        0.00
(1)  The cost suamary totals do not include confidential plants.
                                         421

-------
                     SUMMARY OF EFFLUEOT LOADINGS AND TREATMENT COSTS
                                  STEELMAKING SUBCATEGORY
                              BASIC OXYGEN FURNACE - SEMI-WET	
                                                                 DIRECT DISCHARGERS
SUBCATEGORY LOAD SUMMARY                                         RAW
(TONS/YEAR)	                                         WASTE     BPT

Flow (MGD)                                                       15.3      0

Fluoride                                                         232.5
Total Suspended Solids                                           8,717.4
Total Toxic Metals                                               52.1
Total Organics

SUBCATECORY COST SUMMARY(1)
($X10"6)	
Investment                                                       -         4.31
Annual                                                           -         0.65
Note:  There are no indirect dischargers in this segment.

(1)  The cost sura&ary totals do not include confidential plants.
                                        422

-------
                     SUMMARY OF EFFLUENT LOADINGS AH9 TREATMENT COSTS
                                  STEELMAKING SUBCATECORY
                     BASIC OXYGEN FURNACE - WET-SUPPRESSED COH8USTIOH
                                             DIRECT DISCHARGERS
SUBCATEGORY LOAD SUMMARY
(TONS/YEAR)	

Flow (MGD)

Fluoride
Total Suspended Solids
Total Toxic Metals
Total Organic*

SUBCATEGORY COST SUMMARY
($X10~6)	

Investaent
Annual
RAW
WASTE
37.0
645.2
40,571.7
897.6
BPT
1.8
42.3
101.4
5.0
BAT-1
1.8
42.3
28.2
3.6
BAT-2
1.8
42.3
62.0
2.5
BAT-3
0
-
15.81
4.22
1.23
0.16
1.54
0.21
20.36
4.08
                                             INDIRECT (POTW) DISCHARGERS
SUBCATEGORY LOAD SUMMARY
(TOSS/YEAR)	

Flow (MGD)

Fluoride
Total Suspended Solid*
Total '.oxic Metals
Total Organic*

SUBCATEGORY COST SUMMARY
($X10~6)	

Investment
Annual
RAW
WASTE
7.4
169.0
8,114.3
179.5
PSES-1
0.4
8.5
20.3
1.0
PSES-2
0.4
8.5
5.6
0.7
psrr-s
0.4
8.5
12.4
0.5
PSES-4
0
-
3.06
0.82
0.00
0.00
0.00
0.00
0.00
0.00
                                         423

-------
                     SUMMARY OF EFFLUENT LOADINGS AND TREATMENT COSTS
                                  STEELMAKINC SUBCATEGORY
                        BASIC OXYGEN FURNACE - WET-OPEN COMBUSTION	
                                             DIRECT DISCHARGERS
SUBCATEGORY LOAD SUMMARY
(TONS/YEAR)	

FIou (MCD)

Fluoride
Total Suspended Solids
Total Toxic Metals
Total Organic*

SUBCATEGORY COST SUMMARY

(SX10"6)	

Investment
Annual
(1)
                     RAW
                     WASTE

                     130.1
BPT
                               13.0
                     3,963.7   396.4
                     832,369.1  753.1
                     4,976.4   37.3
                     9.9       1.0
                               58.62
                               13.64
          BAT-1

          13.0

          396.4
          198.2
          27.4
          1.0
          6.69
          0.93
BAT-2

13.0

396.4
436.0
19.4
1.0
5.88
0.86
BAT-3

0
93.59
22.00
                                             INDIRECT (POTW)  DISCHARGERS
SUBCATECORY LOAD SUMMARY
(TON'S/YEAR)	

Flow (MCD)

Fluoride
Total Suspended Solids
Total Toxic Metals
Total Organics

SUBCATECORY COST SUMMARY
(SX10"6)	

Investment
Annual
RAW
WASTE
10.0
304.9
64,028.4
382.8
0.8

PSES-1
1.0
30.5
57.9
2.9
0.08
                               5.37
                               1.25
                                         PSES-2

                                         1.0

                                         30.5
                                         15.2
                                         2.1
                                         0.08
          O.OC
          0.00
                    PSES-3

                    1.0

                    30.5
                    33.5
                    1.5
                    0.08
0.37
0.048
          PSES-4

          0
O.OC
0.00
(1)  The cost summary totals do not include confidential plants.

-------
                     SUMMARY OF EFFLUENT LOADINGS AND TREATMENT COSTS
                                  STEELKAKINC SUBCATECORY
                                     OPEN DEARTH  - WET
                                             DIRECT  DISCHARGERS
SUBCATECORY LOAD SUMMARY
(TONS/YEAR)	

Flow (MOD)

Fluoride
Total Suspended Solidt
Tola! Toxic Metal*
Total Organic!   •

SUBCATECORY COST SUMMARY

($X10"6)	

Investment
Arnu«l
RAW
WASTE

45.6
BPT

2.9
10,407.9  628.6
117,956.5 179.6
10,005.5  25.7
          17.78
          3.75
BAT-1

2.9

628.6
44.9
21.3
BAT-2

2.9

89.8
98.8
2.9
BAT-3

0
          2.05
          0.28
          1.77
          0.28
          24.89
          5.52
Note:  There are no indirect dischargers in this  subdivision.
                                        425
                                                                                                      y

-------
                      SUMMARY OF EFFLUENT LOADINGS AND TREATMENT COSTS
                                  STEELMAKING SUBGATECORY
                             ELECTRIC ARC FURNACE -  SEMI-WET
                                                                 DIRECT DISCHARGERS
SUBCATECORY LOAD SUMMARY
(TONS/YEAR)	

Flow (MCD)

Fluoride
Tola! Suspended Solid*
Total Toxic Metal*
Total Organic!

SUBCATECORY COST SUMMARY

;$X10"6)	

Investment.
Annual
RAW
WASTE

1.4

63.7
4,674.0
330.2
BPT
          1.00
          0.22
Note;  There are no indirect dischargers in this segment.
                                         426

-------
                     SUMMARY or EFFLi-Eirr LOADINGS AMD TREATMENT COSTS
                                  STEELMAKINC SUBCATECORY
                              ELECTRIC ARC FURNACE - WET
DIRECT DISCHARGERS
SOTCATECORY LOAD SUMMARY
(TONS/YEAR)
Flew (HOT)
Fluoride
Total SuspendedSolid*
Total Toxic Metal*
Total Organic!
RAW
WASTE
22.7
1.381.6
117,438.7
4,625.4
1.4

BPT
1.2
63.3
85. 0
47.0
0.07

BAT-1
J.2
63.3
18.1
43.1
0.07
                                                                            BAT-2

                                                                            1.2

                                                                            36.2
                                                                            39.8
                                                                            4.9
                                                                            0.07
                              BAT-3

                              0
SUBCATEGORY COST SUMMARY
Investment
Annual
SUBCATECORY LOAD SUMMARY
(TOK5/YEAR)	

Flow (MOD)

Fluoride
Total Suspended Solids
Total Toxic Metal*
Total Organic*
SUBCATECORY COST SUMMARY

<$X10~*>   	
Investment
Annual
-
IKDIRECT
RAW
WASTE
3.8
230.3
15,573.1
770.9
0.2
14.48
3.80
1.03
0.14
(POTW) DISCHARGERS
gSjM.,
0.2
10.6
14.2
7.8
0.01
PSES-2
0.2
10.6
3.0
7,2
0.0!
2.73
0.72
0.00
0.00
                    1.55
                    0.23
                    PSES-3
                    6.0
                    6,f>
                    0.8
                    0.01
0.18
0.023
                    17.76
                    3.27
0.00
0.22
                                         427

-------
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                                   429
                                                              Preceding page blank

-------
                                                              SUBCATEGORY SUMMARY DATA
                                                                BASIS  Hint DOLLARS
                            SUBCATEGORY:  Vacuum Degassing
                                       :  Carbon and Specialty
MODEL SIZE (TPD):  1200
OFER. DAYS/YEAR :   363
TURNS/DAY       i     3
                            RAW WASTE FLOWS
                            Model Plant                 1.7 MOD
                            31   Direct Dischargers    52.1 MOD
                             0   Indirect Dischargers   3.0 MOD
                             2   Zero Dischargers       3.4 MGD
                            33   Active Plants         55.5 KCD
                            MODEL COSTS ($X10~3)
                            Inves tment
                            Annual
                            $/Ton of Production
                            Investment
                            Annual
                            S/Ton of Production
                            WASTEWATER
                            CHARACTERISTICS
                                 Flow (GPT)
                                 pH (SU)
                                 Manganese
                                 Total Suspended Solids

                            119  Chromium*
                            120  Copper*
                            122  Lead*
                            124  Nickel
                            128  Zinc*


RAW
WASTE
1400
6-9
5
60
0.5
0.3
1
0.1
6
BPT BAT-1
PSES-1 PSES-2
1116 32.0
166 4.3
0.38 0.0098
SSPS-1 NSPS-2
PSHS-l PSNS-2
1116 1148
166 171
0.38 0.39
BPT BAT-1
NSPS-1 NSPS-2
PSES-1 PSES-2
PSNS-1 PSNS-2
25 25
6-9 6-9
5 5
(50)34 (15)10
BAT-2
PSES-3
124
17.3
0.039
HSPS-3
PSKS-3
1240
184
0.42
BAT-2
NSPS-3
PSES-3
PSNS-3
25
6-9
1
(25)22
ZAT-3
PSES-4
1479
201
0.46
HSPS-4
PSNS-4
2595
368
0.84
BAT-3
HSPS-4
PSES-4
PSNS-4
0
0.5 0.5 0.1
0.1 0.1 0.1
0.7 (0.7)0.7 (0.3)0.2
0.1 0.1 0.1
4.5 (4/5)4.5 (0.45)0.4
                            Notes:  All concentrations are in mg/1 unless otherwise noted.
                                 :  BAT, PSES-2 and PSES-4 costs are incremental over BPT/PSES-1 costs.
                                 :  Values in parentheses represent the concentrations used
                                    to develop the limitations/standards for the various levels
                                    of treatment.  All other values represent long term average
                                    values or predicted average performance levels.

                            * Toxic pollutant found in all raw waste samples.
L
                                                                             430

-------
                                          SUMMARY OF EFFLUENT LOADINGS  AND TREATMENT  COSTS
                                                   VACUUM DEGASSING SUBCATEGORY	
                                                                 DIRECT DISCHARGERS
                                                                                   (1)
                    SUBCATEGORY LOAD SUMMARY
                    (TONS/YEAR)	

                    Flow (MGD)

                    Manganese
                    Total Suspended Solids
                    Total Toxic Metals
                    Total Organics

                    SUBCATEGORY COST SUMMARY

                    ($X10~6)	

                    Investment
                    Annual
(2)
                     RAW
                     HASTE

                     55.4
BPT
0.9
                     422.2     7.1
                     5,066.0   48.2
                     667.0     8.4
                               27.90
                               4.10
BAT-1

0.9

7.1
14.2
8.4
          0.78
          0.10
BAT-2

0.9

1.4
31.2
1.3
          3.03
          0.42
                              BAT-3

                              0
          36.00
          4.90
                    Note:  There are no  indirect dischargers in this subcategory.

                    (1)  The raw waste load and BPT cost contributions of the zero discharge operations are
                         included  in fiis data.  However, as these plants have no wastewater discharges, they
                         do not contribute to RAT costs or  to  the BPT and BAT effluent waste lozds.
                    (2)  The cost  summary totals do not include confidential plants.
L
                                                               431

-------
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                                      o
                                                    433
                                                                                   Preceding page blank

-------
                         fi-
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-------
                                                        SUBCATEGORY SUMMARY DATA
                                                           BASIS  7/1/78  DOLLARS
                      SUBCATEGORY:   Continuous  Cueing
                        MODEL SIZE (TPD):   1400
                        OPER. DAYS/YEAR :    365
                        TURKS/DAY       :      3
                      RAW WASTE FLOWS
                      Model Plant                   4.8 MGD
                      25   Direct Discharger*      119.0 MGD
                       7   Indirect Dischargers    33.3 MGD
                      17   Zero Dischargers        80.9 MGD
                      49   Active Plants          233.2 MGD
                      MODLI. COSTS ($X10~3)
          BPT
          PSES-1
BAT-1
PSES--2
BAT-2
PSES-3
BAT-3
PSES-4
                      Investment
                      Annual
                      $/Ton of Production
                      Investment
                      Annual
                      $/Ton of Production
                      WASTE WATER
                      CHARACTERISTICS
                           Plow (GPT)
                           pH (SU)
                           Oil and Grease
                           Total Suspended Solids

                      119  Chromium
                      120  Copper
                      122  Lead
                      125  Selenium
                      128  Zinc



RAW
WASTE
2304
356
0.70


BPT
PSES-1
35.4
4.8
0.0094
HSPS-1
PSKS-1
3442
499
0.98
BAT-1
KSPS-1
PSES-2
PSNS-1
124
17.3
0.034
NSPS-2
PSNS-2
3566
516
1.01
BAT-2
NSPS-2
PSES-3
PSNS-2
1581
219
0.43
KSPS-3
PSMS-3
5023
718
1.40
BAT-3
RSPS-3
PSES-4
PSNS-3
3400      125       25        25
6-9       6-9       6-9       6-9
25    (15)10   (5**)I.O   (10)4.4
60    (50)40    (15)9.8   (25)22

0.65      0.65      0.65      0.65
0.11      0.11      0.11      0.1
0.08      0.08 (0.1)0.08 (0.3)0.08
0.08      0.08      0.08      0.08
0.7       0.7  (0.7)0.7 (0.45)0.4
                      Holes:   All concentrations are in Eg/1 unless otherwise noted.
                           i   BAT and  PSES-2 through PSES-4 costs are incremental  over BPT/PSES-1  costs.
                           :   Values in parentheses represent the concentrations  used
                              to develop the limitations/standards for the various  levels
                              of treatment.  All other values represent long term
                              average values or predicted average performance levels.

                      "Limit for oil and grease is based upon 10 rag/1 (maximum only).
                                                                     435
L

-------
                      SUMMARY OF EFFLUENT LOADINGS AND TREATMENT COSTS
                      	 CONTINUOUS CASTING SUBCATECORY	
                                  DIRECT DISCHARGERS
                                                    (1)
SUBCATEGORY LOAD SUMMARY
(TONS/YEAR)	

Flow (MGD)

Oil and Grease
Total Suspended Solids
Tolal Toxic Metals
Total Organics

SUBCATEGORY COST SUMMARY

($X10~6)	

Investment
Annual
(2)
          RAW
          WASTE

          199.9

          7,611.8
          18,268.2
          493.2
BPT

4.4

66.6
266.5
10.8
                      64.39
                      9.38
             0.88
             0.12
             BAT-2

             0.9

             5.9
             29.3
             1.7
             3.05
             0.42
             BAT-3

             0
             39.75
             5.50
                                  INDIRECT (POTW) DISCHARGERS
SUBCATEGORY LOAD SUMMARY
(TONS/YEAR)	

Flow (MGD)

Oil and Grease
Total Suspended Solids
Total Toxic Metals
Total Organics
          RAW
          WASTE
          33.3

          1,268.6
          3,044.7
          82.2
PSES-l

1.2

18.7
74.6
3.0
PSES-2

0.2

0.7
3.7
0.6
PSES-3

0.2

1.6
8.2
0.5
SUBCATEGORY COST SUMMARY

($X10~6)
Investnent
Annual
                      8.90
                      1.33
             0.14
             0.02
             0.77
             0.09
             8.54
             1.18
(1)  The raw waste load and BPT cost contributions  of the  zero discharge  operations  are
     included in the direct discharger data.   As  these plants  have  no wastewater  discharges,
     they do not contribute to BAT costs  or to the  BPT and BAT effluent waste  loads.

(2)  The cost summary totals do not include confidential plants.
                                        436
                                                                                                         I

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                                                    438

-------

                                  SUBCATECORY SUMMARY DATA
                                    BASIS 7/1/76 DOLLARS
SUBCATEGORYs  Hoi Forming
           <  All Subdivisions
RAW WASTE PLOWS
227  Direct Dischargers
 18  Indirect Dischsrgers
  9  Zero Dischargers
262  Active Plants
WASTE WATER
CHARACTERISTICS
3,594.6 MCO
  294.5 MOT
   85.2 HOT
3,976.3 MOD
     pH (SU)
     Oil and Creese
     Total Suspended Solids

119  Chromium
120  Copper
122  Lead
124  Nickel
128  Zinc
             RAW
             WASTE
BAT-1
BPT
BCT
PSES-1
BAT-2
KSPS-1
PSES-2
PSNS-1
HSPS-2
PSES-3
PSNS-2
             6-9          6-9
             30-130  (5**)2.0
             790-3300 (15)9.8
            6-9
       (5*")2.0
        (15)9.8
             <0.05-12
              0.3-20
             <0.05-11
              0.8-20
              0.6-5.4
0.001 (0.10)0.001
0.011       0.011
0.007 (0.10)0.007
0.006       0.006
0.049 (0.15)0.049
Notes:  All concentrations arc in mg/1 unless otherwise noted.
      s  Values in parentheses represent the concentrations used
        to develop the limitations (or the various levels of
        treataent.  All other values represent long tens
        average values or predicted average performance levels.

**Limil for oil and grease is based upon 10 mg/l (maximum only).
                                        431

-------
                                             SimcATECORY SUMMARY DATA
                                               EASIS 111 IT. DOLLARS
SUBCATECORYt  Hot forming
           t  Primary
           I  Carbon With Scarfan
                        HODCL SIZE Cm):   7400
                        OPCII. DAYS/YEAS :    260
                                        >      3
HAW WASTE FLOWS
Model Pl.nl                  25.2 HCD
JO   Direct Bitcharger*     7S4.8 HCD
 2   Indirect Ditcharger*    SO.] HCD
12   Acliv* Plann          (05.1 HCD
MODEL COSTS ($Xlp'3)

Investment
Annual
S/Ton of Production
         BPT
         »CT
         PSES-l

         4863
        -498
        -0.36
            IAT-1
            fSES-2
                                                                            SAT- 2
                       10132
                       1934
                       1.01
         WM-1
         PSltS-1
         5568
        -SS6
UASTEUATER
CHARACTERISTICS
     flow (CPT)
     pH (SU)
     Oil and Grata*
     Total Suspended Solid*
119  Chroauua
120  Copper
122  Lead
124  Nickel
128  Zinc
RAW
WASTE
»PT
»CT
PSE5-I
3400     1326        140
6-9      6-9         6-9
56  (5«)2.0    (5«)2.0
3000 (15)9.8     (15)9.8
1.3      0.001 (0.10)0.001
S.7      0.011       0.011
6.S      0.007 (0.1010.007
S.7      0.006       0.006
3.1      0.049 (0.15)0.049
BAT-2
KSPS-2
P«S-3
PSHS-2
MottfI  All concentration* are in •£/! ualeaa otherviee noted.
     1  BAT, PSU-2 and PSCS-3 coda art incremental over BPT/PSES-) coati.
     I  Valuea in parentheaet repreaent the concentration* uaed
        to develop the 1 i«utationa/aiandardt for the vanou* level*
        of treatment.  All other value* repreient loot term averaft
        value* or predicted averAge perfonaance level*.
**Lietit for oil and greaie ia baaed vpon 10 •(/! (•axil
                                                          only).
                                                          440

-------
1
                                                                                    DATA
                                                                  BASIS 7/1/78 POUAK5
                   SUBCATlCOtY;   Hoi  forcing
                              I   Primary
                              I   Carbon Without  Scarfen
                   HAW WASTt FU)MS	__

                   Model Plant                    1.7 HO)
                   30   Direct  Dtachargera      2(2.2 MCD
                    2   Indirect  Di«ch«rger«     17.5 MCC
                    1   Zero OUcharger          S.7 HCD
                   33   Active  Plaata           288.4 HO.
  MOKL SJZt (T?D)i   3*00
  OfIt. DAYS/YEA*. I    240
  TURNS/DAY       I      3
                   MQDtL COSTS
                   Invetlvent
                   Ann we 1
                   I/Ton of Production
MT-1
rSE5-

1240
1M
0.19
                                                                                               IAT-2
                                                                                               MI7
                                                                                              0.89
2S61
4&
0.05
itsrs-j
fSKS-2

6816
746
0.76
                   UASTTWATJH
                   CHAIlACTtSISTICS
                        Flow (CPT)
                        pH (SU)
                        Oil p«a4e4 Solid!

                   119  Chroeuw
                   120  Copper
                   122  Le*d
                   124  Nickel
                   128  Ztnc

BPT
(AW tCT
UASIt PSES-1
2300 897
t-9 6-9
»5 (5«*)2.0
2200 (15)9.8
1.9 0.001
11 0.011
7.5 0.007
4.6 0.006
4.0 0.049
»AT-1
XSPS-1
pses-2
PSKS-l
90
6-9
(5«*)2.0
(15)9.8
(0.10)0.001
0.011
(0.10)0.007
O.OO4
(0.15)0.049
1AT-2
HSPS-2
P-.CS-3
FSHS-2
0
_
-
-
fc
-
-
.
-
                   Koteti   All  concentration*  ere in •$/!  unleea  otherwite  noted.
                        !   (AT.  PSES-} «nil  for  oil  and (reaie  ii  baaed upon  10  Bf/1  (eomvja  only).
                                                                            441
                                                                                                                                                    L-1

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                                             SOT CATEGORY SIMtUtY DAT*
                                               BASIS 7/1/78 PQtlAjtS
SWCATZGOM:  Hoi forcing
           I  Primary
           I  Spacialty With Scarfara
»w HASTE nom	

Ho4al Mint                   6.3 HCD
 5   biract Diachargart      31.* MOD
 0   Indirect Diachargara     0.0 HCO
 5   Active Mania           31.4 HCD
                                                                   MOOD. SIZE (TTO)t  1850
                                                                   OTCI. nm.'TCAt I   260
                                                                                   I     1

MOPtl COSTS (IXIO*3)

Itmtimml
Annual
l/Toa ol Producttoo
UASTtUATtl
guRACTtllSTICS
          (crr>

     Oil and Craaaa
     Total Suapandad Selida
                                            IAU
                                            WASTE
                                            3*00     132*        140
                                            6-«      *-»         »-»
                                            H  (5««)2.0    (5»«)2.0
                                            3000 (!})«.*     US>«.t
1022
111
0.31
UT-1
mrc-i
nu-2
fSW-l
4243
703
1.46
iAT-J
itsrs-2
rsu-3
f5»i-2
2610
27. (
0.0*




lit  Chroatu
120  Coprtr
122  Ua4
124  Rickal
I2S  Zinc
                                            12
                                            20
                                            :.§
                                            12
                                            4.1
0.001 (0.10)0.001
0.001       0.001
0.007 (0.10)0.007
0.006       O.OOt
0.04* (0.12)0.04*
                                                                                              IBI'S-2
                                                                                              rsiis-2
                                                                                               U32
Nol«*l  AM conctntral iona ar« in •«/! imlcaa othcrwii* noted.
      i  1AT, rstS-2 and rtES-3 co«l« ara incraawntal over tPT/MtS-1 coat*.
      I  Valuai in ktranthaaaa rapraaant in* coneanlrationa utad
        la davalo^ lha liaitalioni/itandardi lor tha varioua Savala
        of Iraaiatant.  All othar valuaa rapraaant long lan§ avaraga
        valuaa or pradictad avaraga parformanca la*ala.
••Limit for oil and graata ia baaad upon 10 «i/l (MH
                                                          only).
                                                            442

-------
                                                         swtutt SAT*
                                               »AMS 7/1/76
SUICATEOOIT:  Hoi fcr»i«t
           1  trim**}
                        Without Scarfara
                                                                         tizi cm»i  1100
                                                                         Mtt/TCAt I   2W
                                                                   TVUS/MT       :     3
SAW WASTI
Mod<
11
I
1
14
il Plant
Direct Ditcharfert
Indirect. Ditcharaara
Zaro Ditcharger
Active Maait
2.1 NCO
30.4 NO>
i.i HO)
2.t HCD
31.7 HO)
MOPtL COSTS (SKIP'3)
Annual
(/Ton cf Production
                                                                           BSM-l   MSPt-2
                                                                           1«04     4073
                                                                           13*      484
                                                                           0.4}     I. Si
                                                                            MT-J
UASTZUATC*
CHAKACTItlSTlCS
          (CPT)
     pH (S»)
     Oil <»4 Cre.i.
     Ton! Suip«n

11*  ChrovtuB
120  Copper
172  L««d
124  Miek«l
12(  Zinc
                                            HASTg

                                            2300     ««7

                                            «i  (J»«)J.O
                                            2200

                                           <0.05
                                            0.3
                                           -O.Oi
                                            I]
                                            l.t
                                                                BM-l
                                                                MtS-2
                                                                PSKS-1
0.001 (0.10)0.001
0.011       0.011
0.007 (0.10)0.007
0.00*       O.OOt
0.049 (O.I5)0.(X»
Hoteal  All concentration* are tn aig/l uftleaa olnerviae ^oted.
     I  (AT, PSES-2 and PStt-1 coata arc iKcraawntal  over  BfT,f-t£t-l  c»ata.
     I  Value* in parentheee* reprevetit th* cooca«tration* vied
        to develop the ItautatlotM/atandardi for the  varioui laveli
        of treatoent.  All other velvet rerretent  lout ten* averata
••Licit for oil and fraata it baled «po« 10 »j'l  (auxiiwB owl;).

-------
                                             SJJSCATECOM SUMMARY DATA
                                               tASIS 7/1/78 DOLLARS
SUBCATEGORY:  Hot Forcing
           :  Section
           !  Carbon
                                       MODEL SIZE  (TTD):  »50
                                       C?E». DAIS/TEAS  :   260
                                       TURKS/DAT        :     3
HAW WASTE FLOWS
Model Flint
48   Direct Discharger*
 7   Indirect Dischargers
 4   Zero Discharge*
59   Active Fltnts
MODEL COSTS ($X10~3)

Investment
Annual
S/Ton of Production
 15.6 MS
744.6 MO>
104.9 tea
 61. s tica
»i?.7 tea
                                                     MT
                                                     BCT
3S85
267
0.34
                                                BAT-2
                                                FSES-3
                                                1350
                                                1.70
                                                                                    MSPS-1
                                                                                    FSNS-1
                                                                                    327
                                                                                    0.41
vsrs-2
rsns-2

9894
1411
1.78
VASTEWATER
CHARACTERISTICS
     Flov (OPT)
     PR (SO)
     Oil and Crease
     Total Suspended Solids

119  Chroaiua
ISO  Copper
112  Lead
124  Nickel
128  Zinc
                                            HASTE
                         in
                         *CT
                         PSI5-1
                                            5100     11*2        200
                                            6-9      t-9         6-9
                                            38  (5**)I.O    (5**)2.0
                                            990  (1529.8     (15)9.8
                                            0.*
                                            1.9
                                            0.4
                                            1.3
                                            5.4
                         0.001 (0.10)0.001
                         0.011       0.011
                         0.007 (0.10)0.007
                         0.006       0.006
                         O.O49 (0.15)0.049
                                                                           BAT-I
                                                                           KSPS-2
                                                                           PSES-3
                                                                           PSSS-2
Notes:
        All  concentrations are in v$/l mless otb*rvise noted-
        BAT, PSES-2  and PSES-3 costs ar* iacresttctal over BPT/PSES-1 coats.
        Values  in parentheses r*prea«at ts* coocaat rat ions used
        to develop the lisiitatxaes/staadards for  -h« »«riou« levels
        of treatstent.  All otber x>al«c« represent lefts terv average
        values  or predicted av«ra$« s*«r£orstance levels.
         fo
                 nd gr
                                         10 «»
                                                         i only).
                                                               444

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r  r
i  !
i  i
                                                                   SUBCATEGORY SUMMARY DATA'
                                                                     BASIS 7/1/78 DOLLARS
                       SUBCATECORY:  Hoc Forming
                                  ;  Seccioo
                                  :  Specialty
                       MODEL SIZE  (IPD):
                       OPEB.
                       TURNS/DAT
                                 1200
                                  260
                                    3
                       RAW WASTE FLOWS
                       Model Plant                   3.8 MOT
                       17   Direct Dischargers      65.3 MGD
                        1   Indirect Dischargers      3.8 MOD
                        3   Zero Dischargers        11.5 KGD
                       21   Active Plants           80.6 HCD
                       MODEL COSTS (JXIO'3)

                       Investment
                       Annual
                       S/Ton of Production
                       HASTEWATER
                       CHARACTERISTICS	

                            Flow (OPT)
                            PH (SU)
                            Oil and Crease
                            Total Suspended Solids

                       119  Chromium
                       120  Copper
                       122  Lead
                       124  Nickel
                       128  Zinc

RAW
WA3TE
BPT
BCT
PSES-1
1525
94.0
0.30
BPT
BCT
PSES-1
BAT-1
PSES-2
815
117
0.38
BAT-1
NSPS-1
PSES-2
PSNS-1
BAT-2
PSES-3
3297
518
1.66
BAT-2
KSPS-2
PSES-3
PSSS-2
NSPS-1
PSNS-1
1891
150
0.48

KSPS-2
PSNS-2
*372
550
1.76

3200     1344        130
6-9      6-9        6-9
60  (5**)2.0    (5**)2.0
1600 (15)9.8     (15)9.8
0.8
2.9
3.2
6.3
1.4
0.001 (0.10)0.001
0.011       O.Cll
0.007 (0.10)0.007
0.006       0.006
0.049 (0.15)0.049
                       Notes:  All concentrations are in mg/1  unless otherwise noted.
                             :  BAT, PSES-2 and PSES-3 costs are  incremental over BPT/PSES-1 costs.
                             :  Values in parentheses represent the  concentrations used
                               to develop the limitations/standards for  the various  levels
                               of treatment.  All other values represent  long term average
                               values or predicted average performance  levels.
                       **Linit  for oil and grease is baaed upon 10 ag/1  (oaxii
              only).
I	„_
                                                                                   445

-------
                                                                        SUBCATECORY SUMMARY DATA
                                                                          BASIS 7/1/78 DOLLARS
                           SUBCATEGORY:   Hot Forming
                                      :   Flat
                                      :   Carbon Hot Strip tnd Sheet
                        KOi>EL SIZE (TPD):  7250
                        OPEJ. DAYS/YEAR I   260
                        T'JrtNS/DAY       :     3
                           RAW WASTE FLOWS
                           Model Plant                  46.4 MGD
                           30   Direct Dischargers    1392.0 MGD
                            2   Indirect Dischargers    92.8 MGD
                           32   Active Plants         1484.8 MGD
                           MODEL COSTS ($X10"3)

                           Investment
                           Annual
                           S/Ton of Production
                           UASTEWATER
                           CHARACTERISTICS
                                Flow (GPT)
                                pH (SU)
                                Oil and Crease
                                Total Suspended Solids

                           119  Chromium
                           120  Copper
                           122  Lead
                           124  Nickel
                           128  Zinc


RAW
WASTE
BPT
BCT
PSES-1
6589
270
0.14
BPT
BCT
PSES-1
BAT-1
PSES-2
3941
617
0.33
BAT-1
NSPS-1
PSES-2
PSNS-1
BAT- 2
PSES-3
182S3
3504
1.86
BAT-2
NSPS-2
PSES-3
PSNS-2
NSPS-l
PSNS-1
8314
585
0.31

NSPS-2
PSNS-2
22625
3472
1.84

6400     2560        260
6-9      6-9         6-9
30  (5**)2.0    (5**)2.0
790  (15)9.8     (15)9.8

1.8      0.001 (0.10)0.001
0.4      0.011       0.011
0.7      0.007 (0.10)0.007
0.8      0.006       0.006
1.3      0.049 (0.15)0.049
                           Notes:  All concentrations are in ng/1 unless otherwise noted.
                                :  BAT, PSES-2 and PSES-3 costs are incremental over BPT/PSES-1 coats.
                                :  Values in parentheses represent the concentrations used
                                   to develop the limitations/standards for the various levels
                                   of treatment..  All other values represent long tens average
                                   values or predicted average performance levels.

                           **Limit for oil and grease is baaed upon 10 mg/1 (maxiauai only).
L.

-------
                                             SOBCATECORY SDWUSY DATA
                                               BASIS 7/1/78 DOLLARS
smCATECOtY:  Bot fortune
           I  Flit
           i  Specialty Rot Strip and Sheet
                         MODEL SIZE (TFD):
                         OPER. DAYS/TEAK I
                         TURNS/DAY       J
                                   900
                                   260
                                     3
1AH HASTE riOVS
Model Plmt                   5.8 H0>
 7   Direct DUchargen      40.3 ma
 0   Indirect Discharger*     0.0 MOD
 7   Active FUati           40.3 MCD
      COSTS (mo'3)
In«*nent
A*M*1
S/ToB) of Production
          BPT
          BCT
          fSES-1

          1871
          174
          0.74
            BAT-1
            PSES-2

            1000
            148
            0.6)
SAT-J
FSES-3

4053
666
2.85
KSPS-1
PSKS-1

2318
246
1.05
RS?S-2
PSMS-2

5371
764
3.26
UftSTEUATER
CgAlACTEMSTICS
 RAW
 HASTE
BPT
BCT
PSES-1
     Floi. (CFT)
     p8 (SO)
     Oil *o4 CrcaM
     Totcl SiMpmdcd Solid*
11»  Chronioi
120  Copper
122  U*d
124  Nickel
12*  Zioc
 6400     2560        260
 6-9      6-9         6-9
 30  <5**>2.0    <5**)2.0
 790  (15)9.8     (15)9.8
 1.9
 0.3
<0.05
 3.4
 0.6
0.001 (0.10)0.001
0.011       0.011
0.007 (0.10)0.007
0.006       0.006
0.049 (0.15)0.049
BAT-2
KSPS-2
PSES-3
PSKS-2
        All cooeenirelion* «r« in •(/! onl*** otber*i*e noted.
        BAT, PSCS-2 and PSES-3 co*t* ere incrowntal o*er BPT/PSES-1 cod*.
        Value* in perenthett* r*pre*eni toe concentration* u*ed
        to develop the liait*tion*/*taadard* for tb* variou* level*
        of treataent.  All other value* represent too* ten averate
        value* or predicted aver*(* performance level*.

        for oil and grea*e i* baled upoo 13 •*./! duxinua only).
                                                             447

-------
                                              SUBCATECORY  SUMMARY DATA
                                                BASIS  7/1/78  DOLLARS
SUBCATEGORY:  Rot Forming
           I  Flat
           >  Specialty Plate
               MODEL SIZE (TPD):
               OPER. DAYS/YEAR :
               TURNS/DAY       :
                      1000
                       260
                         3
RAH WASTE FLOWS
Model Plant                   1.5 HCD
 5   Direct Dischargers       7.5 MCD
 0   Indirect Dischargers     0.0 MCD
 5   Active Plants            7.5 MCD
MODEL COSTS (jX10~3)

Investment
Annual
$/Ton of Production
BPT
BCT
PSES-

1112
53.6
0.20
BAT-1
P5ES-2

642
91.5
0.35
BAT-2
PSES-3

2588
370
1.62
NSPS-1
PSNS-1

1343
90.9
0.35
NSPS-2
PSNS-2

3289
370
1.42
UASTEWATER
CHARACTERISTICS
     Flow (OPT)
     pH (SU)
     Oil and Grease
     Total Suspended Solids

119  Chromium
120  Copper
122  Lead
124  Nickel
128  Zinc
BPT
RAW BCT
WASTE PSES-1
1500 600
6-9 6-9
130 (5**)2.0
3400 (15)9.8
2.9 0.001
5.1 0.011
11 0.007
20 0.006
1.9 0.049
BAT-1
NSPS-1
PSES-2
PSNS-1
60
6-9
(5**)2.0
(15)9.8
(0.10)0.001
0.011
(0.10)0.007
0.006
(0.15)0.049
BAT-2
NSPS-2
PSES-3
PSNS-2
0
Notes:  All concentrations are in ng/l unless otherwise noted.
     :  BAT, PSES-2 and PSES-3 costs are incremental over BPT/PSES-1 costs.
     :  Values in parentheses represent the concentrations used
        to develop the limitations/standards for the various levels
        of treatment.  All other values represent long term average
        values or predicted average performance levels.

**l»irait for oil and grease is baaed on 10 mg/1 (maximum only).

-------
                                             SUBCATECOSY SUMMARY DATA
                                             	BASIS  7/1/78 DOLLARS
SUBCATECORY:  Hoc Forming
           I  Flat
           t  Carbon Plate
                        MODEL SIZE  (TPD):
                        OFER.  DAYS/YEAK  :
                        TURKS/DAY        ;
                                  11 SO
                                   260
                                     3
RAW WASTE FLOWS
Kodel Plant                  10.7 MCD
11   Direct Discharger!     117.8 MCD
 1   Indirect Discharge™    10.7 MCD
12   Active Plant!          128.5 MGD
HODEL COSTS (SXIO"3)

Investment
Annual
S/Ton of Production
         BPT
         BCT
         PSES-1

         2619
         63.8
         0.08
                       BAT-2
                       PSES-3
                    KSPS-1
                    PSNS-1
UASTEWATER
CHARACTERISTICS
     Flow (CPT)
     pH (SU)
     Oil and Crease
     Total Suspended Solids

119  Chromiua
120  Copper
122  Lead
124  Nickel
128  Zinc
PAW
WASTE
BPT
BCT
PSES-1
BAT-1
NSPS-1
PSES-2
PSNS-1
3400     1360        140
6-9      t>-9         6-9
56  (5**)2.0    C5«)2.0
1500 (15)9.6     (15)9.8
1.3
4.9
2.1
3.9
1.8
0.001 (0.10)0.001
0.011       0.011
0.007 (0.10)0.007
0.006       0.006
0.049 (0.15)0.049
Motesi  All concentrations are in ng/1 unlest otherwise noted.
     :  BAT, PSES-2 and PSES-3 costs are incremental over BPT/PSES-1 rosts.
     :  Values  in parentheses represent the concentrations used
        to develop the Imitations/standards for the various levels
        of treatment.  All other values represent long tern average
        values  or predicted average performance levels.

"Limit for oil and grease is bssed upon 10 ng/1 (Baxiousi only).
                                                            44')

-------
                                              SUBCATECORY  SUMMARY DATA
                                                BASIS  7/1/7B  DOLLARS
8UBCATECOKY:  Hoc Porminj
           >  Pip* and Tub*
           I  Carbon
                        MODEL SIZE (TH>>>
                        OPER. DAYS/YEAH  :
                        TOMS/DAY       :
                                   900
                                   260
                                     3
RAW WASTE TUNS
Model Pilot                   5.C HCD
25   Direct Ditch*rt*rt     124.2 HCD
 1   Indirect Ditch*r|*rt   .  5.0 MCD
26   Active Plant*          129.2 HCD
MODEL COSTS (SXIO'1)

InvettMnt
Annual
S/Ton of Production
VASTEUATER
CHARACTERISTICS
     Plow
     pH (SU)
     Oil *nd Great*
     Total Suspended Solid*

119  ChroeUuB
120  Copper
122  Le*d
124  Nick*l
US  Zinc
RAW
WASTE
BAT-1
PSES-2
676
95.8
0.41
BAT-1
MSPS-1
PSES-2
PSNS-1
BAT-2
PSES-3
3470
562
2.40
BAT-2
NSPS-2
P8ES- 1
PSNS-2
RSPS-1
PSKS-1
U71
241
1.03

NSPS-2
PSNS-2
4664
7M
3.02

357.0     1270        220
6-9      6-9         6-9
56  (5**)2.0    (5**)2.0
1500 (15)9.a     (15)9.8
2.9
5.1
11
20
1.9
0.001 (0.10)0.001
0.011       C.011
0.007 (0.10)0.007
0.006       0.006
0.049 (0.15)0.049
Motet!  All concentration* *r« in •*./! unleu othervii* notid.
     I  BAT, PSES-2 *nd PSES-3 cetti *r< increMnt*! over BFT/fSES-l eo*t*.
     I  V*lu** in p*renthe*e* repretcnt the concentration* u**d
        to develop the li>it*tion*/*t*nd*rd* for the vtriout levtlt
        of trtttMDt.  All othtr value* represent long ten *v«rtf«
        value* or predicted *vera(* performance level*.

•*Li»it for oil and (real* ie bated upon 10 •»/! (atximm only).
                                                             450

-------
                                             SUBCATEGORY SUMMARY DATA
                                               BASIS  7/1/78 DOLLARS
SUBCATECORY:  Hoc Forming
           :  Pipe and Tube
           :  Specialty
                        MODEL  SIZE  CTPD):
                        OPER.  DAYS/YEAX ':
                        TURNS/DAY        :
                                   500
                                   260
                                     3
RAW WASTE FLOWS
Model Plane                   2.8 HGD
 8   Direct Discharger!      22.1 HGD
 0   Indirect Dischargers     0.0 HCD
 8   Active Planta           22.1 HCD
HODEL COSTS (SX10'3)

Investment
Annual
5/Ion of Production
UASTEWATER
CHARACTERISTICS
     Flow (GPT)
     pH (SU)
     Oil and Creaae
     Total Suspended Solid*

119  Chromium
120  Copper
122  Lead
124  Nickel
128  Zinc

RAW
WASTE
BPT
»CT
PSES-1
1264
125
0.95
BPT
BCT
PSES-1
BAT-1
PSES-2
642
91.5
0.70
BAT-1
NSPS-1
PSES-2
PSNS-1
BAT- 2
PSES-3
2911
440
3.38
BAT- 2
NSPS-2
PSES-3
PSNS-2
HSPS-1
PSNS-1
1544
167
1.29

NSPS-2
PSNS-2
3814
516
3.97

552D     1270        220
6-9      6-9         6-9
56  (5**)2.0    (5**)2.0
1500 (15)9.8     (15)9.8
0.2
0.9
2.1
1.3
1.7
0.001 (0.10)0.001
0.011       0.011
0.001 (0.10)0.007
0.006       0.006
0.049 (0.15)0.049
Notes:  All concentration* are in mg/1 unletc otherwise noted.
      I  BAT, PSES-2 and PSES-3 costs are increments! over BPT/PSES-1 costs.
      I  Values in parentheses represent the concentrations used
        to develop the limitations/standards for the various levels
        of treatment.  All other values represent long ttrm average
        values or predicted average performance levels.

••Limit for oil and grease is based upon 10 «g/l (maximum only).

-------
                     SUMMARY OF EFFLUENT LOADINGS AND TREATMENT COSTS
                                 HOT FORMING SUBCATEGORY  	
SUBCATEGORY LOAD SUMMARY
(TONS/YEAR)	

Flow (MGD)

Oil and Grease
Total Suspended Solids
Total Toxic Metals
Total Organics

SUBCATEGORY COST SUMMARY
(SX10~6)	

Investment
Annual
SUBCATEGORY LOAD SUMMARY
(TONS/YEAR)	

Flow (MGD)

Oil and Grease
Total Suspended Solids
Total Toxic Metals
Total Organics

SUBCATEGORY COST SUMMARY
($X10~6)	

Investment
Annual
(3)
(3)
                                                  DIRECT DISCHARGERS
                                                                    (I)
                                                     (2)
                          RAW
                          WASTE
BPT/BCT   BAT-1
                          3,679.9
                                                          BAT-2
1,418.5   145.2
                          174,540.2    3,077.6   314.5
                          5,878,201.0  15,081.0   1,540.8
                          49,460.4     113.9     11.6
                                       460.28
                                      -29.03
          279.24   1,454.59
          42.86    267.05
                                                  INDIRECT (POTW) DISCHARGERS
                          RAW
                          WASTE

                          294.5

                          13,776.7
                          444,155.8
                          3,504.5
PSES-1    PSES-2   PSES-3

124.7     11.9

355.2     25.7
1,337.6   125.6
9.2
                                       32.50
                                      -1.30
          0.9
          23.10
          3.68
108.61
19.26
(1)  The  raw  waste load and  BPT cost contribution* of  the zero discharge  operations  are
     included in the direct  discharger data.  As these plants have no wastewater discharges,
     they do not contribute to BAT costs or to the BPT and BAT effluent waste loads.
(2)  Rav  waste  loads   for  zero  discharge  plants  have  been  included  in  these  totals.
(3)  The cost sunsaary totals do not include confidential plants.
                                       •552

-------
                     SUMMARY OF EFFLUENT LOADINGS AND TREATMENT COSTS
                                   HOT FORMING - PRIMARY
                                   CARBON WITH SCARFERS           	
                                             DIRECT DISCHARGERS
                                                                                                         n
SUBCATEGORY LOAD SUMMARY
(TONS/YEAR) _

Flow (MGD)

Oil and Create
To Ml Suspended Solids
Total Toxic Metals
Total Organics

SUBCATECORY COST SUMMARY
Investment
Annual
RAW
WASTE
754.8
45,857.4
2,456,647.6
18,261.1
BPT/BCT
294.4
638.7
3,129.8
23.6
BAT-1
31.1
67.4
330.4
2.5
BAT-2
0
-
 97.23
-26.94
61.21
9.65
271.62
52.49
                                             INDIRECT (POTV)   DISCHARGERS
SOBCATECORY LOAD SUMMARY
(TONS/YEAR)	

Flow (MGD)

Oil and Great*
Total Suspended Solids
Total Toxic Metals
Total Organics

SUBCATECORY COST SUMMARY
($X10"6)	

Investoenl
Annual
RAW
WASTE
50.3
3,057.2
163,776.5
1,217.4
PSES-1
19.6
42.6
208.7
1.6
PSES-2
2.1
4.5
22.0
0.2
PSES-3
0
-
 4.36
-1.03
3.10
0.47
12.28
2.34
                                         453

-------
                     SUMMARY OF EFFLUENT LOADINGS AND TRF.ATMENT COSTS
                                   HOT FORMING - PRIMARY
                                 CARBOH WITHOUT SCARFERS	
                                             DIRECT DISCHARGERS
                                                               (1)
SUBCATECORY LOAD SUMMARY
(TONS/YEAR)	

Flow (MOD)

Oil and Grease
Total Suspended Solido
Total Toxic Metal•
Total Organict

StmCATECORY COST SUMMARY

(SKIP"*)	

Investoent
Annual
                                                (2)
O)
                     RAW
                     WASTE
                     270.9

                     24,985.1
                     646,674.2
                     8,524.3
BPT/BCT   BAT-!

102.3     10.3

221.9     22.3
1,087.2   109.1
8.2       0.8
                                     44.00
                                    -3.97
          25.10
          3.63
                                                         BAT-2

                                                         0
          120.77
          20.60
                                             INDIRECT (POTW) DISCHARGERS
SUBCATECORY LOAD SUMMARY
(TOSS/YEAR) __

Flow (MOT)

Oil and Crease
Total Suspended Solids
Total Toxic Metals
Total Organic*

SUBCATEGORY COST SUMMARY
(3)
Investment
Annual
                     RAW
                     WASTE
                     17.5

                     1,611.9
                     41,720.9
                     550.0
PSES-l

6.8

14.8
72.5
0.6
                                     J.64
                                     -0.29
PSES-2

0.7

1.5
7.3
0.05
          2.82
          0.42
                                                         PSZS-3
          14.50
          2.49
(!)  The  raw  waste load and  BPT cost contributions of  the  zero discharge operations  are
     included in the direct  discharger data.  As these plants  have no vasteuater discharges,
     they do not contribute to BAT costs or to the SPT and BAT effluent  waste  loads.
(2)  Raw  waste   loads   for  zero  discharge  plants  have  been  included in  these totals.
(3)  The cost sunnary totals do not include confidential  plants.
                                          454

-------
K-T!" ?^S
                                                                             iliinTfuaJrVif-
                                         SIM1ARY OF EFFLUENT LOADIKCS AMD TREATMENT COSTS
                                                      HOT FORMING -  PRIMARY
                                                	SPECIALTY WITH SCARPERS
                                                                DIRECT DISCHARGERS
                   SUBCATECORY LOAD SUMMARY
                   (TONS/YEAR)	

                   Flo*. (HOD)

                   Oil and Greii*
                   Told Su*p«nded Solid*
                   Total Toxic Meltls
                   Total Organic*

                   SUBCATECORY COST SUMMARY

                   (SX10"6)	

                   Invettaenl
                   Annual
RAW
WASTE
31.5
1,910.7
102,360.3
1,736.7
BPT/BCT
12.3
26.6
130.4
1.0
BAT-1
1.3
2.8
13.8
0.1
BAT-2
0
-
 6.74
-0.75
4.72
0.67
25.22
4.18
                   Hot*:  There ar* no indirect (PuTW) diicharger* in thi*
                                                           455

-------
                      SUMMARY OF  EFFLUEOT  LOADINGS AND TREATMENT COSTS
                                   HOT FORMIMC - PRIMARY
                                 SPECIALTY WITHOUT SCARTERS	
SUBCATECORY LOAD SUMMARY
(TONS/YEAR)	

Flow (MOD)

Oil and Crea»e
Tol»l Suipcnded Solid*
Total Toxic Metal*
Total Organics

SUBCATECORY COST SUMMARY
(SX10"6)	

Investment
Annual
(3)
                     DIRECT DISCHARGERS


                     RAV<2>
                     UASTE	
                                                               (1)
                     33.1

                     3,054.1
                     79,050.2
                     546.2
25.7
125.9
1.0
2.6
12.6
0.1
                                     7.25
                                    -0.15
          3.02
          0.36
                                             INDIRECT (POTW)  DISCHARGERS
                    BAT-2
          16.41
          2.42
SUBCATECORY LOAD SUMMARY
(TONS/YEAR)	

Flow (MOD)

Oil and Create
Total Suspended Solidi
Total Toxic Metal*
Total Organic*

SUBCATECORY COST SUMMARY
(SX10"6J	

Inveitaenl
Annual
(3)
                     RAW
                     WASTE
                     5.5

                     509.0
                     13,175.0
                     91.0
PSES-1

2.2

4.7
22.9
0.2
                                     0.97
                                    -0.03
PSES-2

0.2

0.5
2.3
0.02
                                                         PSES-3
          0
          0.14
          5.44
          0.67
(1)  The raw  watte load  and  BPT cost  contribution*  of the  zero discharge operation  are
     included in the  direct  discharger  data.   A* thit  plant  ha* no wasteualer discharge,
     it doe* not contribute to BAT cost* or to the BPT and  BAT effluent «a*le  loads.
(2)  Raw uasle   load*  for  tero  discharge plant*  have  been  included  in  the*e totals.
(3)  The coat summary total* do not  include confidential plant*.

-------
                      SUMMAIY or IFFLUEKT LOADINGS ABO TRZATMEST COSTS
                                   HOT rORMINC - SECTION
                       	              CARBOK
                                                                                                         n
SUBCATECORY LOAD SUHKARY
(TONS/YEAR)	

Flow (MCD)

Oil and Crcut
Total Suspended Solid*
Total Toxic Metal*
Total Organic!

SUBCATECORY COST SVMMARY
(5X10"6)	

Invest. *>ent
Annual
(3)
                                             DIRECT DISCHARGERS
                                                               (I)
RAW<2)
KASTt
808.9
33,346.2
868,756.9
8, 247. 4
BPT/8CT
313.4
680.4
3,334.1
25.2
                                     108.01
                                     1.52
58.53
6.80
                                                                                 319.92
                                                                                 58.25
                                             INDIRECT (POTV) DISQUICIRS
SUBCATEGORY LOAD SUJWARY
(TONS/YEAR)	

Flow (HCD)

Oil and Crease
Total Suspended Solid*
Total Toxic Metal*
Total Organic*

SUBCATECORY COST SOWARY
                                             RAW
                                             WASTE
                                             4.488.9
                                             116.948.0
                                             805.8
Inv**laenl
Annual
                                     PSES-1

                                     52.0

                                     197.3
                                     563.8
                                     3.3
                                     14.12
                                     0.18
PSES-2

4.3

9.3
45.4
0.3
10.05
1.55
                                                                                 PSES-3

                                                                                 0
                                                                                 43.61
                                                                                 7.90
(1)  The raw  vatte  load *id  SPT cot I. conlritniltcn! of  lh«  z«ro di«ch*r(* oprration*  are
     included in the direct  dt»cnirger data.  At these plant*  have no waitewater ditchargei,
     they d-> not contribute to BAT c->»t» or to the BPT ind BAT effluent  wane  loads.
(2)  Raw wane  load*   for  zern  discntrge  plant*  have  been  included in  th«»e  total*.
(3)  The cod suimarjr total* do nol  ncludc confidential  plant*.

-------
r- „-.,-,
                                              SUMMARY OF EFFLCEST LOADINGS AMD TREATMENT COSTS
                                                            HOT FORMING - SECTION
                                                                 SPECIALTY
                         SUBCATEGORY LOAD SUMMARY
                         (TONS/YEAR)	

                         Flow (MCD)
                                                                      DIRECT DISCHARGERS


                                                                         (2)
                                                                                        (1)
                     RAW
                     HASTE
                     76.8
BPT/BCT

27.4
                                               BAT-1
                                               2.7
                                                         BAT-2
                         Oil and Grease
                         Total Suspended Solids
                         Total Toxic Metals
                         Total Organics

                         SUBCATEGORT COST SUMMARY

                         ($X10"6)	

                         Investment
                         Annual
(3)
                     4,999.2
                     133,312.5
                     1,216.5
59.5
291.5
2.2
                                     17.44
                                     0.14
5.8
28.2
0.2
          6.26
          0.87
          41.54
          6.56
                                                                      INDIRECT (POTW) DISCHARGERS
                         SUBCATEGORY LOAD SUMMARY
                         (TONS/YEAS)	

                         Flow (MGD)

                         Oil and Grease
                         Total Suspended Solids
                         Total Toxic Metals
                         Total Organics

                         SUBCATEGORY COST SUMMARY

                         ($X10~6)	

                         Investment
                         Annua1
                     RAW
                     WASTE
                     3.8

                     250.0
                     6,665.6
                     60.8
(3)
PSES-1

1.6

3.5
17.2
0.1
                                     0.05
                                    -0.01
PSES-2

0.2

0.3
1.7
0.01
          0.05
          0.01
                                                         PSES-3
          0.39
          0.06
                         (1)  The raw waste  load and BPT  cost contributions of  the  zero discharge operations  are
                              included in the direct discharger data.  As these plants  have no uastewater  discharges,
                              they do not contribute  to  BAT costs or to the EFT and BAT effluent  waste  loads.
                         (2)  Raw waste  loads  for the  zero discharge  plants  have been  included  in  these  totals.
                         (3)  The cost summary totals do not include confidential  plants.
                                                                458

-------
                     SUMMARY OF EFFLUENT LOADINGS AMD TREATMENT  COSTS
                                     HOT FORMING - FLAT
                               HOT STRIP AND  SHEET - CARBON
                                             DIRECT DISCHARGERS
SUBCATECORY LOAD SUMMARY
(TONS/YEAR)	

Flow (MGD)

Oil and Grease
Total Suspended Solids
Total Toxic Metals
Total Organics

SUBCATEGORY COST SUMMARY
(SXIO"6)	

Investment
Annual
RAW
HASTE
1,392.0

45,305.4
1,193,042.8
7,550.9
                BPT/BCT   BAT-1
556.8

1,208.1
5,919.9
44.7
                125.29
               -1.78
56.6

122.7
601.2
4.5
          86.06
          13.91
                                    BAT-2
          483.37
          95.79
                                             INDIRECT (POTW) DISCHARGERS
SUBCATEGORY LOAD SUMMARY
(TON'S/YEAR)	

Flow (MGD)

Oil and Grease
Total Suspended Solids
Total Toxic Metals
Total Organics

SUBCATEGORY COST SUMMARY
($X10~6)	

Investment
Annual
RAW
WASTE
92.8

3,020.4
79,536.2
503.4
PSES-1

37.1

80.5
394.7
3.0
                3.39
               -0.33
PSES-2

3.8

8.2
40.1
0.3
          5.09
          0.80
PSES-3

0
          23.57
          4.53
                                           459

-------
  r
                                                SUMMARY OF  EFFLUENT  LOADINGS  AND TREATHENT  COSTS
                                                               HOT FORMING  -  FLAT
                                                   	HOT STRIP  AND SHEET - SPECIALTY	
                                                                       DIRECT DISCHARGERS
                          SUBCATEGORY LOAD SUMMARY
                          (TONS /YEAR) _

                          Flew (MGD)

                          Oil and Grease
                          Total Suspended Solids
                          Total Toxic Metals
                          Total Organics

                          SUBCATECORY COST SUMMARY
(1)
                          Investae'l
                          Annual
                     RAW
                     WASTE
                     40.3

                     1,312.3
                     34,557.1
                     271.2
35.0      3.6
171.5     17.4
1.3       0.1
                                     5.19
                                     0.25
          5.40
          0.80
22.58
3.71
                           Note:  There are no  indirect  (POTW) discharges in this segment.

                           (1)  The cost summary totals  do not include confidential plants.
^fa in - "*^
                                                                  400

-------
                                          SUMMARY OF EFFLUENT LOADINGS  AMD TREATMENT  COSTS
                                                         HOT FORMING -  FLAT
                                                           PLATE - CARBON     	
                                                                 DIRECT DISCHARGERS
                     SDBCATEGORY LOAD SUHKARY
                     (TOMS/YEAR)	

                     Flow (MCD)

                     Oil  and Grease
                     Total Suspended  Solids
                     Total Toxi: Metals
                     Total Organics

                     SUBCATEGORY COST SUMMARY

                     (SX10"6)	

                     Investment
                     Annual
RAH
HASTE
117.8

7,157.5
191,718.1
1,789.4
102.2
501.0
3.8
                20.15
               -0.36
10.5
51.6
0.4
          11.72
          1.76
                                    BAT-2
          58.97
          8.03
                                                                 INDIRECT (POTW) DISCHARGERS
                     SUBCATEGORY LOAD SUMMARY
                     (TOSS/YEAR)	

                     Flow (MGD)

                     Oil and Grease
                     Total Suspended  Solids
                     Total Toxic Melals
                     Total Organics

                     SOBCATECORY COST SUMMARY

                     (SXiO"6)	

                     Investment
                     Annual
RAH
HASTE
10.7

650.7
17,428.9
162.7
PSES-1

4.3

9.3
45.6
0.3
                2.81
                0.07
PSES-2

0.4

1.0
4.7
0.04
                                    PSES-3
          1.49
          0.22
          6.27
          0.86
                                                             461
L~

-------
                     SUMMARY OF EFFLUENT LOADINGS AND TREATMENT COSTS
                                    HOT FORMING - FLAT
                                    PLATE - SPECIALTY	
                                             DIRECT DISCHARGERS
                                                               (1)
SUBCATEGORY LOAD SUMMARY
(TONS/YEAR)	

Flow (MGD)

Oil and Grease
Total Suspended Solids
Total Toxic Metals
Total Organics

SUBCATEGORY COST SUMMARY

(SX10"6)	

Investment
Annual
(2)
                     RAW
                     WASTE
                     7.5

                     1,057.8
                     27,665.0
                     332.8
BPT/BCT   BAT-1
3.0

6.5
31.9
0.2
                                     3.19
                                     0.10
0.3

0.7
3.2
0.02
          2.11
          0.30
                                                         BAT-2
          8.28
          1.18
Mote:  There are no indirect (POTW) dischargers in this segment.

(1)  The raw  waste load  and  BPT cost  contributions  of  the  zero discharge operation  are
     included in the  direct  discharger  data.   As this  plant  has no waslewater  discharge,
     it does not contribute to BAT costs or to the BPT and BAT effluent waste loads.
(2)  The cost susnary totals do not include confidential plants.
                                         462

-------
                     SUMMARY OF EFFLUENT LOADINGS AND TREATMENT COSTS
                                HOT FORMING - PIPE AND TUBE
                                         CARBON
                                             DIRECT DISCHARGERS
                                                               (1)
SUBCATEGORY LOAD SUMMARY
(TONS /YEAR) _

Flow (MCD)

Oil and Grease
Total Suspended Solid*
Total Toxic Metals
Total Organics

SUBCATECORY COST SUMMARY
(2)
Investment
Annua 1
                     RAW
                     WASTE
                     124.2

                     4,716.1
                     122,617.6
                     835.4
BPT/BCT   BAT-1

28.6      5.0
62.0
303.8
2.3
                                     22.11
                                     2.64
10.7
52.6
0.4
          13.38
          1.87
                                                         BAT-2

                                                         0
          72.59
          11.81
                                             INDIRECT (POTU) DISCHARGERS
SUBCATEGORY LOAD SUMMARY
(TONS/YEAR)	

Flow (MGD)

Oil and Grease
Total Suspended Solids
Total Toxic Metals
Total Organics

SUBCATECORY COST SUMMARY

($X10~6)	

Investment
Annual
(2)
                     RAW
                     WASTE
                     5.0

                     188.6
                     4,904.7
                     33.4
PSES-1

1.1

2.5
12.2
0.09
                                     1.16
                                     0.14
PSES-2

0.2

0.4
2.1
0.02
          0.50
          0.07
PSES-3

0
          2.55
          0.41
(1)  The  raw  waste load  and BPT  cost  contributions of  the  zero discharge  operation are
     included  in  the  direct  discharger data.  As  this  plant  has no  waslewater  discharge,
     it does not contribute to BAT costs or to the BPT and BAT effluent waste loads.
(2)  The cost  summary totals do not include confidential plants.
                                          463
                                                   ..AJ.—

-------
                     SUMMARY OF EFFLUENT LOADINGS AND TREATMENT COSTS
                                HOT FORMING - PIPE AND TUBE
                                        SPECIALTY
                                             DIRECT DISCHARGERS
SUBCATECORY LOAD SUMMARY
(TONS/YEAR)	

Flow (MOD)

Oil and Create
Tolal Suspended Solids
Tolal Toxic MeLati
Total Organics

SUBCATECORY COST SUMMARY

($X10"6)	

Investment.
Annual
(1)
                     RAW
                     WASTE
                     22.1

                     838.4
                     21,798.7
                     148.5
BPT/BCT   BAT-1
5.1

11.0
54.0
0.4
                                     3.68
                                     0.27
                    BAT-2
0.9

1.9
9.4
0.07
          1.73
          0.24
          13.32
          2.03
Note:  There are no indirect (POTW) discharger* in this segnent.

(1)  The cost suanary total* do not include confidential plants.


-------

<


rj
1

m
(ft
tfi
O.
i*
t
o
                                           465

-------
                              i
                           r
     OC
     
-------
                                  SUBCATEGORY SUMMARY DATA
                                   BASIS 7/1/78 DOLLARS
SUBCATEGORY:  Salt Bath Descaling
           :  Oxidizing
           l  Batch-Sheet/Plate
                                     MODEL SIZE (TPD)s     60
                                     OPER. DAYS/YEAS :    260
                                     TtnWS/DAY       t      2
RAW WASTE FLOWS
Model Plant
5    Direct Discharger*
0    Indirect Dischargers
5    Active Plant*
MODEL COSTS (SXIO"3)
0.04 MOD
 0.2 MOD
   0 HCD
 0.2 MOD
                         BPT/BCT   BAT-1     BAT-2
                         HSPS-1    NSPS-2    NSPS-3
                         PSES-1    PSES-2    PSES-3
                         PSNS-1    PSNS-2    PSNS-3
Investment
Annual
$/Ton of Production
WASTEWATER
CHARACTERISTICS
     Flow (CPT)
     pH (SU)
     Chromium (Hexavalent)
     Total Suspended Solid*

 23  Chloroform
11A  Antimony
US  Arsenic*
119  Chromium*
120  Copper*
123  Mercury
124  Nickel
125  Selenium*
127  Thallium
128  Zinc
               RAW
               WASTE
                         364
                         53.9
                         3.46
          50.9
          6.8
          0.44
BPT/BCT   BAT-1
NSPS-1    NSPS-2
PSES-1    PSES-2
PSKS-1    PSHS-2
               700       700       700
               11-13     6-9       6-9
               200       0.05      0.05
               500   (30)23.8  (15)9.8

               0.04      0.04      0.04
               0.2       0.1       0.1
               0.024     0.024     0.024
               240  (0.4)0.28 (0.1)0.03
               1          0.04      0.03
               0.015     0.015     0.015
               7     (0.3)0.25 (0.1)0.04
               0.024     0.024     0.024
               0.12      0.12      0.12
               0.1       0.06      0.06
1984
285
18.27

BAT-2
NSPS-3
PSES-3
PSNS-3
Note*:  All concentrations are in mg/1 unless otherwise noted.
     :  BAT, NSPS.PSES and PSNS costs are incremental over
        BPT/NSPS-1/PSES-l/PSNS-l costs.
     :  Values in parentheses represent the concentrations used
        to develop the linitations/standards for the various levels
        of treatment.  All other values represent long term average
        values or predicted average performance levels.

 *Toxic pollutant found in all raw waste samples.
                                      4C7

-------
                                 SUBCATECORY SUWARY DATA
                                   BASIS 7/1/78 DOLLARS
SOBCATEGORY:  Salt Bath Descaling
           I  Oxidizing
           i  Batch - Rod/Wire/Bar
                      MODEL SIZE (TPD)t   115
                      OPE*. DAYS/YEAR :   260
                      TURKS'DAY       I     2
RAW WASTE FLOWS
Model Plant                  0.05 HCO
 3   Direct Discharger*      0.1  MGD
 1   Indirect Diicharger*    0.05 HCD
 4   Active Plants           0.2  HCD
MODEL COSTS ($X10~3)

Inves latent
Annual
$/Ton of Production
WASTEWATER
CHARACTERISTICS	

     Flow (OPT)
     pH (SU)
     Chroaiu* (Hexavalent)
     Total Suspended Solids

 23  Chloroform
114  Antioony
115  Arsenic*
119  Chromium*
120  Copper*
123  Mercury
124  Nickel
125  Scleniua*
12?  Thallium
12S  Zinc
          BPT/BCT   BAT-1
          BSPS-1    NSPS-2
          PSES-1    PSES-2
          PSNS-1    PSNS-2
          387
          57.4
          1.92
54.9
7.2
0.24
          BPT/BCT   BAT-1
          NSPS-1    NSPS-2
RAW       PSES-1    PSES-2
WASTE     psw3-i    psNs-2
420       420       420
11-13     6-9       6-9
200       0.05      0.05
500   (30)23.8  (15)9.8

0.04      0.04      0.04
0.2       O.I       0.1
0.024     0.024     0.024
240  (0.4)0.28 (0.1)0.03
1         0.04      0.03
0.015     0.015     0.015
7    (0.3)0.25 (0.1?0.04
0.024     0.024     0.024
0.12      0.12      0.12
0.1       0.06      0.06
BAT-2
NSPS-3
PSES-3
PSKS-3

2042
298
9.97

BAT-2
NSPS-3
PSES-3
PSKS-3
Notesi  All concentrations are in mg/1 unless otherwise noted.
      :  BAT, NSPS, P?ES and PSNS costs are incremental over
        BPT/NSPS-1/PSES-1/PSSS-1 costs.
      :  Values in parentheses represent the concentrations used to
        develop the limitations/standards for the various levels of
        treataent.  All other values represent long tens average
        values or predicted average performance levels.

*  Toxic pollutant found in all raw waste saapies.
                                          468

-------
                                  SUBCATZCOft* SUMMARY DATA
                                    BASIS 7/ .78  DOLLARS
SUBCATEGORY:
            I
Sell Bath Defecting
Oxidising
Batch - Pip* and Tub*
RAW WASTE FIOWS
Model Pint                  0.06 HCD
 2   Direct Discharger*       0.1 MCD
 0   Indirect Dischargers       0 HCD
 2   Active PUnti            0.1 HCD
HODEL COSTS
Investment
Annual
$/Ton of Production
WASTEWATER
CHARACTERISTICS	

     Floy (CPT)
     pB (SU)
     Chroaiua (Hexavalent)
     Total Suspended Solids

 23  Chloroform
114  Antimony
115  Arsenic*
119  Chromium*
120  Copper*
123  Mercury
124  Nickel
125  Selenium*
127  Thallium
128  Zinc
                               RAW
                               WASTE
                                         435
                                         64.3
                                         7.07
            MODEL SIZE (TPD)s    35
            QVr,».. DAYS/YEAR :   260
            TOMS/DAY       t     2
                                         •PT/BCT   BAT-J
                                         HSPS-1    NSPS-2
                                         PSES-1    PSES-2
                                         PSNS-l    PSNS-2
          62.5
          8.2
          0.90
BPT/BCT   BAT-1
HSPS-1    NSPS-2
PSES-1    PSES-2
PSKS-1    PSNS-2
                               1700      1700      1700
                               11-13     6-9       6-9
                               200       0.05      0.0?.
                               500   (30)23.8  (15)9.6

                               0.04      0.04      0.04
                               0.2       0.1       0.1
                               0.024     0.024     0.024
                               240  (0.4)0.28 (0.1)0.03
                               1         0.04      0.03
                               0.015     0.015     0.015
                               7    (0.3)0.25 (0.1)0.04
                               0.024     0.024     0.024
                               0.12      0.12      0.12
                               0.1       0.06      0.06
BAT-2
HSPS-3
PSES-3
PSKS-3

2278
337
37.03

BAT-2
HSPS-3
PSES-3
PSNS-3
Notes:  All concentrations sre in Bg/l unless otherwise noted.
     :  BAT, NSPS, PSES, end PSNS costs ere incremental over
        BPT/NSPS-1/PSES-l/PSHS-l costs.
     :  Values in parentheses represent the concentrations used to
        develop the limitations/standards for the various levels of
        treatment.  All other values represent long lens average
        values or predicted average performance levels.

*  Toxic pollutant found in all raw waste samples.
                                        4fi'J

-------
                                 SUBCATtCDfcY SUMMARY DATA
                                   BASIS  7/1/78 DOLLARS
SUB CAT! GORY:
           i
           I
Sail B«lh De»c*lin(
Oxiditint
Continuous
            MODEL SIZE (TPD):   140
            OPCR. DAYS/YEA! s   260
            TURKS /DAY       t     2
RAW WASTE FLOWS
Model PUnt                  0.05 HCD
 7   Direct Diichargcra      0.3  MCD
 1   Indirect Diicharger*    0.05 HCD
 8   Active Plants           0.4  MO
MODEL COSTS <$X10~3)
Invettaent
Annu*I
J/Ton of Production
WASTEWATER
CHARACTERISTICS
     Flo- (CPT)
     pH (SU)
     Chroniua (Hexavalenl)
     Total Suspended Solid*
23
114
115
119
120
123
124
125
U7
128
Chloroform
Antimony
Ar*enic*
ChrooiuB*
Copper*
Mercury
Nickel
Selenium*
Thai 1 iua
Zinc
                               RAW
                               WASTE
BPT/BCT
NSPS-1
P5ES-1
PSWS-1
375
55.7
1.53
BAT-1
HSPS-2
PSES-2
PSNS-2
53.6
7.0
0.19
BAT- 2
WPS-3
PSES-3
PSBS-3
2042
294
S.13
BPT/»CT
MSPS-1
PSES-I
PSSS-1
BAT-1
HSPS-2
PSES-2
PSNS-2
                               3JO       330       330
                               11-13     6-9       6-9
                               200       0.05      0.05
                               500   (30)23.8  (15)9.8

                               0.04      0.04      0.04
                               0.2       0.1       0.1
                               0.024     0.024     0.024
                               240  (0.4)0.28 (0.1)0.03
                               1         0.04      0.03
                               0.015     0.015     0,015
                               7    (0.3)0.25 (0.1)0.04
                               0.024     0.024     0.024
                               0.12      0.12      0.12
                               0.1       0.04      0.06
BAT-2
SSPS-3
PSES-3
PSHS-3
Note*:  All concentration* art in •;/! unle** othervic* noted.
     »  BAT, PSES, PSKS jnd SSPS co*t* are incresenlal over
        BPT/PSES-1/PSNS-l/SSPS-l CO*tf.
     :  Value* in p*renlhe*e* represent the concentration* u*ed to
        develop the limitations/standard* for the variou* level* of
        treatment.  All other value* repre»ent long term average
        value* or predicted average perfo.i»,jnce level*.

*  Toxic pollutant found in all raw «a«te faaple*.

-------
                                  SUBCATECORY  SUMMARY DATA
                                    BASH  7/1/78  DOLLARS
SUBCATECORY I  S«H bath Descaling
           t  Reducing
           t  Batch
                        MODEL SUE (TTD)l   1)0
                        OPER. DAYS/YEAR I   260
                        TOWS/DAY       t     3
RAW WASTE FLOWS
Model Plaat                  0.04 MCD
 4   Direct Dischargers      0.2  HCD
 1   Indirect Discharger*    0.04 HCD
 5   Active Plants           0.2  MOD
MODEL COSTS OXIO'3)

Invest»ent
Annut1
S/Ton of Production
VASTCWATEt
CHARACTERISTICS

     Pic* (CPT)
     pH (SI!)
     Chroaiua (Hexavalent)
     Iron (Di»folv*d)
     Total Suspended Solids

114  Antimony*
118  Cadviu*
119  Chro»iu«*
120  Copper*
121  Cyanide
122  Lead*
124  Nickel*
12)  Seleniua*
126  Silver
12$  Zinc*









RAW
WASTE
32}
11-12
0.26
12.4
420
BIT/BCT
HSPS-1
PSES-1
PSrS-1
291
41. 5
1.23
BPT/BCT
NSPS-1
PSCS-!
PSHS-I
325
6-9
0.0)
1
(30)23.8
BAT-1
KSPS-2
PSES-2
PSKS-2
39.6
i.2
0.15
BAT-1
KSPS-2
PSCS-2
PSSS-2
32S
6-9
0.05
0.5
(15)9.8
BAT-2
HSP5-3
PSES-3
PS KS -3
1552
215
6.36
BAT-2
HSPS-3
PSES-3
PSHS-3
0
.
.
_
-
0.48        0.1         0.1
0.042       0.042       0.042
5.6    (0.4)0.28   (0.1)0.03
0.4         0.04        0.03
0.038 (0.25)0.038 (0.?5)O.J38
0.45
3
0.028
0.06
0.092
0.1
(0.3)0.25
01.018
0.06
0.06
0.06
(0. DO. €4
0.018
0.06
0.06
Hotel!  Alt concentrations are in »»/! unlcia otherwise noted.
     >  BAT, PSES.PSNS and NSPS coata arc incrmentjl over
        BPT/PSES-1/PSKS-l/KSPS-l cola.
     t  Value* in parentheses represent the concentrations used to
        develop the 1iautations/standard* for the various  level* of
        treataent.  All other values represent Ion; term average
        values or predicted averate performance levels.

*  Toxic pollutant found in all raw uaste saaples.
                                       471

-------
                                 SUBCATECORY SUMMARY DATA
                                   BASIS 7/1/78 DOLLARS
SOBCATEGORY:
Salt Bath Descaling
Reducing
Continuous
MODEL SIZE (TPD):    20
OPER. DAYS/YEAR :   260
TURNS/DAY       :     3
RAW WASTE FLOWS
Model Plant                 0.04 MOD
 2   Direct Dischargers     0.08 MOD
 0   Indirect Dischargers      0 MGD
 2   Active Plants          0.08 MGD
MODEL COSTS ($X10~3)

Investment
Annual
$/Ton of Production
WASTEWATER
CHARACTERISTICS	

     Flow (GPT)
     pH (SU)
     Chromium (Hexavalent)
     Iron (Dissolved)
     Total Suspended Solids

114  Antimony*
118  Cadmium
119  Chromium*
120  Copper*
121  Cyanide
122  Lead*
124  Nickel*
125  Selenium*
126  Silver
128  Zinc*









RAW
WASTE
1820
11-12
0.26
12.4
420
0.48
0.042
5.6
0.4
0.038
0.45
3
0.018
0.06
0.92
BPT/BCT
NSPS-1
PSES-1
PSNS-1
354
48.8
9.38
BPT/BCT
NSPS-1
PSES-1
PSNS-1
1820
6-9
0.05
1
(30)23.8
0.1
0.042
(0.4)0.28
0.04
BAT-1
NSPS-2
PSES-2
PSNS-2
36.2
4.9
0.94
BAT-1
NSPS-2
PSES-2
PSNS-2
1820
6-9
0.05
0.5
(15)9.8
0.1
0.042
(0.1)0.03
0.03
BAT- 2
NSPS-3
PSES-3
PSNS-3
1582
212
40.77
BAT-2
NSPS-3
PSES-3
PSNS-3
0
-
-
-
-
_
-
-
-
(0.25)0.038 (0.25)0.038
0.1
(0.3)0.25
0.018
0.06
0.06
0.06
(0.1)0.04
0.018
0.06
0.06
-
-
-
-
-
Notes:  All concentrations are in mg/1 unless otherwise noted.
      :  BAT, NSPS, PSES, and PSNS costs are incremental over
        BPT/NSPS-1/PSES-l/PSNS-l costs.
      :  Values in parentheses represent the concentrations used to
        develop the limitations/standards for various  levels of
        treatment.  All other values represent long term average
        values or predicted average performance levels.

*  Toxic pollutant found in all raw waste samples.


-------
                     SUMMARY OF EFFLUENT LOADINGS AND TREATMENT COSTS
                             SALT BATH DESCALING SUBCATECORY
                                                       DIRECT DISCHARGERS
SUBCATECORY LOAD SUMMARY
(TONS/YEAR)	

Flow (MGD)
                               RAW
                               WASTE

                               1.0
BPT/BCT   BAT-1     BAT-2

1.0       1.0       0
Dissolved Iron
Total Suspended Solids
Total Cyanide
Total Toxic Xetals
Total Organics

SUBCATECORY COST SUMMARY

($X10'6)	

Investment
Annual
(2)
                               3.3
                               429.
                               (1)
                               161.
                               (1)
0.3
21.4
(1)
0.8
(1)
                                         4.92
                                         0.73
0.1
8.9
(1)
0.4
          0.92
          0.11
          35.23
          5.05
                                                       INDIRECT (POTW) DISCHARGERS
SUBCATECORY LGA9 SUMMARY
(TONS/YEAR)	

Flow (MGD)

Dissolved Iron
Total Suspended Solids
Total Cyanide
Total Toxic Xetals
Total Organics
SUBCATECORY

($X10~6)

                  UMMARY
Investment
Annual
RAW
HASTE
0.1
0.6
70.6
(1)
30.0
(1)

PSES-1
0.1
(1)
3.5
(1)
0.1
(1)

PSES-2
0.1
(1)
1.4
(1)
(1)
(1)

PSES-3
0
_
-
-
-
-
                                         1.19
                                         0.18
          0.26
          0.04
          9.52
          1.37
(1)  Load is less than 0.05 tons/year.
(2)  Cost Sunury totals do not include confidential plants.
                                          473

-------
                     SUMMARY OF EFFLUENT LOADINGS AND TREATMENT COSTS
                       SALT BATH DESCALING SOBCATEGORY - OXIDIZIHG
                                             DIRECT DISCHARGERS
SUBCATECORY LOAD SUMMARY
(TOSS/YEAR)	

Flow (MGD)

Total Suspended Solids
Total Toxic Metals
Total Organics

SUBCATEGORY COST SUMMARY

($X10~6)	

Investment
Annual
(2)
RAW
WASTE
0.8
319.0
158. 5
(1)
BPT/BCT
0.8
15.2
0.6
(1)
BAT-1
0.8
6.3
0.3
(1)
BAT-2
0
-
                               0.61
                                         0.72
                                         0.09
          27.07
          3.95
                                             INDIRECT (POTV) DISCHARGERS
SUBCATEGORY LOAD SUMMARY
(TONS/YEAR)	

Flow (MGD)

Total Suspended Solids
Total Toxic Metals
Total Organics

SUBCATEGORY COST SUMMARY
(SX10"6)	

Investment
Annual
RAW
HASTE
0.1
51.3
25.5
(1)
PSES-l
0.1
2.4
0.1
(1)
PSES-2
0.1
1.0
(1)
(1)
PSES-3
0
-
                               1.08
                               0.16
0.24
0.04
8.90
1.29
(1)  Load is less than 0.05 tons/year.
(2)  The cost summary totals do not include confidential plants.
                                        474

-------
                     SUMMARY OF EFFLUENT LOADINGS AND TREATMENT COSTS
                        SALT BATH DESCALING SUBCATEGORY - REDUCING
                                             DIRECT DISCHARGERS
SUBCATEGORY LOAD SUMMARY
(TONS/YEAR)	

Flow (MGD)

Dissolved Iron
Total Suspended Solids
Total Cyanioe
Total Toxic Metals
Total Organic*

SUBCATEGORY COST SUMMARY
($X10~6)	

Investment
Annual
SUBCATEGORY LOAD SUMMARY
(TONS/YEAR)	

Flow (MGD)

Dissolved Iron
Total Suspended Solids
Total Cyanide
Total Toxic Metals
Total Organic*

SUBCATEGORY COST SUMMARY
($X10"6)	

Investment
Annual
RAW
WASTE
0.2
3.3
110.2
(1)
2.7

BPT/BCT
0.2
0.3
6.2
(1)
0.2

BAT- 1
0.2
0.1
2.6
(1)
0.1

BAT- 2
0
_
-
-
-
-
INDIRECT
RAW
WASTE
0.04
0.6
19.3
(1)
0.5
0.81
0.12
(POTW)
PSES-1
0.04
(n
1.1
(I)
(1)
0.20
0.02
DISCHARGERS
PSES-2
0.04
(1)
0.4
(1)
(1)
                    8.16
                    1.10
0.11
0.02
0.02
0.002
0.62
0.08
(1)  Load is less than 0.05 tons/year.
                                          475

-------
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—



                                        477
Preceding page blank

-------
                                                 SDBCATECORY SUMMARY DATA
                                                   BASIS 7/1/78 DOLLARS
SUBCATEGORY:  Sulfuric Acid Pickling
           :  Strip/Sheet/Plate
           t  Heutralitation and Acid Recovery
MODEL SIZE (TPD):  1660
0?ER. DAYS/YEAR :   320
TURNS/DAY       :     3
RAM WASTE TU)VS
Rinses and Concentrates
Model Plant
23 Direct Dischargers
1 Plant Hauling All Wastes
2 Acid Recovery Plants
30 Active Plants
MODEL COSTS ($X10~3)
0.3 MCD
6.9 MCD
0.3 MCD
0.6 MCD
9.0 MCD
Fume Scrubbers (Additional Flow)
Model Plant
14 Direct Dischargers
0.19 MCD
2.7 MCD
n L Mrn
0 Plants Hauling All Wastes 0 MCD
0 Acid Recovery Plants 0 MCD
16 Active Plants 3.1 MCD
BPT/BCT BAT-l
PSES-1 PSES-2
Investment
Neutralisation
Acid Recovery
Annual
Neutralisation
Acid Recovery
S/Ton of Production
Neutralization
Acid Recovery
1545
3048
1060
567
1.99
1.07
Investment
Annual
S/Ton of Production
WASTEWATER BPT/BCT
CHARACTERISTICS






115
118
119
!20
122
124
126
128
Xate

Flow (CPT)
pH (SU)
Dissolved Iron
Oil and Crease
Total Suspended Solids
Arsenic*
Cadmium
Chromium*
Copper*
Lead*
Nickel*
Silver
Zinc*

t BAT and PSES-2 through
Conc
20

15
6-9
1
(10)4.

4
(30)23.8
0.
0.
0.
0.
(0.15)0.
0.
0.
(0. !<0.

1
04
04
04
1
15
04
06

BAT-2
PSES-3
703
88.4
0.17
NSPS-2
PSNS-2
2060
1119
2.11
Total
9.6
1 6
0.3
0.6
12.1


BAT-2/PSES-3
NSPS-2 /PSNS-2
Conc 6
Rinse
40
FS<»
15
Flow
MCD
MCD
MCD
MCD
MCD
BAT-3
PSES-4
2969
441
0.83
NSPS-3
PSNS-3
4326
1472
2.77
BAT-3/PSES-4
NSPS-3 /PSNS-3

0
6-9
0.
(5**)2
(15)9.
0.
0.
0.
0.
(0.1)0.
0.
0.
(0.1)0.

5

8
1
04
03
03
06
04
04
06

-
-
-
_
-
-
-
-
-
-


      t   DAl  ana  rsc.3—£  tnrougn  rito—«»  co»is  are  incr*-»eni.«i  over or* ^rac-a-i co*i».
      :   Values in parentheses represent  the  concentrations used ;o develop the limita-
         tions/standards for  the various  levels of treatment.  All other values represent
         long term average  values or  predicted average performance levels.

 *  Toxic pollutant  found  in all raw waste samples.
**  Limit for oil and grease is based  upon  10 sig/1 (maximum only).
    Concentration is less  than  0.01  mg/1.
;i) Flow in  gallon per  minute (CPM).
.2) Zero discharge of process wastewater pollutants  can be achieved with acid recovery sysle
                                                               478
           ^-..^. .^^^-L-^-a^^^i^A^^i^

-------
                                                 nnCATECORY SDtMARY DATA
                                                   BASIS 7/1/78 DOLLARS
SUBCATECORYl  Solfuric Acid Pickling
           i  Rod/Wire/Coil
           I  N«ulrali«*tion and Acid Recovery
MODEL SIZE (TPD)t  370
OPER. MYS/YEAlt s  260
TURNS/DAY       >    3
RAH WASTE FLOWS
Riniti and Concentrate*
Model Flint
16 Direct Di*charger*
1ft Indirect Di*ch*rgera
2 Plant* Heulinf All Uaale*
5 Acid Recovery Plente
41 Active Plent*
«
MODEL COSTS (JXIO J)
InvcetMnt
Neutral itet ion
Acid Recovery
Annual
Heutraliiation
Acid Recovery
S/Ton of Production
Neutralisation
Acid Recovery


Inveeteieni
Annual
S/Ton of Production
WASTE WATE«
CHARACTERISTICS

no. (CPT)
pH (SU)
Di**olved Iron
Oil and Cree*e
Total Suspended Solida
115 Arienic*
tit Cadniua
119 ChroaiiuD*
1 20 Copper*
122 Lead*
124 Nickel*
126 Silver
128 Zinc*
Noteit All concentretion* are
1 BAT and PSES-2 through
1 Valuei in parentheses
FUM Scrubber* (Additional Flow)
0.10 HOT Model Pleat 0.19 MCO
1.7 MOT 2 Direct Diachargere 0.4 HCD
1.9 HOD 2 Indirect Diachargere 0.4 HCD
0.2 HCD 0 Plant* Hauling All Viite* 0 HCD
0.5 HCD 0 Acid Recovery Flint* 0 MO)
4.3 HCD 4 Active Plant* 0.8 MCO
BPT/BCT BAT-1
FSES-1 PSES-2

1026 133
1092

32) 16.8
170

3.38 0.17
1.77
NSPS-1
PSKS-1
1033
324
3.37
BPT/»CT BAT-l/PSIS-2
RAW WASTE PSES-I NSPS-1 fTSKS-l
(1) (1) CODC * (1) Conc * (1)
Cone Rin*e PS " 'total1 Rin«e FS " Rine* PS
20 260 US 207 280 IS SO IS
g/l unle** otherwise noted.
PSCS-4 roit* are incremental over BPT/PSES-1 coet*.
represent the concentration* u*ed to develop the limta-
total Flow

2.1
2.3
0.2
O.S
S.I
BAT-2
FSES-3

173
-

22.1
-

0.23
"
NSPS-2
PSNS-2
1073
329
3.42
BAT-2/PSES-3

HCD
HCD
MCO
HCD
HCD
BAT-3
PSES-4

1715
-

239
-

2.48
—
KSPS-3
PSKS-3
261 S
S46
S.68
BAT-3/PSES-4
NSPS-.2/PSKS-2 KSPS-3 'PSNS-3
Conc 4 ...
Rinie PS
SO IS
6-9
0.5
(5**)2.0
(15)9.8
0.1
0.02
0.03
0.03
(0.1)0 06
0.04
0.02
(0.1)0.06



0

-
*
-
_
-
-
-
-

-
-



tion*/*tandard» for the variou* leveli of treatetent. All other value* represent
long lent average value* or predicted average oerforunc* leveli.
 *  Toxic pollutant  found  in all  rev vvtt*  g/l.
(1) Flow  in gallon per ainute  (CPM).
(2) Zero diich*rge of proem vailevalcr  pollutenl*  can be echieved vith acid recovery *yatc«*.

-------
                                               SUBCATSGOtY SUMMARY DAT*
                                                 BASIS 7/1/78 DOLLARS	
SUBCATEGORY: Sulfuric Acid Pickling MODEL SIZE (TPD):
: Bar/Billet/Bloom OPER. DAYS/YEAR :
i Neutralization and Acid Recovery TURNS/DAY :
RAW WASTE FLOWS

Model Plant 0.06
15 Direct Dischargers 1.0
3 Indirect Dischargers 0.2
4 Plants Hauling All Uasles 0.3
0 Acid Recovery Plants 0
22 Active Plants 1.5

MODEL COSTS (SXIO"3)
Investment
Neutralization
Acid Recovery
Annual
Neutralization
Acid Recovery
$/Ton of Production
Neutralization
Acid Recovery


Investment
Annaul
S/Ton of Prcduc on
WASTE WATER
CHARACTERISTICS

Flow (GPT)
pH (SU)
Dissolved Iron
Oil and Crease
Total Suspended Solids
115 Arsenic*
118 Cadnium
119 Chromium*
120 Copper*
122 Lead*
124 Nickel*
126 Silver
128 Zinc*

Fume Scrubbers 'liditional Flow)
MCO Model Plant 0.19 MCD
KCD 2 Direct Dischargers 0.2 MCD
MCD 0 Indirect Dischargers 0 MCD
MGO C Plants Hauling All Wastes 0 MCD
MCO 0 Acid Recovery Plants 0 MCD
MCD 2 Active Plants 0.2 MCD
BPT/BCT BAT-1
PSES-1 PSES-2

1122 259
1744

AO7 32.5
283

2.17 0.17
1.51
NSPS-1
PSNS-1
1293
428
2.29
»PT/ECT{2> BAT-l/PSES-2
RAW WASTE PSES-1 NSPS-1 /PSNS-1
(1) (1) C°K * (1) Conc & (1)
Conc Rinse FS '"Total1" Rinse FS v ' Rinse FS l"
20 70 135 180 90 27 30 15

-------
                                                SUBCATCCORY  SUHMARY DATA
                                                  8AS1S  7/1/78  DOLLARS
SUBCATCGOIYi   Sulfuric Acid  Pickling
           I   Pipe/Tube/Other
           I   Heutralitation and Acid Recovery
MOKL SIZE (TPO)t   220
OPER. DAYS/TEAR t   260
TUCKS/DAY       I     3
RAW WAS« nous
Rinses and Concentrates
Kodel Flsnl 0.11 MOD
9 Indirect Dischargers 1.0 HCD
4 Plants Hauling All Wastes 0.4 HCD
1 Acid Recovery Plenl 0.1 MCD
31 Active PUnis J.4 HCD

HODEL COSTS ($X10~3)
Invesusenl
Neutralisation
Acid Recovery
Annual
Neutralisation
Acid Recovery
f/Ton of Production
Neutralisation
Acid Recovery


Investment
Annual
I/Ton of Production
WASTE WATER
CHARACTERISTICS

•lo» (CPT)
pH  BAT-l /PSES-2
RAW WASTE PStS-1 NSPS-l'PSKS-i
... / . , Cone 4 ... Cone 4 ( . .
Cone Rinse fS "'Totel ' Rinse PS l" Rinse rs
20 480 13} 211 VX> 1} 70 1}
3
8.79
1AT-3/PSES-4
NSPS-3 /PSNS-3

0

•
-
-
.
-
-
-
-
-
-
-

t BAT and PSES-2 through PSEi-4 costs are incremental over BPT/PSES-1 costs.
1 Values in parentheses represent
tiont/stsa<
Concentration is less thsn 0.01 •*/
1.


(1) Flow in gallon per sunule (CPU).
f.2) Ztro discharge of process waotewater  pollutants  can  be  echieved with acid recovery syste
                                                               481
                                                                                                                                   *•

-------
                                                SOBCtTZGOftT SUMMIT DAT*
                                                  tASIt Hint DOLLARS
SDBCATCCORYi   Hydrochloric Acid Pickling
           I   Strip/Sheet/Plate
           I   Neutralisation tmd Acid Regeneration
RAW WASTE FLOWS	

Rini«» end Concentretea

Model PUnt                          1.13 MCD
21      Direct DUchargera           21.6 HOD
 3      Indirect Dieehargere          3.4 HCD
 4      Acid Regeneretion Pleats      4.} MCD
28      Activ* PUnti                31.S MCD
                            MODEL SIZE (TPD)l  4020
                            Oftl. DAYS/YEAI t   320
                            TVMS/DAY       I     3
TUB* Scrubbtn (Addition*! flox)

Model Pint                   0.19 MCD
20   Direct DUcherrer*        3.8 MCD
 2   Indirect Diicherger*      0.4 MCD
 4   Acid te|*»eralion Pleat*  0.8 MCD
26   Active Pleat*             5.0 MCD
                                                      Totil Ploi.
                               27.4
                               3.8
                               J.3
                               34.5
                       MCD
                       MCD
                       MCD
                       MCD
MODEL COSTS ($X10'3)
Inve»unnl
     Neulrelixetion
     Acid Regeneration
Annual
     Neulrtliieliofi
     Acid Regeneration
$/Ton of Production
     Heutralisalion
     Acid Regeneration
        2231
        50J7

        1734
       -765

        1.35
       -0.5»
                       BAT-1
                       PtES-2
1447
1592

181
202

0.14
0.1*
1608
1770

202
225

0.16
0.17
4204
4645

667
751

0.52
0.58
Invei latent
Annual
)/Ton of Production
                                                    NSPS-3
                                                    P»HS-3

                                                    5»46
                                                    2322
                                                    1.80
                                                      432

-------
   SUB CATEGORY SUWUKY DATA
   HYDROCHLORIC ACID PICKLING
   STRIP/SKEET/FLATE
   PACE 2	
   UASTEWATER
   CHARACTERISTICS
        Flew (CPT)
          (Naturalization)
        Flew (CPT)
          (Acid  Regeneration)
        pH (SO)
        Dissolved Iron
        Oil and  Great*
        Total Suspended Solida

   114  Antimony*
   115  Arsenic*
   US  Cadmium
   119  Chromium*
   120  Copper*
   122  Lead*
   124  Nickel*
   12S  Zinc*
                                                             RAW MAS ft
                                                                      BPT/BCT
                                                                       fSKX-l
                                       Cone
 10

 10

-------
                                             fWCAYlOOtY SWWAir DAT*
                                                     tnnt  points
SClCATf.CO«Tl Hvdrockloric Acid Mckliac
I tad/Uire/Coil
t *e*trallaalto*
SAU WASTE rUHIS
Rinee* and Concentrate* foaw Scrubber* (Additional rl
Model riant 0.04 l*» Model riant
7 Direct Di*cn*rger» 0.3 HC& 4 Direct Di*chart*r*
1 Indirect fiitchargera 0*4 HCS> ) Indirect ritcnarger*
11 Active riant* 0.7 teat 7 Active riant*
irr/»CT
Hooei COSTS ($iio~J) rsts-.i
tava*uaenl 717
Annual 1*0
• /Ton of 7ro*ucli«i t.O*


Imeitaenl
Annual
»/Ton of rrodoction
uAsnuATti trt'nct
CHAtACTEtmiCt IAU UAVTT. riK-l
( » \ (\\ Cone 4 f . v
Cone «in«e FS Total »i«»e rS
riov (err) to 4*0 135 itt 4*0 15
pR (SB) C. O»

lltiat/itaivdardt for IH* v*r'«*» l«v«lt of tr««td»»flt. All ?tKer val«*e* -eprt
long terv average valur* or vredicted average performance level*.
e Tonic noltutant found in all rev *a*te *a*tple*.

VML\. SIZC 
0>% WQ> 1») HC&
Oaft KCD 1.0 NCD
1.4 NCZ> I.I HCP
IAT-1 UT-J IAT-3
ntt-i rsts-s rs«-4
32.4 7».0 l*)2
4.1 10.2 274
O.It 0.44 11.47
mrt-i tsrs-2 gars-3
rsiK-i rs»s-2 rs«-3
73* 714 2t3»
1*3 l«« 452
7.t2 t.OI l*.32
UT-1AMM-2 UT-2/MIS-3 »AT-3^rJU-4
irsM-i/MW-i KS»!-2/rs»s-} wrs-j/rsm-s
c«« • (1) Cont • (1)
III me r« »in*« n *
•0 15 40 13 0
*-* »-»
1 0.2
(10)4.4 (5*»)3.5
(30)23.1 (15)*. II
O.t 0.1
0.1 O.I
0.01 0.01
0.04 0.03
0.04 0.03
(0.15)0.1 (0.1)0.04
C.I5 0.04
(o.t)o.o* io.no.ot

•*ent

(1)  rio»  in talloo >er  Binute (cn<).


-------
                                                SWCATCOOCY so*urr MTA
                                                  MSIt 7/1/7> POUAtt
IWCATECOtYl  Hydrochloric AcU
           I  Pipe/Tub*
           I  »*utralit.itoe,
                                                               HOOT.. *ne CTTOM   r.o
                                                               Cm. MYf/YtA*  I   2*0
                                                               TUWS/DAY        I     )
HAH HAST* rvom
Iintt« and Concentrate!

Hod«; Plant
 2   Direct Ditchargtrt
 1   Indirect Ditcharger
 1   Active Plant!
KOMI COSTS miO'*)

In vet latent
Annual
t/Ton of Production
Invetleient
Annual
(/Too of Production
                                                                      (Additional fle»)
0.11 HCD
 O.I HCO
 0.1 HCD
 0.) HCD
Hod<
I
0
I





il PUtt
Direct Oiacbarger
Indirect Ditcharten
Active/ Pint
IPT/ICT
m*-i
12}
174
t.o*
0.1* HCD
0.2 HCD
0 HCD
0.2 HCD
1AT-1
m«-2
)*.«
J.I
O.U
                                                                                      mrt-i
                                                                      vsn-i
                                                                      PSKi-2
                                                                      75*
                                                                      H5
                                                                      J.77
                                                                                                             Tat*I riofc
0.4 HCD
0.1 HCD
0.5 HCD
                                                                                                                  UT-)
                                                                                                                  ftrt-i
    2M2

    1J.2J
WAmUATtt
CHAtACVtlltSTICS
RAW
VAST!

(It 1 1






114
11)
us
11*
120
122
124
12»

riax (CPT)
pH (SO)
Dittolved Iron
Oil and Create
Total Sutpendad Soltda
Ant IOOA**
Artenic*
Cadmint
ChroenuBJ*
Copper*
Lead*
Nickel*
Itnc*
reew
10
2.0
(15). .1
0.1
0.1
0.01
0.0)
0.0)
(0.1)0.04
0.64
(o.no.ot
0

«.
•
-
.
•
-
•
.
.
-
•
Notett  All concent rat iona are in e>g/l unleea wlwrvia* noted.
      I  (AT and FSL1-2 throvgh KtS-4 coatt are iacrewntal aver aTTAMU-1  coeta.
      I  Vtluea  in ptrenlheaee repretent the coacentralioftt vaed ta drvelo* the livila-
        liont'ilanetrdt for Ike variout levelt of tr*«'ewnt.  *1! other veluee repre«e*t
        long :er* average velvet or predicted average perforvja*£a levelt.
    Toxic pollutant fowk4 i* all rev vaste •agk9lee.
    L«'il (or oil an4 greeae tt bated upon 10 atgyi (saK
    Cjn.entrtlion it lt» than 0.01
    Flov in gallon per atiovt« (CPH).
                             only).

-------
                  DA-A
»AS1» 7/J/7*
SO»CATZGO*Yi CoBfciution Acid Picklia*
I k«tch Slrlp/IM*t/Pl*l«

tin,c. «d Co«.«r.l..
Hod«l PUnl 0.07 NO)
* Direct Dne»*rfcr« 0.* HCS
0 Indirect Dl>ch«rf«rt 0 HCD
1 Plant M*in»«
flo>. (cm 20 440
pH (51)) <1-2.J !.»-».
Ditiolvcd Iron 20,000 170
riuorid* 4100 170
Oil end tr»««t 2.1 4.*
Tol«l kuif**4*t falidt 140 t)
til. AnliBony* NA O.btt
.IS C.t>«r« 170 1.2
2 l**« 4600 )7
:• Zinc* 11 0.7



tloni/il«n411ut«flt found in all r«» •.••it BMplfft.
k* LIMI; for oil •*•< tr<«*« t* b«t«d u»o« 10 •(/! (•<
'«* H^l *n*!vt*tf.
mccL sixt (m»i
OPtl. MYS/YIM t
TV»Ht/MY 1
rmt Serutb«r« (Aitditkonil Plou) J««
Ko4»l PUnl O.l« 'IU>
* Dirvtl »i»cK«r,»r» |.j MC9 1,7
0 lndir«ct Di»cK«rt*ri 0 IKS 0
0 PUnti H*ulln| All Wtitc* 0 MS» . 0.)
* Acn»« Pl«Bti 1.1 HCD 1.1
»/T/»CT MT-i UT-2
PSMil P»«-2 . P5W-1
«07 M.O •'.*
lit ».•> 11.4
4.H o.ia 0.2*
Wrt-l MPf-2
ttM'l P"*»'2
T,J 7^
ito iti
4.*I 4.74
»PT/»CT IAT-I/PSM-? MT-2/P1C*-)
«Asn nrs-j_ wtp*-i/»tir*-i K5PS-:^t»s-2
( 1 ) ( 1 ) C01K * ( 1 ) C^>*K * ( 1 ) C0ni: * (!)
Pt '"TOI.J"' lint* Pf '" «in.f rt " dim* P» '"
in II) 4M 15 *0 15 60 1)
t 'I-J 'l-«.l *-« *-» *-»
>•»•< t70 1 1 O.J
1*00 uoo t) n i)
4.4 10 (10)4.4 (10)4.4 M«)J
It 37 (XD23.I ()0)2).l (li)».»
o.* 0.4* o.i o.i e.i
o.oi c.oi o.oi o.oi o.ii
I.I 41 (0.4)0.2* (04)0.2* (0.1)0.0)
t.») ].* t'.Oi 0.04 0.0)
0.0) 0.04 f'.O. 0.04 O.t>*
1.* *l (0.1)0.2) (0.3IO.J4 (0.1)0.04
c.:> o.ti o.o* c.04 o.o*



itwni. All <•< h«r **l«*< r.prmnt
p,t(orm.nc. ).«!..

• itmm onlr>.

liO
2M>

Pl«
MCB
MO.
HCD
rxa>
AATO
Pit* -4
1)74
21*
J.J*
wri-J
.•»$»«-)
2272
)**
».»7
iAT-)/r»r»-*
mp«-)/Ptn-t

0

-
.
.
•
m
.
,
-
-
.
'










-------
{*'"*"&"'
                                                                SUBCATEGORY SUMMARY DATA
                                                                  BASIS 7/1/78 DOLLARS
SUBCATEGORY: Combination Acid Pickling
: Batch Strip/Sheel/Plate
RAW WASTE FLOWS
Rinses and Concentrates
Model Plant 0.07 MCD
9 Direct Dischargers 0.6 MGD
0 Indirect Dischargers 0 MCD
1 Plant Hauling All Wastes 0.1 MGD
10 Active Plants 0.7 MGD

MODEL COSTS (SXIO"3)
Inves tmunt
Annual
$/Ton of Production


Investment
Annua 1
S/Ton of Production
WASTEWATER
CHARACTERISTICS

Flow (GPT)
pH (SU)
Dissolved Iron
Fluoride
Oil and Grease
Total Suspended Solids
114 Antimony*
118 Cadmium
119 Chromium*
120 Copper*
122 Leao
124 Nickel*
128 Zinc*
Notes: All concentrations are in mg/1
: BAT and PSES-2 through PSES-4 c
: Values in parentheses represent
tions/standards for the various
MODEL SUE (T?D);
OPER. DAYS /YEAR :
TURNS /DAY :











Fume Scrubbers (Additional
Model Plant
6 Direct Dischargers
0 Indirect Dischargers

Flow)
0.19 MCD
1.1 MCD
0 MGD
0 Plants Hauling All Wastes 0 MGD













Conc
20












RAW
Rinse
440
6 Active Plants
BPT/BCT
PSES-1
807
188
4.82





BPT/BCT
WASTE PSES-1
(1) (1) Conc &
FS l 'total ' Rinse FS
135 183 460 15

-------

                                                       SUBCATECORY SUMMARY DATA
                                                       _ BASIS 7/1/78 DOLU>llQ
      SUBCATECORY:  C«,bi
                    combination Acid Pickling
                    Continuous Strip/Sheet/Plate
     HAW WASTE FLOWS

     Rinses and Concent ran

     Model Plant
     14   Direct Dischargers
      1   Indirect  Discharger
     IS   Active  Plants


    MODEL COSTS  ($X10~3)

    Investment
    Annual
    S/Ton of Production
    Investment
   AnruaI
   S/Ton of Production


   VAST3 WATER
   CHARACTERISTICS
       Flow  (CPT)
       pH Tota,
1480 135
1-9-8.2 <]-3
1*0 560
170 1800
4.6
93
0.069
37
1.2
37
0}
. /
4.6
16
0.6
0.01
1.1
0.63
0.03
1.6
0.29
760

170 15
6-9
OC
• J
15
(5**)2
(15)9.8
0.1
0.01
(0.1)0.03
0.03
0.03
(0.1)0.04
BAT-3 /PSES-*
JJSPS-3/PSIS-2
0
-



                                                                                                           0.06
 *  Toxic pollutant found in ail rav waste sample*.
**  Licit for oil and grease is based upon 10 ng/1 (uxi
    Concentration is less than 0.01 Mg/1.
,O\  Not analzed.
    Not  analyzed.
*1)  Flow in gallon per ninute (CPU).
                                                            only).

-------
C"
n
                                                         SU3CATECORY SUMMARY DATA
                                                           BASIS 7/1/78 DOLLARS
         SUBCATEGORY:  Combination Acid Pickling
                    :  Rod/Wire/Coil
MODEL SIZE (TPD):
OPER. DAYS/YEAR  :
TURNS/DAY        :
270
260
  3
         RAW WASTE FLOWS
Rinses and Concentrates
Model Plant
9 Direct Dischargers
8 Indirect bischargers
17 Active Plants

MODEL COSTS (SXIO*3)
Investment
Annual
S/Ton of Production


Investment
Annual
S/Ton of Production
WASTE WATER
CHARACTERISTICS

Flow (GPT)
pH (SU)
Dissolved Iron
Fluoride
Oil and Grease
Total Suspended Solids
114 Antimony*
118 Cadmium
119 Chromium*
120 Copper*
122 Lead
124 Nickel*
128 Zinc*
Notes: All concentrations are
: BAT and PSES-2 through
: Values in parentheses
Fume Scrubbers (Additional Flew)
0.14 MGD Model Plant 0.19 MO
1.2 MCD 5 Direct Dischargers 1.0 MGD
1.1 MCD 5 Indirect Dischargers 1.0 MCD
2.3 MGD 10 Active Plants 2.0 MCD
BPT/BCT BAT-1
PSES-1 PSES-2
977 97.2
256 12.2
3.65 0.17
NSPS-1
PSNS-1
930
248
3.53
BPT/BCT BAT-1 /PSES-2
RAW WASTE PSES-1 NSPS-1 /PSNS-1
(1) (1) Conc * (1) Ct>nc & (1)
Cone Rinse FS Total Rinse FS Rinse FS
20 490 135 231 510 15 70 15

-------
                                                             ,y.
                                                 SUBCATECORY SUMMARY DATA
                                                  BASIS 7/1/78 DOLLARS
SUBCATECORY:  Combination Acid Pickling
           :  Bar/Billel/Bloom
MODEL SIZE (TPD):
OPER. DAYS/YEAR :
TURNS/DAY       :
 60
240
RAW WASTE FLOWS

Model Plant
3 Direct Dischargers
1 Indirect Discharger
I Plant Hauling All Wastes
5 Active Plants

MODEL COSTS ($X10~3)
Investment
Annual
$/Ton of Production


Investment
Annual
S/Ton of Production
WASTE WATER
CHARACTERISTICS

Flow (GPT)
PH (SU)
Dissolved Iron
Fluoride
Oil and Grease
Total Suspended Solids
114 Antimony*
118 Cadmijm
119 Chromium*
120 Copper*
122 Lead
124 Nickel*
128 Zinc*
Notes: All concentrations are
: BAT and PSES-2 through
: Values in parentheses
Fuve Scrubbers (Additional Flow)
0.01 MOD Model Plant 0.19 MCD
0.04 MOD 1 Direct Discharger 0.2 MCD
0.01 MCD 0 Indirect Dischargers 0 MCD
0.01 MCD 0 Plants Hauling All Wastes 0 MCD
0.06 MCD 1 Active Plant 0.2 MCD
BPT/BCT BAT-1
PSES-1 PSES-2
669 21.6
164 2.8
10.51 0.18
NSPS-1
PSNS-1
672
164
10.51
BPT/BCT BAT-1 /PSES-2
RAW WASTE PSES-1 NSPS-1 /PSKS-1
(1) (1) C°nC & (1) C°nc & (11
Cone Rinse FS l 'Total Rinse FS v ".inse FS
20 210 135 145 230 15 40 15

-------
                                                SUBCATECORY SUMMARY  DATA
                                                  BASIS 7/1/78  DOLLARS
SUBCATEGHRY: Combination Acid Pickling
: Pipe/Tube
RAW WASTE FLOWS

Model Plant 0.05 MCD
11 Direct Dischargers 0.5 MCD
8 Indirect Dischargers 0.4 MCD
1 Plant Hauling All Wastes 0.05 MGD
20 Active Plants 0.95 MCD

MODEL COSTS (SXIO"3)
Investment
Annual
5/Ton of Production


Investment
Annual
S/Ton of Production
..•ASTEWATER
CHARACTERISTICS

Flow (GPT)
pH (SU)
Dissolved Iron
Fluoride
Oil and Crease
Total Suspended Solids
114 Antimony*
118 Cadmium
119 Chromium*
'.20 Copper*
\22 Lead
124 Nickel*
'28 Zinc*
:otes: All concentrntions are in mg/1
. BAT and PSES-2 throuRh PSES— 4 c
: Values in parentheses represent
tions/slandards for the various
MODEL SIZE (TPD):
OPER. DAYS/YEAR :
TURNS /DAY !
Fume Scrubbers (Additional Flow)


Model Plant
3 Direct

Dischargers
3 Indirect Dischargers














Conc
20

-------
                     SUMMARY OF EFFLUENT LOADINGS AND TREATMENT COSTS
                             ACID PICKLING - ALL SUBDIVISIONS
                                       ALL PRODUCTS              	
                                  DIRECT DISCHARGERS
SUBCATEGORY LOAD SUMMARY
(TONS/YEAR)	

Flow (MGt»

Dissolved Iron
Fluoride
Oil and Grease
Total Suspended Solids
Total Toxic Metals
Total Organics
RAW(1>(2)
HASTE
72.5
277,873.5
18,512.6
1,070.8
8,688.1
6,384.5

BPT/BCT
58.4
75.8
302.4
342.1
1,803.7
48.4
             BAT-1

             9.8

             12.6
             44.7
             56.1
             303.9
             8.0
             BAT-2

             9.8

             6.4
             44.7
             26.6
             125.2
             4.9
             BAT-3

             0
SUBCATEGORY COST SUMMARY

($X10"6)	

Investment
Annua1
                        (3)
150.06
54.22
64.62
7.93
76.91
9.56
362.69
55.32
                                  INDIRECT (POTW) DISCHARGERS
SUBCATEGORY LOAD SUMMARY
(TONS/YEAR)	

Flow (MGD)

Dissolved Iron
Fluoride
Oil and Grease
Total Suspended Solids
Total Toxic Metals
Total Organics
RAW
WASTE
14.2
45,495.0
5,035.1
192.4
1,554.2
1,053.9

PSES-1
10.7
13.1
45.5
58.1
314.3
8.1
             PSES-2

             2.1

             2.5
             8.5
             10.8
             58.7
             1.4
             PSES-3

             2.1

             1.3
             8.5
             4.7
             24.1
             0.9
             PSES-4

             0
SUBCATEGORY COST SUMMARY
($xio'6;	

Investment
Annual
                        (3)
24.88
9.26
5.48
0.68
7.15
0.91
63.20
9.04
(1)  Raw waste loads for the plants which haul all wastes have been included in these totals.
(2)  Raw waste loads fo. the acid recovery plants have been included in these totals.
(3)  The cost summery totals do not include confidential plants.
                                       491

-------
                     SUMMARY OF EFFLUENT LOADINGS AND TREATMENT COSTS
                            SULFURIC ACID PICKLING SUBCATEGORY
                   STRIP/SHEET/PLATE;    NEUTRALIZATION AND ACID RECOVERY
                                  DIRECT DISCHARGERS
SUBCATEGORY LOAD SUMMARY
(TONS/YEAR)	

Flow (MGD)

Dissolved Iron
Oil and Grease
Total Suspended Solids
Toiai Toxic Metals
Total Organics
RAW
WASTE
                                     (1K2)
10.5

78,438.0
224.1
3,501.7
434.9
BPT/BCT

7.8

10.4
45.7
247.0
5.9
BAT-1

1.8

2.4
10.7
58.1
1.4
BAT-2

1.8

1.2
4.9
23.9
1.0
                                                   BAT-3

                                                   0
SUBCATEGORY COST SUMMARY

($X10~6)	
Investment
Annua1
                        (3)
            26.71
            14.91
             13.52
             1.69
             15.90
             2.00
             67.16
             9.98
                                  INDIRECT (POTW) DISCHARGERS
SUBCATECORY LOAD SUMMARY
(TONS/YEAR)	

Flow (MGD)
RAW
WASTE

1.6
PSES-1
            1.2
             PSES-2
                         0.3
                          PSES-3
                                                                        0.3
                                       PSES-4
Dissolved Iron
Oil and Crease
Total Suspended Solids
Total Toxic Metals
Total Organics
11,843.8
33.8
528.7
65.7
1.6
7.3
39.4
0.9  •
0.4
1.8
9.8
0.2
0.2
0.8
4.0
0.2
SUBCATEGORY COST SUMMARY

(SX10~6)	
Investment
Annual
            2.55
            1.59
             0.90
             0.11
             1.06
             0.13
             4.47
             0.66
(1)  Raw waste loads for the plants which haul all wastes have been included in these totals.
(2)  Raw waste loads for the acid recovery plant? have been included in these totals.
(3)  The cost suraaary totals do not include confidential plants.
                                             492
                                                                                                        1

-------
                     SUMMARY OF EFFLUENT LOADINGS AND TREATMENT COSTS
                            SULFURIC ACID PICKLING SUBCATECORY
                     ROD/WIRE/COIL;  NEUTRALIZATION AND ACID RECOVERY
DIRECT DISCHARGERS
SUBCATECORY LOAD SUMMARY
(TONS/YFAR)
Flow (MCD)
Dissolved Iron
Oil and Crease
Total Suspended Solids
Total Toxic Metals
RAW(1)(2)
WASTE
2.8
8,419.0
33.1
360.8
49.9
TPT/BCT
2.2
2.4
10.6
57.3
1.3
BAT-1
0.3
0.4
1.6
8.8
0.2
Total Organics
SUBCATEGORY COST SUMMARY

($X10'6)	
Investment
Annual
SUBCATECORY LOAD SUMMARY
(TONS/YEAR)	

Flow (MCD)

Dissolved Iron
Oil and Grease
Total Suspended Solids
Total Toxic Metals
Total Organics
                        (3)
-
INDIRECT
RAW
WASTE
2.2
6,845.5
26.9
293.4
40.6
17.23
4.08
2.08
0.26
(POTW) DISCHARGERS
PSES-1
1.9
2.1
9.1
49.3
1.1
PSES-2
0.4
0.4
1.8
9.7
0.2
                                                                        BAT-2

                                                                        0.3

                                                                        0.2
                                                                        0.7
                                                                        3.6
                                                                        0.1
                          2.70
                          0.34
                          PSES-3

                          0.4

                          0.2
                          0.8
                          4.0
                          0.1
                          26.75
                          3.73
                                       PSFS-4
SUBC YTEGORY COST SUMMARY

($X10'6)	
                        (3)
Investment
Annual
6.87
2.21
1.19
0.15
1.55
0.20
15.56
2.17
(1)  Rau wcsle loads for the plants which haul all wastes have been included in these totals.
(2)  Rau waste loads for r.he acid recovery plants have been included in these totals.
(3)  The cost suomary totals do not include confidential plants.
                                           493

-------
                     SUMMARY OF EFFLUENT LOADINGS AND TREATMENT COSTS
                            SULFURIC ACID PICKLING SUBCATEGORV
                    BAR/BILLET/BLOOM!	NEUTRALIZATION AND ACID RECOVERY
                                  DIRECT DISCHARGERS
SUBCATEGORY LOAD SUMMARY
(TONS/YEAR)	

Flow (MGD)

Dissolved iron
Oil and Grease
Tolal Suspended Solids
Total Toxic Metals
Tolal Organics

SUBCATEGORY COST SUMMARY

(?X10"6)	

Investment
Annual
SUBCATEGORY LOAD SUMMARY
(TONS/YEAR)	

Flow (MGD)

Dissolved Iron
Oil and Grease
Total Suspended Solid.*)
Total Toxic Metals
Tolal Organics
(3)
          1.6

          6,854.1
          17.6
          298.8
          38.6
BPT/BCT

1.0

1.1
4.8
26.2
0.6
BAT-1

0.4

0.4
1.8
9.5
0.2
                      9.88
                      2.93
             3.34
             0.42
                                  INDIRECT (POTW) DISCHARGERS
          RAW
          WASTE

          0.2

          822.5
          2.1
          35.8
          4.6
PSES-1

0.2

0.2
0.9
5.0
0.1
PSES-2

0.06

0.1
0.3
1.7
(2)
BAT-2

0.4

0.2
0.8
3.9
0.1
             3.93
             0.50
PSES-3

0.06

(2)
0.1
0.7
(2)
                                                             BAT-3

                                                             0
             24.38
             3.45
                                       PSES-4
SUBCATEGORY COST SUMMARY

($X10~6)
Investment
Annual
                      1.71
                      0.65
             0.46
             0.06
             0.54
             0.07
             3.35
             0.48
(1)  Raw waste loads for  the  planls which haul all wastes have been  included in these totals.
(2)  Load is less than or equal to 0.05 ton/year.
(3)  The cosl summary lolals do nol include confidential planls.
                                          494
                                                                               J

-------
                     SUMMARY OF EFFLUENT LOADINGS AND TREATMENT COSTS
                            SULFURIC ACID PICKLING SUBCATEGORY
                    PIPE/TUBE/OTHER;  NEUTRALIZATION AND ACID RECOVERY
                                  DIRECT DISCHARGERS
SUBCATEGORY LOAD SUMMARY
(TONS/YEAR)	

Flow (MGD)

Dissolved Iron
Oil and Grease
Total Suspended Solids
Total Toxic Metals
Total Organic*

SUBCATEGORY COST SUMMARY

($X10~6)	

Investment
Annua1
SUBCATEGORY LOAD SUMMARY
(TONS/YfcAR)	

Flow (MGD)

Dissolved Iron
Oil and Greane
Total Suspended Solids
Total Toxic Metals
Total Organic*
          RAW
          WASTE
          3.0

          7,819.2
          39.1
          358.4
          47.6
BPT/BCT

2.0

2.2
9.8
52.8
1.2
BAT-1

0.3

0.4
1.6
8.4
0.2
BAT-2

0.3

0.2
0.7
3.5
0.1
(3)
                      8.74
                      2.11
             1.39
             0.17
                                  INDIRECT (POTW) DISCHARGERS
          1.2

          3,083.8
          15.4
          141.3
          18.8
             PSES-2

             0.2

             0.2
             0.8
             4.1
             0.1
SUBCATECORY COfT SUMMARY

($X10~6)
Investment
Annua1
                        (3)
                      2.05
                      0.60
             0.29
             0.04
                                                             BAT-3

                                                             0
             2.12
             0.27
             29.08
             4.12
             PSES-3

             0.2

             0.1
             0.3
             1.7
             0.1
                                                             PSES-4
             0.44
             0.06
             6.04
             0.86
(1)  Raw waste loads for the plants which haul all wastes have been included in these totals.
(2)  Raw waste loads for the acid recovery plants have been included in these totals.
(3)  The cost summary totals do not include confidential plants.
                                         495

-------
                     SUMMARY OF EFFLUENT LOADINGS AND TREATMENT COSTS
                          HYDROCHLORIC ACID PICKLING SUBCATEGORY
                  STRIP/SHEET/PLATE:  NEUTRALIZATION AND ACID REGENERATION
                                  DIRECT DISCHARGERS
SUBCATEGORY LOAD SUMMARY
(TONS/YEAR)	

Flow (MGD)

Dissolved Iron
Oil and Grease
Total Suspended Solids
Total Toxic Metals
Total Organics

SUBCATEGORY COST SUMMARY

($X10'6)	

Investment
Annual
32.6

161,273.1
479.5
2,260.5
2,027.7
BPT/ECT

29.1

36.8
170.8
923.9
23.3
            52.46
            19.46
             39.22
             4.76
             BAT-2

             4.5

             3.0
             12.1
             59.:
             2.6
             43.45
             5.33
             111.88
             17.63
                                  INDIRECT (POTW) DISCHARGERS
SUBCATEGORY LOAD SUMMARY
(TONS/YtAR)	

Flow (MGD)

Dissolved Iron
Oil and Grease
Total Suspended Solids
Total Toxic Metal*
Total Organics
SUBCATEGORY COST SUMMARY

(SX10"6)  	
Investment
Annual
RAW
WASTE

3.8

18,603.0
55.3
261.4
233.9
PSES-1

3.4

4.6
20.1
108.7
2.7
            1.76
            1.60
                                          496
PSES-2

0.5

0.7
3.1
16.7
0.4
             1.86
             0.23
PSES-3

0.5

0.4
1.4
6.9
0.3
PSES-4
             2.07
             0.26
             5.41
             0.86

-------
                      SUMMARY  OF  EFFLUENT LOADINGS AND TREATMENT COSTS
                           HYDROCHLORIC ACID PICKLING SUBCATEGORY
                              ROD/WIRE/COIL!   NEUTRALIZATION
SUBCATEGORY LOAD SUMMARY
(TONS/YEAR)
Flow (MGD)
Dissolved Iron
Oil and Grease
Total Suspended Solids
Total Toxic Metals
DIRECT
RAW
WASTE
1.1
1,414.2
11.8
35.4
15.9
DISCHARGERS

BPT/BCT
0.4
0.4
1.9
10.2
0.3

BAT-1
0.1
0.1
0.6
3.2
0.1
Total Organics
SUBCATEGORY COST SUMMARY

($X10"6)	.
Investment
Annual
SUBCATEGORY LOAD SUMMARY
(TONS/YSAR)	

Flow (MGD)

Dissolved Iron
Oil and Grease
Total Suspended Solids
Total Toxic Metals
Total Organics
            3.86
            0.78
             0.18
             0.02
                                  INDIRECT (POTW) DISCHARGERS
RAW
WASTE

0.9

1,218.5
10.2
30.5
13.7
PSES-1

0.4

0.4
2.0
10.8
0.3
PSES-2

0.1

0.1
0.5
2.8
0.1
SUBCATEGORY COST SUMMARY

($X10~6)	
Investment
Annual
                        (1)
            4.70
            1.15
             0.25
             0.03
(1)  The cost summary totals do not include confidential  plants.
                                         497
                                                                        BAT-2

                                                                        0.1

                                                                        0.1
                                                                        0.3
                                                                        1.3
                                                                        0.1
                                                                                     BAT-3
             0.51
             0.06
             10.92
             1.55
PSES-3

0.1

0.1
0.2
1.1
0.1
                                       PSES-4
             0.62
             0.08
             15.04
             2.13
                                                                                                              m
                                                                                                              Ps
                                                                                                              &
                                                                                                              &


-------
                     SUMMARY OF EFFLUENT LOADINGS AND TREATMENT COSTS
                          HYDROCHLORIC ACID PICKLING SUBCATEGORY
                                PIPE/TUBE:  NEUTRALIZATION	
                                  DIRECT DISCHARGERS
SUBCATEGORY LOAD SUMMARY
(TONS/YEAR)	

Flow (MGD)

Dissolved Iron
Oil and Grease
Total Suspended Solids
Total Tcxic Metals
Total Organics
RAW
WASTE

0.4

545.2
4.5
13.6
6.1
BPT/BCT

0.2

0.3
1.2
6.4
0.2
BA7-1

0.05

(1)
0.2
1.2
(1)
BAT-2

0.05

(1)
1.0
0.5
(1)
BAT-3

0
SUBCATEGORY COST SUMMARY
($X10"6)	
Investiient
Annual
                        (2)
            0.96
            0.21
             0.07
             0.009
             0.13
             0.02
             2.80
             0.38
                                  INDIRECT (POTW) DISCHARGERS
SUBCATEGORY LOAD SUMMARY
(TONS/YEAR)	

Flow (MCD)

Dissolved Iron
Oil and Grease
Total Suspended Solids
Total Toxic Metals
Total Organics
RAW
WASTE

0.1

146.1
1.2
3.6
1.6
PSES-l

0.1

0.1
0.5
2.9
0.1
PSES-2

0.01

(1)
0.1
0.3
(1)
PSES-3

0.01

(1)
(I)
0.1
(1)
                                       PSES-4
SUBCATECORY COST SUMMARY

(SX10"6)      	
Investment
Annual
            0.03
            0.006
             0.001
             0.0002
(1)  Load is less than or equal to 0.05 ton/year.
(2)  The cost summary totals do not include confidential plants.
             0.003
             0.0003
             0.06
             0.008

-------
                      SUMMARY OF  EFFLUENT LOADINGS AKD TREATMENT COSTS
                           COMBINATION ACID PICKLING SUBCATECORY
                         BATCH STRIP/SHEET/PLATE:  NEUTRALIZATION
SUBCATEGORY LOAD SUMMARY
(TONS/YEAR)	

Flow (MGD)

Dissolved Iron
Fluoride
Oil and Grease
Total Suspended Solids
Total Toxic Metals
Total Organics
DIRECT DISCHARGERS

RAW<»
WASTE

1.9

1,349.3
2,819.5
20.1
74.5
226.8
BPT/BCT

0.8

0.8
12.2
3.6
19.4
0.6
             BAT-1
0.2
0.2
3.4
1.0
5.4
0.2
                          BAT-2
             0.2
0.1
3.4
0.5
2.2
0.1
                                       BAT-3
SUBCATEGORY COST SUMMARY

(SXIO"6)	
                        (2)
Investment
Annual
            3.21
            0.74
             0.42
             0.05
             0.68
             0.09
             12.16
             1.66
(1)  Raw waste loads for the plants which haul all wastes have b«en included in these totals.
(2)  The cost sumary totals do not include confidential plants.
Note:  There are no POTW dischargers in this segnent.

-------

                     SUMMARY OF EFFLUENT LOADINGS ADD TREATMENT COSTS
                          COMBINATION ACID PICKLING SUBCATEGORY
                      CONTINUOUS STRIP/SHEET/PLATE;  NEUTRALIZATION
DIRECT DISCHARGERS
SUBCATEGORY LOAD SUMMARY
(TONS/YEAR)
Flow (MGD)
Dissolved Iron
Fluoride
Oil and Grease
Total Suspended Solids
Total Toxic Metals
Total Organics
SUBCATEGORY COST SUMMARY
($X10~6)
Investment
Annual
SUBCATECORY LOAD SUMMARY
(TONS/YEAR)
Flow (MCD)
Dissolved Iron
Fluoride
Oil and Grease
Total Suspended Solids
Total Toxic Metals
Total Organics
SUBCATECORY COST SUMMARY
($X10~S
Investment
Annual
RAW
HASTE
15.1
9,089.0
10,502.9
202.0
1,615.8
3,026.4
-
INDIRECT
RAW
WASTE
1.1
657.6
759.8
14.6
116.9
219.0
-
BPT/BCT
:z.9
17.2
258.0
75.7
409.3
13.2
17.57
6.56
BAT-1
1.7
2.3
34.2
10.0
54.3
1.8
3.14
0.39
BAT- 2
1.7
1.1
34.2
4.6
22.4
0.7
5.36
0.68
BAT-3
0
-
41.09
7.02
(POTW) DISCHARGERS
PSES-1
0.9
1.2
18.5
5.4
29.3
0.9
0.35
0.12
PSES-2
0.1
0.2
2.5
0.7
3.9
0.1
0.04
0.005
PSES-3
0.1
0.1
2.5
0.3
1.6
(1)
0.07
0.008
PSES-4
0
-
0.50
0.09
(1)  Load is less than or  equal  to  0.05  ton/year.
                                          son

-------
sww»w*
                                     SUMMARY OF EFFLUENT LOADINGS AND TREATMENT COSTS
                                           COMBINATION ACID PICKLING SUBCATEGORY
                                              ROD/WIRE/COIL:  NEUTRALIZATION
                                                  DIRECT DISCHARGERS
SUBCATEGORY LOAD SUMMARY
(TONS/YEAR)	

Flow (MGD)

Dissolved Iron
Fluoride
Oil and Grease
Total Suspended Solids
Total Toxic Metals
Total Organics
                                                  2.2

                                                  1,775.2
                                                  2,878.7
                                                  24.0
                                                  117.5
                                                  421.9
            BPT/3CT

            1.3

            1.5
            21.9
            6.4
            34.8
            1.2
                         BAT-1

                         0.3

                         0.3
                         4.5
                         1.3
                         7.2
                         0.2
                          BAT-2

                          0.3

                          0.2
                          4.5
                          0.6
                          3.0
                          0.1
                                                                                                     BAT-3
                SUBCATEGORY COST SUMMARY
                Investment
                Annual
            5.84
            1.55
                                                           0.99
                                                           0.12
                                      1.44
                                      0.18
                                                                                                     3.14
                SUBCATECORY LOAD SUMMARY
                (TONS/YEAR) _

                Flow (MGD)
                                                  INDIRECT (POTW) DISCHARGERS
RAW
WASTE

2.1
                                              PSES-1
                                              1.2
                                                           PSES-2
                                                           0.3
                                                                        PSES-3
                                                                        0.3
                Dissolved Iron
                Fluoride
                Oil and Grease
                Total Suspended Solids
                Total Toxic Metals
                Total Organics
1,664.7
2,699.4
22.5
110.2
395.6
1.3
19.7
5.8
31.2
1.0
                                                           0.3
                                                           4.2
                                                           1.2
                                                           6.7
                                                           0.2
                                      0.1
                                      4.2
                                      0.6
                                      2.6
                                      0.1
                SUBCATEGORY COST SUMMARY

                ($X10~6)	 	
                Investment
                Annual
                                              3.20
                                              0.87
                         0.41
                         0.05
                                      0.59
                                      0.08
                                       7.08
                                       1.00
                                                          501

-------
r
                                          SUMMARY OF EFFLUENT LOADINGS AND TREATMENT COSTS
                                                COMBINATION ACID PICKLING SUBCATECORY
                                                 BAR/BILLET/BLOOH;  NEUTRALIZATION

SUBCATECORY LOAD SUMMARY
(TONS /YEAR)
Flow (MGD)
Dissolved Iron
Fluoride
Oil and Crease
Total Suspended Sol:' as
Total Toxic Metals
Total Organics
DIRECT
RAW(1)
WASTE
0.2
181.4
460.3
2.7
6.8
17.8
-
DISCHARGERS

BPT/BCT
0.06
0.1
1.0
0.3
1.6
0.1
-


BAT-1
0.03
12)
0.5
0.1
0.7
'2>
-
                                                                                             BAT-2

                                                                                             0.03

                                                                                             (2)
                                                                                             0.5
                                                                                             0.1
                                                                                             0.3
                                                                                             (2)
                                       BAT-3
                     SimCATECORY COST SUMMARY

                     <$X10~6)
                                             (3)
                     Investment
                     Annua1
                     SUBCATECORY LOAD SUMMARY
                     (TONS/YEAR)	

                     Flow  (MCD)

                     Dissolved  Iron
                     Fluoride
                     Oil and Crease
                     Total Suspended  Solids
                     Total Toxic Metals
                     Total Organics
-
INDIRECT
RAW
WASTE
0.01
10.0
25.4
0.1
0.4
1.0
0.60
0.20
0.06
0.008
(POTW) DISCHARGERS
PSES-1
0.01
(2)
0.2
0.1
0.4
(2)
PSES-2
0.002
(2)
(2)
(2)
0.1
(2)
                          0.16
                          0.02
                          PSES-3

                          0.002

                          (2)
                          (2)
                          (2)
                          (2)
                          (2)
                          4.54
                          0.62
                          PSES-4
                     SUBCATECORY  COST  SUMMARY

                     ($X10~6)
                     Investment
                     Annual
0.56
0.18
0.04
O.C05
0.10
0.01
2.72
0.37
                     (1)   Raw waste  loads  for  the plants which haul all wastes have been included in these totals.
                     (2)   Load  is  less than or «qual to 0.05 ton/year.
                     (3)   The cost summary totuxs do not include confidential plants.
                                                              502

-------
                      SUMMARY OF EFFLUENT LOADINGS AND TREATMENT COSTS
                           COMBINATION ACID PICKLING SUBCATEGORY
                      	 	  PIPE/TUBE:  NEUTRALIZATION   	
SUBCATEGORY LOAD SUMMARY
(TONS/YEAR)	

Flow (MGD)

Dissolved Iron
Fluoride
Oil and Grease
Total Suspended Solids
Total Toxic Metals
Total Organics
DIRECT DISCHARGERS

RAW(1)
I'ASTE       BPT/BCT
1.1
            0.6
                         BAT-1
                         0.1
715.8
1,851.2
12.3
38.3
70.9
0.6
9.3
2.7
14.8
0.5
0.1
2.1
0.6
3.4
0.1
             BAT-2

             0.1

             0.1
             2.1
             0.3
             1.4
             (2)
SUBCATEGORY COST SUMMARY

($X1Q"6)	
                        (3)
Investment
Annual
SUBCATEGORY LOAD SUMMARY
(TONL'/YEAR)	

Flow (MGD)

Dissolved Iron
Fluoride
Oil and Grease
Total Suspended Solids
Total Toxic Metals
Total Organics
-
INDIRECT
RAW
WASTE
1.0
599.5
1,550.5
10.3
32.0
59.4
3.00
0.69
0.21
0.03
(POTW) DISCHARGERS
PSES-1
0.4
0.5
7.1
2.1
11.2
0.4
PSES-2
0.1
0.1
1.8
0.5
2.9
0.1
                                      0.53
                                      0.07
                                      PSES-3

                                      0.1

                                      0.1
                                      1.8
                                      0.2
                                      1.2
                                      (2)
                          14.84
                          2.04
                                                   PSES-4
SUBCATECORY COST SUMMARY
($X10~6)	
Investment
Annual
                        (3)
            1.10
            0.28
0.04
0.005
0.11
0.01
2.97
0.41
(1)  Raw waste loads for the plants which haul all wastes have been included in these totals.
(2)  Load is less than or equal to 0.05 ton/year.
(3)  The cost summary totals do not include confidential plants.
                                          503
                                                                                                            t

-------
o
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  i
II
^
                            505
Preceding page blank

-------
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                       506

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                                                                                                     |§

                                                                                                     II
                                                                                                    1
                                                                                                     111
                                               507

-------
                                 SUBCATECORY SUMMARY DATA
                                   BASIS 7/1/76 DOLLARS
SUBCATECORY:
        Cold Formis*
        Cold Rollins
     :  ReeircuUtion
                           HODEt SIZE (TPD):
                           OPER. DAYS/YEAR  :
                           TURNS/DAY        «
SINGLE
STAND
 450
 348
   3
MULTI
STAND
2400
 348
   3
 Single Stand^

 Model Plant
 13   Direct Di»eh»rger»
  3   Indirect Ditcharger*
 10
 26
Contract Htuled
Active Pl»nt»
 Multi Stand

 Model Plant
  21    Direct  Diacharger»
   3    Indirect Ditchargera
   3    Contract Hauled
  27    Active  Plant*
0.002 MCD
 0.03 MCD
0.006 MCD
 0.02 MOD
 0.06 MCD
                        0.06 MCD
                          1.3 MCD
                          0.2'MGD
                          0.2 MCD
                          1.7 MCD
                                               BPT/BCT
                                               PSES-1
                                                                       BAT-3
                                                                       PSES-4
   Inveitaent
        Single  St«nd
        Multi Stand
   Annual
        Single  Stand
        Multi  Stand
   S/Ton of Production
        Single Stand
        Multi Stand
208
494
29.9
55.0
0.19
0.066
NSPS-1
PSNS-1
8.0
49.5
1.3
6.7
0.008
0.008
NSPS-2
psrs-2
184
1142
24.2
147
0.15
0.18
NSPS-3
PSHS-3
538
1946
75.0
291
0.48
0.35
NSPS-4
PSNS-4
    Inveitoent
         Single  Stand
         Multi  Stand
    Annual
         Single Stand
         Multi Stan
-------
SUBCATECORY SUMMARY DATA
COLD FORMING-RECIRCULATION
PAGE 2
WASTEWATER
CHARACTERISTICS





1
11
13
23
39
55
60
65
72
76
77
78
80
81
84
85
86
87
114
115
118
119
120
122
124
128
Flow (GPT) Single Stand
Flow (GPT) Multi Stand
pH (SU)
Oil and Grease
Total Suspended Solids
Acenaphlhene
1,1, 1-Trichloroethane
1,1-Dichloroethane
Chloroform
Fluoranthene
Naphthalene
4,6-Dinitro-o-cresol
Phenol
Benzo (a) Anthracene
Chrysene
Acenaphlhylene
Anthracene
Fluorene
Phenanthrene
Pyrene
Telrachloroethylene
Toluene
Trichlorocthylene
Ant imony*
Arsenic*
Cadmium*
Chromium*
Copper*
Lead*
Nickel*
Zinc*
Notes: All concentrations are

{ BAT and PSES-2 through
RAW
WASTE
5 f5'
25 [10:
6-9
14700
1013
0.055
0.063
0.011
0.037
0.27
1.5 (0
0.063
0.17
0.16
0.11
0.14
0.14
3.5
0.91
0.30
C.036 (0.
0.012
0.009
0.031
0.26
0.11
2.5
7.1
2.9
3.3
3.7
IlPT/BCT
NSPS-1
PSES-1
PSNS-1
5 K
25 [lO]
6-9
(10)7
(30)16
0.01
0.063
0.011
0.002
0.01
.1***)0.012 (0
0.063
0.093
0.005
0.001
0.01
0.01
0.01
0.01
0.005
15***)0.035 (0.
0.004
0.002
0.031
0.1
0.016
(0.4)0.28
0.1
(0.15)0.1
(0.3)0.2
(0.1)0.06
BAT-1
NSPS-2
PSES-2
PSNS-2
5 K)
25 [10
6-9
(5**)2.0
(15)9.8
0.01
0.063
0.011
0.002
0.01
.1***)0.012
0.025
0.093
0.005
0.001
0.01
0.01
0.01
0.01
0.005
15***)0.035
0.004
0.002
0.031
0.05
0.016
(0.1)0.03
0.03
(0.1)0.06
(0.1)0.04
(0.1)0.06
BAT-2
NSPS-3
PSES-3
PSNS-3
5 M
], 25 DO:
6-9
(5**)2.0
(15)9.8
0.01
0.063
0.011
0.002
0.01
(0.02)0.012
0.025
0.05
0.005
0.001
0.01
0.01
0.01
0,01
0.005
(0.15***)0.035
0.004
0.002
0.031
0.05
0.016
(0.1)0.03
0.03
(0.1)0.06
(0.1)0.04
(0.1)0.06
BAT-3
NSPS-4
PSES-4
PSNS-4
0
0
_
-
-
_
_
_
_
_
-
_
_
_
-
_
-
_
-
_
-
-
-
-
-
-
-
-
-
-

in mg/1 unless otherwise noted.
PSES-4 costs are
incremental over BPT/PSES-1
costs.

     :  Values in parentheses represent the concentrations used to develop the
        limitations/standards for various levels of treatment.  All other values
        represent long tern average values or predicted average performance levels.
     :  Values in brackets represent NSPS/PSNS flows.

*   Toxic pollutant found in all raw waste sanplcs.
**  Limit for oil and grease is based upon 10 mg/1 (maximum only).
*** Maximum limit only.
    PSNS/NSPS flow

                                               SO1)

-------
                                                SUBCATECORY SUMMARY DATA
                                                  BASIS  7/1/78 DOLLARS
SUBCATECORY:  Cold *oning
           :  Cold Rolling
           :  Combination
MODEL SIZE (TPD):  4800
OPER. DAYS/YEAR  :   348
TORNS/DAY        :     3
RAW WASTE FLOWS
Model Plant                   1.4 MGD
10   Direct Discharger!      14.0 MGD
 0   Indirect Dischargers     0.0 MOD
10   Active Plants           14.0 MGD
MODEL COSTS ($X10"3)

Investment
Annual
$/Ton o£ Production
 Investment
 Annual
 $/Ton of Production
WASTEWATER
CHARACTERISTICS	

      Flow  (CPT)
      pH  (SU)
      Oil and Grease
      Total Suspended  Solids

  39   Fluoranthene
  55   Naphthalene
  78   Anthracene
  80   Fluorene
  61   Phenanthrene
  84   Pyrene
  85   Tetrachlorothylene
 115   Arsenic*
 119   Chromium*
 120   Copper*
 122   Lead
 124   Nickel*
 128   Zinc*












RAW
WASTE
300 [130]
6-9
1481
843
0.071
4 (0
0.18
0.98
5.1
0.05
0.02 (0.
0.16
0.03
0.89
0.1
0.21
0.15
BPT/BCT
PSES-1
1540
299
0.18
RSPS-1
PSNS-1
1182
202
0.12
BPT/BCT
NSPS-1
PSES-1
PSNS-1
300 [l30
6-9
(10)7
(30)16
0.01
.1***)0.012 (0
0.01
0.01
0.01
0.005
15***)0.02 (C.
0.1
(0.4)0.03
0.1
(0.15)0.1
(0.3)0.2
(0.1)0.06
BAT-1
PSES-2
S61
77.9
0.047
HSPS-2
PSNS-2
1652
266
0.16
BAT-1
BSPS-2
PSES-2
PSNS-2
300 [130j
6-9
(5**)2.0
(15)9.8
0.01
.1***)0.012 (0
0.01
0.01
0.01
0.005
15***)0.02 (0.
0.05
(0.1)0.03
0.03
(0.1)0.06
(0.1)0.04
(0.1)0.06
BAT-2
PSES-3
3988
553
0.33
HSPS-3
PSNS-3
3731
533
0.32
BAT-2
NSPS-3
PSES-3
PSNS-3
300 [130|
6-9
(5**)2.0
(15)9.8
0.01
.1***)0.012
0.01
0.01
0.01
0.005
15***)0.02
0.05
(0.1)0.03
0.03
(0.1)0.06
(0.1)0.04
(0.1)0.06
BAT-3
PSES-4
12298
2470
1.48
NSPS-4
PSNS-4
6920
1386
0.83
BAT-3
NSPS-4
PSES-4
PSNS-4
0
-
-
-
_
-
-
-
-
-
-
-
-
-
-
-
-
 Notes:   All  concentrations  are  in mg/1  unless  othervise  noted.
      :   BAT  and PSES-2 through  PSES-4  are  incremental  over  BPT/PSES-1  costs.
      :   Values  in parentheses represent the  concentrations  used  to develop
         the  limitations/standards for  various  levels of  treatment.  All  other
         values  represent  long term average values or predicted average performance  levels.
      :   Values  in brackets  represent NSPS/PSNS flows.

 *    Toxic pollutant  found  in all raw  waste  samples.
 **   Limit for  oil  and grease is  based  upon  10 ng/1  (maximum only).
 ***  Maximum limit  only
      NSPS/P3NS  flow
                                                   510

-------

                                  SU8CATECORY SUMMARY DATA
                                   BASIS 7/1/78 DOLLARS
SUBCATECORY:  Cold Forming
           t  Cold Rolling
           :  Direct Application
                              SINGLE    MULTI
                              STAKD     STASP
           HODEL SIZE (TTO):   2000      2700
           OPER. DAYS/TEAR :    348       348
           TURNS/DAY       :      3         3
HAW WASTE FLOWS
Sin»l« Stand

Model Plant                   0.2 HOT
 9   Direct Diachargera       1.8 MCD
 0   Indirect Diichargert       0 MCD
 1   Contract Hauled          0.2 MCD
10   Active Plant!            2.0 MCD

Multi Stand

Model Plant                   1.1 MCD
10   Direct DUchargere      11.0 MCD
 0   Indirect Diachargera     0.0 MCD
 1   Contract Hauled          1.1 NOD
11   Active Planta           12.1 MCD
MODEL COSTS
Invealaenl
     Single Stand
     Multi Stand
Annual
     Single Stand
     Multi Stand
I'Ton oi Production
     Single Stand
     Hulli Stand
                                             BPT/BCT
                                             PSES-1
714
1216

102
206

0.15
0.22
          BAT-1
          PSES-2
153
539

20.1
75.3

0.029
0.080
          BAT-2
          PSES-3
2057
3367

26*
468

0.38
0.50
          8AT-3
          PSES-4
2633
7887

461
1842

0.66
1.96
Inveetaent
     Single Stand
     Multi Stand
Annual
     Single Stand
     Hul'.i Stand
$/Ton of Production
     Single Stand
     Hulti Stand
0.09
0.20
0.10
0.27
                                                                 HSFS-3
                                                                 PSNS-3
1456
3983

194
557

0.28
0.59
                              HSPS-4
                              PSNS-4
2014
7670

290
1548

0.42
1.65
                                             Sll
                                                                      J

-------
SUBCATECORY NUMMARY DATA
COLD FORMING-DIRECT APPLICATION
PAGE 2	
WASTEWATER
CHARACTERISTICS




6
11
55
78
85
86
115
117
119
120
122
124
128
Flow (GPT) Single Stand
Flow (GPT) Multi Stand
pH CSU)
Oil and Grease
Total Suspended Solids
Carbon Tetrachloride
1,1, 1-Trichloroe thane
Naplhalene
Anthracene
Tetrachloroethylene
Toluene
Arsenic
Beryllium
Chroaium
Copper*
Lead
Nickel*
Zinc
RAW
WASTE
90 [25]
400 [2901
6-9
1215
135
0.007
0.043
4.4 (0.
0.014
0.02 (0.1
0.69
0.02
0.01
0.04
0.17
BPT/BCT BAT-1
NSPS-1 NSPS-2
PSES-1 PSES-2
PSKS-1 PSNS-2
90 t
400 t
6-9
(10)7
(30)16
0.007
0.043
1***)0.012
0.01
!5: 90 125]
190 400 K903
6-9
(5**)2.0
(15)9.8
0.007
0.043
(0.1***)0.012 (0.
0.01
BAT-2 BAT-3
NSPS-3 NSPS-4
PSES-3 PSES-4
PSNS-3 PSNS-4
90 t
400 \
6-9
(5**)2.0
(15)9.8
0.007
0.043
1***)0.012
0.01
IS) 0
!90J 0
-
-
-
_
.

-
5**-*)0.02 (0.15***}0.02 (0.15***)0.02
0.004
0.02
0.006
(0.4)0.04
0.1
0.39 (0.15)0.1
0.2
0.098
(0.3)0.2
(0.1)0.06
0.004
0.02
0.006
(0.1)0.03
0.03
(0.1)0.06
(0.1)0.04
(0.1)0.06
0.004
0.02
0.006
(0.1)0.03
0.03
(0.1)0.06
(0.1)0.04
(0.1)0.06
-
-
-
-
.
-
-
-
Note.*:  All concentrations are in «g/l unless otherwise noted.
      :  BPT and PSES-2 through PSES-4 ire increnenlal over BPT/PSES-1 costs.
      I  Values in parentheses represent the concentrations used to develop
        the proposed liailations/standards.  All other value* represent long
        lent average values or predicted average performt'.ce levels.
      :  Values in brackets represent NSPS/PSNS flows.

*     Toxic pollutant found in all raw waste sanples analyzed.
**    Licit for ail and greaiie is based upon 10 ng/1 (uxiaiusj only).
***   Maximum limit only.
      NSPS/PSNS flow
                                                                                                                      «1
                                                                                                                      ii
                                                                                                                      si

-------
                         SUBCATECORY SUMMARY PATA
                           BASIS 7/1/78 DOLLARS
SUBGATECORY:
              Cold Fonaing
              Cold Worked Pipe «nd Tube
              Uting Water
MODEL SIZE (TPD):   500
OPER. DAYS/YEAR :   260
TURNS/DAY       :     3
RAW WASTE FLOWS
Model Plant                   1.5 MOD
 9   Direct Dischargers      13.3 MGD
 2   Indirect Dischargers     3.0 MGD
 4   Zero Dischargers         5.9 MOD
15   Active Plants           22.2 MGD
MODEL COSTS (SX10"3)
Investsrent
Annua1
S/Ton of Production
WASTE WATER
CHARACTERISTICS
     Flow (CPT)
     pH (SU)
     Oil anJ Grease
     Total Suspended Solids
120  Copper
124  Nickel
128  Zinc
RAW
WASTE

2960
6-9
65
25

0.07
0.025
0.23
Note:  All concentrations are in ng/1 unless otherwise noted.
                                         513

-------
                         SOBCATEGOKY SOMURY DATA
                           BASIS 7/1/78 DOLLARS
SOBCATECORYt
           I
           I
Cold Forming
Cold Uorktd Pip* tat Tub*
Ueing Oil
MODEL SIZE (TPD):   270
OPER. DATS/YEAR I   260
TURNS/DAY       i     3
RAW HASTE FLOWS
Motel Plant
1 Direct Ditcharger
0 Indirect Diacharger*
IS Plant* Hauling U«tt«
Solution*
2 Z*ro Di*ch*rg*r*
1 Khar Di*ch*rger
19 active Pl*nt*
1.3 MGD
1.3 MGO
0.0 MGO

19.3 HCD
2.6 NCD
1.3 HCD
24. 5 MCD
      COSTS ($X10~3)
InvestMnt
Annual
S/Ton of Production
UASTEUATER
CHARACTERISTICS
     FlOH (CPT)
     pH (SU)
     Oil and Cr**a*
     Total Su*p*n
-------
                      SUMMARY  OF  EFFLtEKT LOADINGS AND TREATMENT  COSTS
                              	COLD  FORMING  SUBCATEGORY
                                             DIRECT DISCHARGERS
                                                               (1)
SUBCATEGORY LOAD SUMMARY
(TONS/YEAR)	

Flow (MGD)

Oil and Crease
Total Suspended Solids
Total Toxic Metala
Total Organics

SUBCATEGORY COST SUMMARY
(SX10'6)	

Investment
Annual
(2)
                     73.3

                     2,742,937.8
                     44,570.5
                     320.6
                     356.9
28.1

285.8
653.0
21.4
4.1
28.1

81.7
400.0
9.8
4.0
                                  34.86   12.98
                                  4.57    1.84
BAT-2

28.1

81.7
400.0
9.8
3.8
                 113.95
                 15.-.4
                                                             BAT-3
                   268.31
                   53.4S
                                             INDIRECT (POrW) DISCHARGERS
SUBCATEGORY LOAD SUMMARY
(TONS/YEAR)	

Flow (MOD)

Oil and Grease
Total Suspended Solids
Total Toxic Metals
Total Organics

SUBCATECORY COST SUMMARY

(?X10"6)	

Investment
Annual
(2)
                     RAW
                     WASTE

                     3.2

                     4,194.9
                     355.0
                     11.4
                     8.1
PSES-1  PSES-2

0.2     0.2
1.9
4.4
0.3
0.2
                                  0.15
                                  0.02
0.6
2.7
0.2
0.2
        0.09
        0.01
PSES-3

C.2

0.6
2.7
0.2
0.2
         1.99
         0.26
          3.89
          0.57
(1) The raw waste load and BPT cost contributions of the zero discharge operations are
    included in the direct discharger data.  As these plants have no wastewater discharges,
    they do not contribute to BAT costs or to the BPT and BAT effluent waste loa
-------
                      SUMMARY OF EFFLUEOT LOADINGS AND TREATMENT COSTS
                                 COLD FORMING SUBCATECORY
                                      COLD ROLLING
                                             DIRECT DISCHARGERS
                                                               (1)
SUBCATEGORY LOAD SUMMARY
(TONS/YEAR)	

Flow (MGD)

Oil and Grease
Total Suspended Solids
Total Toxic Metals
Total Organic*

SUBCATECORY COST SUMMARY

(SX10"6)	

Investment
Annual
(2)
                     RAW
                     WASTE

                     29.6

                     86,942.3
                     22,502.3
                     93.7
                     336.5
BPT/BCT   BAT-1
28.1

285.8
653.0
21.4
4.1
                               27.71
                               3.64
28.1

81.7
400.0
9.8
4.0
          12.98
          1.84
BAT-2

28.1

81.7
400.0
9.8
3.8
          113.95
          15.44
                    BAT-3

                    0
          268.31
          53.48
                                             INDIRECT (POTW) DISCHARGERS
SUBCATEGORY LOAD SUMhARY
(TONS/YEAR)	

Flow (MGD)

Oil and C.-ease
Total Suspended Solids
Total Toxic Metal*
Total Organic*

SUBCATEGORY COST SUMMARY

(SX10"fe)	

Investment
Annual
(2)
                     RAW
                     WASTE

                     0.2

                     3,986.2
                     274.7
                     5.4
                     2.1
PSES-1

0.2

1.9
4.4
0.3
0.2
                               0.06
                               o.ooa
PSES-2

0.2

0.6
2.7
0.2
0.2
          0.09
          0.01
PSES-3

0.2

0.6
2.7
0.2
0.2
          1.99
          0.26
          3.89
          0.57
(1)  The raw waste load and BPT cost contributions of the rero discharge operations
     (contract haul) are included in the direct discharger data.   As these  plants  have
     no uastewater discharges, they do not contribute to BAT costs or to the BPT and  BAT
     effluent waste loads.
(2)  The cost summary totals do not include confidential plants.

-------

                     SUMMARY OF EFFLUENT LOADINGS ASD TREATMENT COSTS
                                 COLD FORMING SU3CATECORY
                                COLD WORKED PIPE AND T>JBE	
                                                       DIRECT DISCHARGERS
SUBCATECORY LOAD SUMMARY
(TONS/YEAR) _

Flow (MCD)

Oil and Greaie
Total Suspended Solid*
Total Toxic Metals
Total Organics

SUBCATECORY COST SUMMARY
(1)
Investment
Annual
                               RAW
                               WASTE

                               43.7

                               2,655,995.5
                               27,068.2
                               226.9
                               20.4
BPT/BCT
BAT
                                              7.15
                                              0.93
                                                       INDIRECT (POTW)  DISCHARGERS
SUBCATECORY LOAD SUMMARY
(TONS/YEAR)	

Flow (MCD)

Oil and Greaie
Total Suspended Solids
Total Toxic Metals
Total Toxic Organics

SUBCATEGORY COST SUMMARY
UX10"6)	

Investment
Annual
                               RAW
                               WASTE

                               1.0

                               208.7
                               80.3
                               1.0
PSES
                                              0.09
                                              0.01
(1) The cost sunaary totals do not include confidential plants.

-------
                     SUMMARY OF EFFLUENT LOADIKCS AND TREATMENT COSTS
                                 COLD FORMING SUBCATECORY
                        COLD ROLLING - RECIRCULATION, SINGLE STAND
                                             DIRECT DISCHARGERS

SUBCATECORY LOAD SUMMARY
(TONS/YEAR) _

Flow (MOD)
                                                <2>
RAW
HASTE

0.05
BPT/BCT BAT-1

0.03    0.03
                 BAT-2
         0.03
                           BAT-3
Oil and Crease
Total Suspended Solids
Total Toxic Metals
Total Organics

SUBCATECORY COST SUMMARY
:sxio'6) _

Investment
Annua 1
76.1
1.5
0.6
0.3
0.7
(1)
(1)
             1.10
             0.16
0.1
0.4
(1)
(1)
        0.10
        0.02
0.1
0.4
(1)
(1)
         2.32
         0.31
          6.80
          0.95
                                             INDIRECT (POTW) DISCHARGERS
SUBCATECORY LOAD SUMMARY
(TONS/YEAR)
RAW
WASTE
             PSES-1  PSES-2   PSES-3
                                        PSES-4
Flow (MCD)

Oil and Grease
Total Suspended Solids
Total Toxic Metals
Total Organics

SUBCATECORY COST SUMMARY

(SXIO"6)	

Investment
Annua1
0.007

144.1
9.9
0.2
0.1
                                                          0.007   0.007
0.)
0.2
(1)
(1)
             0.03
             0.005
(1)
0.1
(1)
(1)
        0.02
        0.003
0.007

(1)
0.1
(1)
(1)
         0.42
         0.06
          1.22
          0.17
(1)  Load is less than or equal to 0.05 ton/year.
(2)  Raw waste loads fot contract haul plants have been included in these
     totals.

-------
                                                                                                      i!
                                                                                                      If
                     SUMMARY OF EFFLUENT LOADINGS AND TREATMENT COSTS
                                 COLD FORMING SUBCATECORY
                         COLD ROLLING - RECIRCULATIOK. KULTI STAMP
DIRECT DISCHARGERS
SUBCATEGORY LOAD SUMMARY
(TONS /YEAR)
Flow (MCD)
Oil «nd Crease
Total Suspended Solidi
Total Toxic Metal*
Total Organic*
SUBCATEGORY COST SUMMARY
($X10"6>
Investment
Annual
SUBCATEGORY LOAD SUMMARY
(TONS/YEAR)
Flow (MCD)
Oil and Crease
Total Suspended Solida
Total Toxic Metal*
Total Organic*
SUBCATECORY COST SUMMARY
(SX10'6)
Investment
Annual
RAW<»
WASTE
1.4
30,736.6
2,118.1
41.6
15.7
-
INDIRECT
RAW
WASTE
0.2
3,842.1
264.8
5.?
2.0
-
BPT/BCT
1.3
12.8
29.3
1.7
0.7
$.83
0.40
BAT-1
1.3
3.7
17.9
0.6
0.6
0.97
0.13
BAT-2
1.3
3.7
17.9
0.6
0.5
22.32
2.87
BAT-3
0
-
3*. 04
5.68
(POTW) DISCHARGERS
PSES-1
0.2
1.8
4.2
0.2
0.1
0.03
0.003
PSES-2
0.2
0.5
2.6
0.1
0.1
0.07
0.009
PSES-3
0.2
0.5
2.6
0.1
0.1
1.57
0.20
PSES-4
0
-
2.67
0.40
(1)  Raw waste loads for contract  haul  plant*  have  b«en included
     in these totals.

-------
   Jf
DIRECT DISCHARGERS
SUBCATECORY LOAD SUHHARY
(TONS /YEAR)
Flow (MOD)
Oil and Grease
Total Suspended Solids
Total Toxic Metals
Total Organic*
SUBCATECORY COST SUMMARY
(SX10"6)
Investment
Annual
RAW
WASTE
14.4
30,966.6
17,626.5
32.2
217.5
f
BPT/BCT
14.4
146.4
334.5
10.2
1.6
7.57
1.29
BAT-1
14.4
41.8
204.9
4.6
1.6
5.80
0.81
Note:  There are no indirect dischargers  in this  segment.
                     SUMMARY OF EFFLUENT LOADINGS AND TREATMENT COSTS
                                 COLD FORMING SIWCATECORY
                                COLD ROLLING - COMBINATION	                                   I   j
                                                                                                        !   1
                                                                        BAT-2        BAT-3

                                                                        14.4         0

                                                                        41.8
                                                                        204.9
                                                                        4.6
                                                                        1.6
                                                                        41.25         127.19
                                                                        5.72          25.55
                                          520

-------
                     SUMMARY OF EFFLUENT LOADINGS AND TREATMENT COSTS
                                 COLD FORMING SUBCATEGORY
                      COLD ROLLING - DIRECT APPLICATION  SINGLE STAND
DIRECT DISCHARGERS
SUBCATEGORY LOAD SUMMARY
(TONS/YEAR)
Flow (MGD)
Oil and Grease
Tolal Suspended Solids
Total Toxic Metals
Tolal Organic*
SUBCATEGORY COST SUMMARY
<$xi
-------

                     SUMMARY OF EFFLUENT LOADINGS AND TREATMENT COSTS
                                 COLD FORMING SUBCAPiCORY
                      COLD ROLLING - DIRECT APPLICATION. MULTI STAND
SUBCAT CORY LOAD SUMMARY
(TONS/YEAR)
Flow (MOD)
Oil and Crease
Total Suspended Solid*
Tolal Toxic Metals
Total Organic*
SUBCATECORY COST SUMMARY
(SX10"6)
Investment
Annua 1
DIRECT
RAW")
WASTE
11.9
20,958
2,328.
16.0
89.2
-
DISCHARGERS
BPT/BCT
10.8
.9 109.8
8 250.9
8.3
1.5
9.19
1.21
BAT-1
10.8
31.4
153.7
3.9
1.5
5.19
0.72
                                                                        BAT-2        BAT-3

                                                                        10.8         0

                                                                        31.4
                                                                        153.7
                                                                        3.9
                                                                        1.5
                                                                        32.41         75.92
                                                                        4.50         17.73
Note:  There are no indirect dischargers in this segment.

(1) Raw was'.e loads for contract haul plants have been included in these totals.
                                          522

-------
                      SUMMARY OF EFFLUENT LOADINGS AND  TREATMENT  COSTS
                                  COLD FORMING SUBCATECORY
                           COLD WORKED PIPE  AND TUBE  -  USING  WATER
                                                       DIRECT DISCHARGERS
SUBCATECORY LOAD SUMMARY
(TONS/YEAR)	

Flow (MOD)

Oil and Crease
Total Suspended Solids
Total Toxic Metals
Total Toxic Organic!

SUBCATEGORY COST SUMMARY

($X10"6)	

Investment
AnnuaI
SUBCATEGORY LOAD SUMMARY
(TONS/YEAR)	

Flew (MCD)

Oil and Grease
Total Suspended Solids
Total Toxic Metals
Tc'.al Toxic Organics

SUBCATEGORY COST SUMMARY

($X10~6)	

Investment
Annual
RAW
WASTE

19.2

1,356.7
521.8
6.8
BPT/BCT
BAT
               4.06
               0.53
                                                       INDIRECT (POTW) DISCHARGERS
RAW
WASTE

3.0

208.7
80,3
1.0
PSES
               0.09
               0.01
                                           523

-------
                     SUMMARY OF EFFLUENT LOADINGS AND TREATMENT COSTS
                                 COLD FORMING SUBCATEGORY
                     	  COLD WORKED PIPE AND TUBE - USING OIL
                                                       DIRECT DISCHARGERS
                     *

SUBCATEGORY LOAD SUMMARY                               RAW            BPT/BCT
(TONS/YEAR)	                               WASTE	    BAT                            £!
                                                                                                     i
Flow (MCD)                                             24.5           0

Oil and Grease                                         2,654,638.8
Total Suspended Solids                                 26,546.4
Total Toxic Metals                                     220.1
Total Organics                                         20.4

SUBCATEGORY COST SUMMARY
($X!0~6)    	
Investment                                             -              3.09
Annual                                                 -              0.40
Note:  There are no indirect dischargers in this subdivision.

(1) The cost summary totals do not include confidential plants.

-------

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-------
                                  StraCATECORY  SUMMARY  DATA
                                    BASIS  7/1/78  DOLLARS
SUBCATECORYJ  Alkaline Cleaning
            I  Bitch
        MODEL SIZE (TPD):   ISO
        OPER. DAYS/YEAR I   250
        TURKS/DAY       1     2
RAW WASTE FLOWS
Model Plant                  0.04 MOT
22   Direct Dischargers       0.8 HOT
 9   Indirect Discharger*     0.3 MGD
31   Active Plant*            1.1 MCO
HODEL COSTS ($X10~3)
Investment
Annual
$/Ton of Production
Investment
Annual
$/Ton cf Production
WASTEVATER
CHARACTERISTICS
     Flow (OT) NSPS only
     Flow (OPT)
     pH (SU>
     Diaiolved Iron,
     Oil and Grease
                   (1)
     Total Suspended Solid*

 36  2(6-Dinilrololu*ne
 39  Fluoranthene
 84  Pyrene
114  Antimony
119  Chromium
121  Cyanide
122  Lead
124  Nickel
125  Seleniua
128  Zinc*
                           (1)









RAW
WASTE
50
250
7-11
0.38
13
10
0.016
0.017
0.11
0.048
0.085
0.019
0.038
0.013
0.07
0.12
BPT/
BCT
381
49.8
1.33




BPT/
BCT

250
6-9
0.38
(10)4.4
(30)23.8
0.016
0.017
0.011
0.048
0.04
0.019
0.038
0.013
0.07
0.06

BAT-1
37.6
5.0
0.13
KSPS
237
30.7
0.82
BAT-1
NSPS
50
25
6-9
0.38
(5**)2
(15)9.8
0.016
0.01
0.005
0.048
0.03
0.019
0.038
0.013
0.07
0.0«

BAT-2
840
108
2.88





BAT-2

0
-
_
.
-
_
-
-
-
-
_
-
-
-
-
Not*it  All concentrations are in nx/1 unle** otherwise noted.
     t  BAT costs are incremental ,ver BPT costs.
     I  Value* in parentheses reprerent the concentration* used
        to develop the limitations/standards for the various levels
        of treatment.  All other values represent long term average
        values or predicted average performance levels.
 * Toxic pollutant found in all rax waste samples.
•* Limit for oil and grease is based upon 10 mg/1 (maxii
only).
(1) The BPT and BCT total suspended solids and oil and grease limitations for alkaline
    cleaning operations are applicable when alkaline cleaning uastewater* are co-treated
    with wastevaters from other steel finishing operations.
                                                  r>27
                                                    M

                                                    k

-------
                                  SUBCATECORY SCKUET DATA
                                   BASIS  7/1/78 DOLLARS
SUBGATECORY:
              Alkaline Cleaning
              Continuou*
RAW WASTE FLOWS
Model Flint                   O.S MCD
22   Direct Discharger*      11.6 MCD
 9   Indirect Discharger*     4.7 MCD
31   Active Plant!           16.3 MCD
                                                                  MODEL  SIZE  (TPD):   1500
                                                                  OPER.  DAYS/YEAR :   250
                                                                  TURNS/DAY        :      2
MODEL COSTS (SXlp"3)
                                                       BPT/BCT   BAT-1
                                                                           BAT-2
InveitBent
Annual
$/Ton of Production
Investment
Annual
$/Ton of Production
WASTE WATER
CHARACTERISTICS
          (CPT)  NSPS only
     Flow  (CPT)
     pH (SU)
     Dis«olved Iron. .
     Oil and  Cre**«U'
     Total Suspended Solid*

 36  2,6-Dinitrotolu*n*
 39  Fluoranthene
 84  Pyrene
114  Antimony
119  Chromium
121  Cyanide
122  Lead
124  Nickel
125  Selenium
128  Zinc*
                           (1)







RAH
UASTE
SO
350
7-11
0.38
13
10
0.016
0.017
0.011
0.0*8
0.085
0.01*
0.038
0.013
0.07
0.12
832
US
0.31





BPT/BCT

3SO
6-9
0.38
(10)4.4 (5*
367
46.1
0.12
NSPS
553
73.8
0.20
»AT-1
NSPS
50
35
6-9
0.38
*)2
(30)23.8 (15)9.8
0.016
0.017
O.OU
0.048
0.04
0.019
0.038
0.013
0.07
0.06
0.016
0.01
0.005
0.048
0.03
0.019
0.038
0.013
0.07
0.06
                                                                           BAT-2
Notei:  All concentration* are in *n/\ unlea* otherviae noted.
      I  BAT co»t» are incremental over BPT coat*.
      :  Value* in parenthe*** represent the concentration* u*ed
        to develop the liBitat>on*/*t*ndard* for ih* variou* level*
        of treatment.  All other value* repreceat lone ten* average
        values or predicted average performance level*.
 •Toxic pollutant found in all raw uaate *a*ple*.
**Limit for oil and great* is baled upon 10 wat'l (max
                                                          only).
(1)  The BPT and BCT total suspended *olid* and oil and greaae limitations for alkaline
     cleaning cperation* arf applicable when alkaline cleaning wastevaters are co-treated
     with wastewater* from other Heel finishing operation*.

-------
                     SUMMARY OF EFFLUEHT LOADINGS ATO TREATMENT COSTS
                              ALKALIHE CLEANING SUBCATECORY	
                                             DIRECT DISCHARGERS
SUBCATECORY LOAD SUMMARY
(TONS/YEAR)	

Flo*. (MGO)

Dissolved Iron
Oil and Create
Tot*l Suspended Solid*
Total Toxic Metal*
Total Organic*

SUBCATECORY COST SUMMARY

($X10~6)	

Investment
Annual
(2)
                     RAW
                     HASTE

                     12.4

                     4.9       4.9       0.5
                     167.8     56.8      2.6
                     129.1     307.2     12.6
                     4.8       3.4       0.3
                     0.9       0.9       0.1
                               12.26
                               1.68
          7.61
          0.96
                    BAT-2
57.72
8.10
                                             INDIRECT (POTW) DISCHARGERS
SUBCATECORY LOAD SUMMARY
(TONS/YEAR)	

Flow (MCD)

Dissolved Iron
Oil and Create
Total Suspended Solid*
Total Toxic Metal*
Total Organic*

SUBCATECORY COST SUMMARY

(SX1.0"*)	

Investment
Annual
                     5.5

                     1.9
                     68.7
                     52.8
                     1.9
                     0.3
                               PSES
(3)
(1)  Total Organic* load include* total cyanide.
(2)  The coat summary total* do not include
     confidential plant*.
(3)  General Pretreatnent Regulation* apply, 40 CFR Part 403.
                                                                                       \

-------
                     SUMMARY OF EFFLUENT LOADINGS AND TREATMENT COSTS
                               ALKALINE CLEANING SUBCATEGORY
                                          BATCH
                                                       DIRECT DISCHARGERS
SUBCATECORY LOAD SUMMARY
(TONS/YEAR)	

Flow (MCD)

Dissolved Iron
Oil and Crease
Total Suspended Solid*
Total Toxic Metals
Total Organics

SUBCATECORY COST SUMMARY
($X10"6)	

Investment
Annual
(2)
                               RAW
                               WASTE

                               0.8

                               0.3
                               11.2
                               8.6
                               0.3
                               0.1
BPT/BCT   BAT^l

0.8       0.08
0.3
3.8
20.5
0.2
0.1
                                         1.98
                                         0.26
(1)
0.2
0.8
(1)
(1)
          0.46
          0.06
          10.35
          1.32
                                                       INDIRECT (POTW) DISCHARGERS
SUBCATEGORY LOAD SUMMARY
(TONS/YEAR)	

Flow (MCD)

Dissolved Iron
Oil and Grease
Total Suspended Solids
Total Toxic Metals
Total Organic*

SUBCATECORY COST SUMMARY

(JXlO^j	

Investment
Annual
                               RAW
                               WASTE

                               0.4

                               0.1
                               4.6
                               3.5
                               0.1
                               (1)
(1)  Load is less than or equal to 0.05 ton/year.
(2)  The cost summary totals do not include
     confidential plants.
(3)  Total Organics load includes i.otal cyanide.
(4)  General Pretreatment Regulations apply, 40 CFR part 403.
                                         53.')

-------
                     SUMMARY OF EFFLUENT LOADINGS AND TREATMENT COSTS
                               ALKALINE CLEANING SUBCATECORY
                                       CONTINUOUS
                                                       DIRECT DISCHARGERS
SUBCATECORY LOAD SUMMARY
(TONS/YEAR)	

Flo* (MCD)

Dissolved Iron
Oil «nd Grease
Total Suspended Solids
Total Toxic Me£al»
Total Organics

SUBCATEGORY COST SUMMARY

(SXIO"6)	

Investment
Annual
                        (2)
                                                       RAW
                                                       WASTE

                                                       11.6

                                                       4.6
                                                       156.6
                                                       120.5
                                                       4.5
                                                       0.8
          BPT/BCT   BAT-1
                              BAT-2
          11.6

          4.6
          53.0
          286.7
          3.2
          0.8
                                                                 10.28
                                                                 1.42
1.2

0.5
2.4
11.8
0.3
0.1
                    7.15
                    0.90
          47.37
          6.78
                                                       INDIRECT (POTW) DISCHARGERS
SUBCATEGORY LOAD SUMMARY
(TONS/YEAR)	

Flow (MCD)
RAW
WASTE

4.7
                                                                 PSES
                                                                 (3)
Dissolved Iron
Oil and Grease
Total Suspended Solids
Total Toxic Metals
Total Org*nics

S13CATEGORY COST SUMMARY

(SXIO'6)	

Investment
Annual
                                                       1.8
                                                       64.1
                                                       49.3
                                                       1.8
                                                       0.3
(1)  Total organics load includes total cyanide.
(2)  The cost summary totals do not include confidential plants.
(3)  General Pretreatmenl Regulation? apply, »0 CFR part 403.

-------
                            HOT  COATING / GALVANIZING
                           TREATMENT MODELS  SUMMARY
BPT/BCT/PSES-I/
NSPS-I/PSKS-I
BAT-2/ PSES-3/
NSPS-3/PSNS-3
                                                              SOLIDS
       HOT COATING RINSE WATER FLO* RATES (OPT)
PRODUCT
Strip /Shttt a
MIK. Products
Wir» Product!
a Fosttntrt
BPT/BCT/PSES-162 .,,
600
2400
ALL OTHER MODELS121
ISO
600
  (IIFumt »crubt>«» fk» ol BPT/BCT/PSES-l/NSPS-l/PSNS-l: lOO gpm/(crut>b*r
  (2)Fum« icrubb*r 'low at all othf «xxJel»: 15 gpm/tcrubb*r
                                        533
                                                                       Preceding page blank

-------
 BPT/BCT/PSES-I/
 NSPS-I/PSNS-I
       rOOjs>m
                       HOT  COATING/TERNE a OTHER METALS
                          TREATMENT  MODELS  SUMMARY
BAT-l/PSES-2
IS»pm-
FUME
SCRUBBER
SLOWDOWN

RINSE
WATER
7

3AT-2/ PSES-3/
ISPS -3 /PSNS-3
IS jpm-
FUME
SCRUBBER
SLOWDOWN

RINSE
REDUCTION

7
— •
| POLYMER]
1 , r

EQUALIZATION C>
3
o
'ANK REACTION
TANK
?[ LIME)
q

EQUALIZATION C»
3
0
TANK
T
VACUUM
FILTER
' toSolit
]
r
., 1
I^CLARIFIER 	 J |
i 	 * 	 1 1
VACUUM
FILTER
Sfllidt
1
ash^" ' •>
—{ FILTERj— ^

NSPS-Z/PSES- 1

BAT-3/PSES-4
NSPS-4/PSNS-4
',fS«V,V!!!
^•1 EVAPORATION \— i
Uc. 	
       HOT COATING  RINSE WATER FLOW RATES (GPTI
PRODUCT
Strip/Sheet a
Misc. Products
Wire Products
a Fosterers
BAT/BCT/PSES'I ft 2 / . ..
BAT" I/NSPS~I/PSNS"I
600
2400
ALL OTHER MODELS^
150
600
(I)  Fume scrubbtr flow al  BPT/BCT/PSES - I/NSPS' I/PSNS'I 15 qpm/jcrubMr
12) fumt »crubt«r oi all other models  15 qpm/»crubber
                                       S34

-------
                                                 5L1CATTCOBT  SlWHAgY DATA
                                                   1ASIS  7/1'78
SUVCATEGOtY:
              Hot Costing - Cslvanltlnff.
              Script Sheet and Miscellaa*ous Products
MODEL SIZE 'TPD):  800
OPER. DAYS/YtAi :  260
TURKS/DAY       :    3
RAW WASTE FLOWS
ftlnses
Model Plant 0.5 .ICO
25 Direct Dischargers 12.0 MCD
5 Zero Dischargers 0.1 MCD
33 Active Plants 13.5 HCt>

MODEL COST (SX:0~3)
Investment
Plants Without Scrubbers
Plants with Scrubbers
Annual
Plants Without Scrubbers
Plants With Scrubbers
$/T?n cf Production
Plants Without Scrubbers
Plants with Scrubbers


Investment
Plants Without Scrubbers
Plants With Scrubbers
Annual
Plants Without Scrubbers
Plants With p -rubbers
$/Ton of Production
Plants Without Scrubbers
Plants with Scrubbers


WASTEWATER
CHARACTERISTICS Ko
Hot. (CPT) oOO
pH (SU) 2-9
Dissolved Iron ... 16

Oil and Crease 60
Total Suspended Solids 120
115 An«nic* 0.2
119 Chromium 7
120 Copper* O.t
122 Lead 0.6
124 Nickel 1
128 Zinc* 120
Notes: All concentrations are la m
i SAT and PSES-2 through PSES

Fuase Scrubbers (Additional Plow)
Model Plant 0.3 MCD
11 Direct iriachjrgers 3.2 MCD
1 Zero Dischargers >0.03 MCD
13 Active Plant. 3.5 MCD
HT/BCT IAT-1
P5ES-1 PSES-2

739
94) S9.1

120
154 8.3

0.58
0.7* 0.04
XSPS-I
PSSS-1

7)9
94)

120
154

0.5t
0.74
HSPS-I
PSSS-I
RAW WASTE PSES-1 PSES-2
Scrub w, Scrub BPT'SCT BAT-I
<» 600(1) 600(2>
2-» 6-9 6-9
1C 1 I
0.6 (0.02)0.01 (0.02)0.01
45 (10)4.4 (10)4.4
100 (30)23.1 (30)23.8
0.12 1.1 0.1
4 0.04 0.04
O.J 0.04 0.04
0.4 (0.15)0.1 (0.15)0.1
0.4 0.15 0.15
«0 (0.1)0.06 (0.1)0.06
g/l unless otherwise noted.

Total flow

IS. 2 MCD
1.7 MCD
O.I MCD
17.0 MCD
SAT-2
PSES-)

40<
491

51. «
63.3

0.25
0.30
KSPS-2 NSPS-)
PSNS-2 PSK3-)

822 942
951 1095

128 14)
152 170

0.61 0.69
0.7) 0.8:
XSPS-)
PSXS-)
SSPS-2 P5ES-3
PJ'IS-2 I«T-J
150(J> 150(!)
6-9 6-9
1 0.5
(0.02)0.01 (0.02)0.01
(10)4.4 (5**)2
(30)21.8 (15)9.8
0.1 0.1
0.04 0.0)
0.04 0.0)
(0.15)0.1 (0.1)0.06
0.15 0.04
(0.1)0.06 (0.1)0.06







BAT -3
PSES-4

2593
2864

402
452

1.9)
2.17
NSPS-4
PSNS-4

3127
3467

493
559

2.)7
2.69
NSPS-4
PSNS-4
PSES-4
JAT-3
0
-
.

.
-
.
-
-
-
-
*

1 lautai lons/ttandards (or the various levelt of treatment. All other
values represent long term
* Toxic pollutant found in all raw
** Limit for oil and grease is H*»e
galvanizing line.
each galvanizing ;ine.
(3) Limitat ions/»t*nd»rd« apply C.A
averages or predicted average performance levels.
wattewater samples.
d upon !0 mg/'. Emaiimua only).

P P
ly to plants discharging wasf^waters from a chrof



scrubber ,«rv.r,g each
Spa per scru er serving
Bate rinsing ttep.







-------
SUBCATEGORY  SUMMARY DATA
  BASIS 7/1/78 DOLLARS
SUBCATEGO1Y: Hot. Coating - Galvanising
> Wire Producta and Fastenera

RAW WASTE FLCUS
Rinses Fume Scrubbers (Additional Flow)
Model Plant 0.24 MCD Model Plant 0.3 MCD
14 Indirect Dischargera 3.4 MCD 7 Indirect Dischargers 2.0 MCO
1 Zero Discharger 0 MCD 0 Zero Dischargera 0 MCD
30 Active Plants 7.0 MCD 13 Active Plants 3.7 MCD
- BPT/8CT BAT-1
MODEL COST (SX10 > PSES-I PSES-2
InvestssetA
Plann without Scrubbera 557
Plants With Scrubbera 724 59.1
Annual
Planta Without Scrubbera 83.9
Plants With Scrubbers 113 8.3
$/Ton of Production
Plants Without Scrubbers 3.23
Plants With Scrubbera 4.35 0.32
NSPS-1
PSNS-I
Investaent
Planta without Scrubbera 557
Plants With Scrubbers 724
Annual
Plants Without Scrubbers 83.9
Plants With Scrubbers 113
$/Ton of Production
Plants Without Scrubbers 3.23
Plants With Scrubbers 4.35
MSPS-1
PSNS-1
VASTEWATEt MU WASTE PSES-1 PSES-2
CHARACTERISTICS No Scrub W/Scrub BPT/SCT BAT-1
Flow (CPT) 2400 U) 2400(1> :400(2)
pfl (SO) 3-9 3-9 6-9 6-9
Dissolved Iron ... 10 5 1 1
Heiavalent Chromium11' 0.2 O.I (0.02)0.01 (0.02)0.01
Oil and Crease 25 15 (10)4. 4 C0)t.4
Total Suspended Solids 80 50 (30)23.8 (30)23.8
115 Arsenic 0.25 0.15 0.1 0.1
119 Chromium* 2 1 0.04 0.04
120 Copper* 0.8 0.4 0.04 0.04
122 Lea4* 2 1 (0.15)0.1 (0.15)0.1
124 Nickel* 0.5 0.2 0.15 0.15
128 Zinc* 10 5 (0.1)0.06 (0.1)0.06
Notes: All concentrations are in mg/1 unless otherwise noted.
: Values in parentheses represent the concentrations used to develop
limitations/standards for the various l«rvels of treatment. All other valuea
represent long term averages or predicted average performance levels.
MODEL SIZE (TPD)l
OPER. DAYS/YEAR I
TURNS /DAY I

Total Flow
5.3 MCD
5.4 MCD
0 MCD
10.7 MCO
BAT- 2
PSES-1

85.5
205

11.1
27.3

0.43
I.Oi
HSPS-2 NSPS-3
PSNS-2 PSNS-3

421 471
383 694

65.0 71.5
92.6 107

2.50 2.75
3.56 4.12
NSPS-3
PSNS-3
HSPS-2 PSES-3
PSNS-2 BAT-2
600 600(J>
6-9 6-9
1 0.3
(0.02)0.01 (0.02)0.01
(10)4.4 (5**>2
(30)23.8 (15)9.8
O.I O.I
0.04 0.03
0.04 0.03
(0.15)0.1 (0.1)0.06
0.15 0.04
(0.1)0.06 (0.1)0.06




too
260
3






BAT-3
PSES-4

1982
2363

283
157

10.88
13.73
NSPS-4
PSNS-4

2367
2832

344
437

13.23
16.81
NSPS-4
PSNS-4
PSES-4
BAT-3
0
.
„
_
_
-
.
.
.
_
_
-




: PStS-1 /BPT/BCT is the selected BAT for those operations without fume scrubbers.
* Toxic pollutant found in all raw wastewater samples.
** Limit for oil and grease is based upon 10 mg/1 (maximum only).
(1) Additional limitations for fume scrubbers are provided, bised upon 100 gpm per
(2) Additional limitations for fume scrubber slowdowns are provided, baaed upon 15
eac*i galvanizing line.
(3) Limitations/standards apply only to plants discharging wastewaters from a chrom


scrubber serving each
gp* per scrubber serving

ate rinsing step.






       330
-i

-------
                                                 SfBCATTCORY StVWSY DAW
                                                   BASIS 7/1/76 DOLLARS

I All Products

RAW WASTE rT-OWS
Rinse*
Model Planl 0.22
4 Direct Discharger* 0.9
1 Indnect Discharger 0.2
5 Active Plant* 1.1

MODEL COST (JXIO"J)

Plant* Without Scrubber*
Plant* With Scrubber*
Annual
Plant* Without Scrubber*
Plant* With Scrubber*
$/Ton of Production
Plant* Without Scrubber*
Plant* With Scrubber*


Investment
Planl* Without Scrubber*
Plant* With Scrubber*
Annual
Plant* Without Scrubber*
Plant* With Scrubber*
Plant* Without Scrubber*
Planl* With Scrubber*


WASTE WATFK
CHARACTERISTICS
ri.n. (KPT)
pH (Sl'>
Dissolved Iron
Oil and Crease
T in
Total Suspended Solid*
115 Ar«enir
118 Cadnion*
119 Chroai .m*
120 Copper
122 Lead*
124 Nickel*
128 Zinc*
Notes: All concentrations jre
: BAT and pif.S-2 through
: Values in parentheses
1 iiBitalions/sundar Is




Fune Scrubber* (Additional
HCO Model Planl
"JX> 3 Direct Discharger*
MCD 0 Indirect Discharger*
MCD 3 Active Plant*
BPT/BCT


477
557

70.1
64.3

0.74
0.89
NSPS-1
PSNS-I

477
557

70.1
84.3
0.74
0.89
NSPS-1
PSNS-!
RAW WASTE PSfS-I
No Scrub W'Scrub BPT/BCT
600 ll> 600 ' "
2-8 2-8 6-9
40 25 1
)0 20 (10)4.4
1 ? 0 . *}
75 50 (30)21.8
0.15 O.I 0.1
0.1 0.2 O.I
5 1 0.04
0.6 0.. 0.04
1.2 0.8 (0,15)0.1 (0
1 0.6 0.15
1.5 I (0.1)0.06 (
in mg/1 unless otherwise noted.
MODEL SITE
OPER. DAYS
TURNS /DAY

Flow) Total Mo*
0.14 MCD
0.4 MCD 1.3 MCD
0 MCD O.J MCS
P. 4 .1CD 1.5 MCD
BAT-l
PSES-2

.
53.8

.
7.4

-
0.08S
NSPS-2
PSVS-2

452
545

65.1
80.5
0.69
0.45
.

PSES-2 NSPS-2
BAT-l PSSS-J
fMI(» .50(J>
6-9 6-»
1 I
(10)4.4 (10)4.4 («•
0.5 0.5
(10)23.8 (30>:i.» (1
O.I 0.1
0.1 n.l
0.04 0.04
0 . 04 0 . a*
.15)0.1 (0.15)0.1 (f).
0.15 0. 1)
0.1)0.06 (O.DO.C6 (0.

f TPD) :

:






BAT- 2
PSES-3

178
242

;;.6
31.4

0.24
0.33
V?PS-3
PSN'S-3

499
602

'!.2
M.O
0.75
0.93
NSPS-3
PSSS-J
PSES-3
BAT-2
150(2)
6-9
0.5
• ) ?
C.I
5">.8
". 1
0.15
0. Tl
0.01
'.1 0. 06

365
260
3






BAT- 3
PSES-4

2030
2260

286
328

3.0I
3.46
NSPS-4
PS\'S-4

2351
2620

335
3S4
3.53
4.35
HSPS-4
PSXS-4
PSES-4
BAT- 3
0
-
-
-
-
-
.
-
-
-
.
.
-

PSf.S-4 cc»t» are incremental over BPT'PSES-1 co*ts.
represent the concentration* used to develop
f IT the various levels of treatment. All
other value*


represent long tern averse* or predicted average performance levels.
: PS£S-1/BPT/SCT is l he
selected RAT for thc-se operations without
rum* scrubber*.


* Toxic pollutant found-in all raw waslevaler samples.
** Litait for oil and grease  >*  bafed  upon 10 BR./1 (naxiiBua only).

(1)  Additional Imitations  for  f
-------
                                                SUBCATECORY SUMMARY DATA
                                                  BASIS 7/1/78 DOLLARS
SUBCATECORY: Hot Coating - Other Metallic Coatings
l Strip, Sheet and Hiscellaneoua Products
RAW WASTE FLOWS
Rinses Fume Scrubbers (Additional Flow)
Model Plant 0.3 MCD Model Plant 0.1 MCD
0 Indirect Dischargers 0 MCD 0 Indirect Dischargers 0 MCD
4 Active Plants 0.9 MCD 0 Active Plants 0 MCD
BPT/BCT BAT-1
MODEL COST (SX10~J) PfES-1 PSES-2
Investment
Plants Without Scrubbers 571
Plants With Scrubbers 660 53.8
Annual
Plants Without Scrubbers 85.5
Plants With Scrubbers 106 7.4
$/Ton of Production
Plants without Scrubbers 0.69
Plants With Scrubbers O.H2 0.06
NSPS-l
MODEL COST (SXIOM PSNS-1
Investment
Plants Without Scrubbers 371
Plants With Scrubbers 660
Annual
Plants Without Scrubbers 89.5
Plants With Scrubbers 106
$/Ton of Production
Plants Without Scrubbers 0.69
Plants With Scrubbers 0.82
NSPS-1
PSNS-1
WASTEWATER RAW WASTE PSES-1 PSES-2
CHARACTERISTICS No Scrub W/Scrub BPT/BCT BAT-1
Flow (CPT) 600 (l) 600
6-»
1
1
(10)4.4
0.5
(30)23.8
0.1
0.04
0.04
0.04
(0.15)0.1
0.15
(0.1)0.06








BAT-2
PSES-3

234
339

30.1
43.6

0.23
0.34
US PS- 3
PS Its- 3

624
790

94.3
120

0.73
0.92
KSPS-3
PSKS-3
PSES-3
BAT- 2
150(2>
»-*
0.1
0.1
(5**>2
0.1
(15)9.8
0.1
0.03
0.03
0.03
(O.DO.C4
0.04
(0.1)0.06








BAT- 3
PSES-4

2232
2605

323
383

2.48
2.95
NSPS-4
PSNS-4

2620
3055

387
460

2.98
3.54
NSPS-4
PSNS-4
PSES-4
BAT- 3
0
-
_
-
-
_
-
—
_
.
.
_
.
-



: PSES-1/BPT/BCT is the selected BAT for those operations without fusw scrubbers.
* Toxic pollutant found in all rew watlewater samples analyzed.
** Lieut for oil and gresse is based upon 10 mg/1 (maximum only).
(1) Additional limitations for fua* scrubbers are provided, bssed upon 100 gpm per


scrubber serving


esch



     coat ing 1 in*.
(2)  Additional limitaliont for fuae scrubber blowdovo* are provided, baavd upon 15 gp« per acrubb«r s*r»ii*«: each
     co*itL'iS line.


                                                       538

-------
                                                     \
                                                 SUBCATECORY SWKARY DATA
                                                   BASIS  7/1 HS  DOLLARS
SUBCA'tWRYl  Hot Coaling - Oth*r Metallic Coating!
/
RAW WASTE FLOWS
Rinse! Fume Scrubbers (Additional Flow)
Model Plan- 0.04 HCO Model Plant 0.14 MOT
2 Direct Dilchargeri 0.07 MCD 0 Direct Dilchargeri 0 MCD
6 Active Plant! 0.21 MCD 0 Active Plant! 0 MCD
8W/BCT BAT-1
MODEL COST (SX10°> PSES-! PSES-2
Xnvectwent
Plant! Without Scrubber! 22)
Plants With Scrubber! 404 53.8
Annual
Plant* Without Scrubber! 31.4
Plant! With Scrubbers 57. 9 7.4
S/Ton of Production
Plant! without Scrubber! 8.0)
Plant! With Scrubber! 14.8) 1.90
KSPS-1
PSW-1
Inveataent
Plant! Without Scrubber! 22)
Plant: With Scrubber! 404
Annual
Plant! Without Scrubber! 31.4
Plant! With Scrubber! )7.9
5/Ton of Production
Plant! Without Scrubber! 8.0)
Plant! With Scrubbers 14. 8)
XSPS-l
PSSS-1
WASTEWATER RAW WASTE PSES-1 PSES-2
CHARACTERISTICS Ho Scrub W/Scrub BPT/BCT HAT-I
Flow (CPT) 2400 (1) 2400* " 2400(2)
pH (SU) 3-9 3-9 6-9 6-9
Aluaimm 20 ) 1 1
Dissolved Iron 30 8 1 1
Oil and C real e 30 1) (10)4.4 (10)-. 4
Tin 2 I 0.5 0.5
Total Suspended Solid! 2)0 7) (30)23.8 (30)23.8
11) Arienic 0.2 0.1 O.I 0.1
118 Cadmus 0.2 0.1 0.04 0.04
119 Chro»iu»* 0.2 O.I 0.04 0.04
UO Copper* 0.3 0.1 0.04 0.04
122 Lead* 0.6 0.2 (0.15)0.1 (0.15)0.1
124 Nickel* 0.4 0.2 0.1) 0.15
128 Zinc* 1 0.5 (0.1)0.06 (0.1)0.06
Notes! All concentration! are in »g/ 1 unle!! otherwise noted.
: Value! in parenLhe!e! represent Lhe concentration! used to develop the
1 imitations/standards for the various levels of treatment. AH other value!
represent long tern averages or predicted average performance levels.
OPEK. DATS/TtAR : ZOO
TURKS /DAY : 2

Total Flow

0.07 MCD
0.14 MGO
0.21 MCD











NSPS-2
PSNS-2

161
335

22.8
48.6

).85
12.46


NSPS-2
PSNS-2
600<"
6-9
1
I
(10)4.4
0.5
(30)23.8
O.I
0.04
0.04
0.04
(0.15)0.1
0.15
(0,1)0.06









BAT-2
PSES-3

20.8
91.8

2.9
12.4

0.74
3.18
NSPS-3
PSXS 3

176
368

24.9
52.8

6.38
13.54
KSPS-3
PSNS-3
PSES-3
BAT-2
600<2)
6-9
0.1
0.5
:)**)2
0.1
( IS)*. 8
0.1
0.03
0.03
0.03
(0.1)0.06
0.04
(0.1)0.06









SAT-;
PS!3-4

104)
ms

137
205

35. !3
52.56
SSPS-4
PSSS-4

1200
is:-.

159
145

40. 77
62. §2
NSPS-4
PSK3-.
PSES-4
BAT- 3
0
-
.
.
-
.
-
_
_
-
-
_
_
-




: PSEE-1 /SPT/BCT ii the selected &AT for tho*e operations without fuae scrubbers.
* Toxic pollutant found in all raw waslewater staples.
** Limit for oil and grease is based upon 10 ••,/! (naxTBUM! onlv).
(1) Additional 1 inflation! for fime scrubbers are provided, based upon 100 gp« per


scrubber serving


each



     coating line.
(2)  Additional Imitations for fuaie scrubber blowdowns are provided, based uoon  15 gpsi per scrubber  serving each
     coating line.

-------
                     SUMMARY OF EFFLUENT LOADINGS AND TREATMENT COSTS
                               HOT COATING-ALL. SUBDIVISIONS
                                       ALL  PRODUCTS
SUBCATT.CORY COST SUMMARY
($xio"fci(r	

Investment
Annual
SUBCATECORY LOAD SUMMARY
(TONS/YEAR)	

Flow (MCD)

A1 tit. i nun
Dissolved Iron
Hexavalenl Chromium
Oil and Grease
Tin
Total Suspended Solid.
Total Toxic Metals
Total Organic*
S'JBCATECORY COST SUMMARY