-------
    10
    10
  o
  o
  Z
    10
    10
            SLUDGE REMOVAL
            CHEMICALS
            ENERGY
            MATERIALS
                                               LABOR
                                               DEPRECIATION
                                               CAPITAL
                                             I	l_| L LI 1    11  i | | | | 11
                     0.01
                       I I I I 1 1 1
 0-1  FLOW,  mgd  L0
1  1 I 1 I 11 I	L_ L  I  I l r | ) i
                                                       10.0
                                                          i i 11 I
              10
                  100
      1,000
 FLOW.cu m/day
                                        10,000        100,000


                   Figure  VIII-3

SECONDARY  ALUMINUM COMBINATIONS 1&4, OPTION  F
  10'
  10s
o
u
 SLUDGE REMOVAL
 CHEMICALS
 ENERGY	
 MATERIALS
O
  10*
                                                          LABOR
                                                          DEPRECIATION
                                                          CAPITAL
-L—1	1, i I III!	_L._J	1  1 1 i )ll    l  l   I
                  0.01
                                                              10.0
     ,                             '   FLOW,  mgd
     L ' 'IJ'' ''	'	-••' ' I I III	1	1  I I I I III	i  !  .  . i i 11!    .   	,|
           10             |Q°           1,000          10,000        100,000
                                  FLOW, cu m/dav
                                  Figure VIII-4

               SECONDARY ALUMINUM  COMBINATIONS  2&5,  OPTION A

                                        816

-------
  I07
  to5
S
j
9
o
                                 SLUDGE REMOVAL-
                                 CHEMICALS-
                                 ENERGY
                                 MATERIALS-
                                                         LABOR
                                                         DEPRECIATION
                                                         CAPITAL
                  o.oi
        OJ  FLOW,  m,d  '-°
                                    10.0
           10
100            1,000
         FLOW, cu m/dov
                           10,000
100,000
                                 Figure  VIII-5

              SECONDARY ALUMINUM COMBINATIONS 2&5,  OPTION  C
  I06
o
u
o
t-
  104
                                 SLUDGE REMOVAL-
                                 CHEMICALS'
                                 ENERGY-
                                LA80R
                                DEPRECIATION
                                CAPITAL
                   0.01
                   i  i
         -  FLOW, mgd
                                    10.0
           10
100            1,000
         FLOW, cu m/doy
                           10,000
100,000
                                 Figure VIII-6

               SECONDARY ALUMINUM COMBINATIONS 2&5,  OPTION F
                                        317

-------
  10
  10°
-------
    10  p
    to
  en
  O
  o
  r
  z
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                                                         LABOR
                                                          EPRECIATION
                                                         CAPITAL
            0.01
[ L ILL i_t i	1  t  I I I t I .' I
                                  °'' FLOW, m,d  L°
                                  I  I I I I I I I    I   I I  I I I I I I
         10.0
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                   100            1,000
                            PLOW, cu m/day
                         Figure VIII-9
10,000
100,000
               SECONDARY ALUMINUM COMBINATION  3,  OPTION  F
io6  =
10"
10
                                   Labor and
                                   Material
                                 Figure  VIII-10

               COOLING TOWER  COSTS  (CASTING CONTACT COOLING)

                                      819
-------
                          DEPRECIATION
                          CAPITAL
    Figure VIII-11
HOLDING TANK COSTS
         820
-------
                  SECONDARY ALUMINUM SUBCATEGORY

                            SECTION IX

     BEST PRACTICABLE CONTROL TECHNOLOGY CURRENTLY AVAILABLE
EPA promulgated best practicable control technology currently
available (BPT) effluent limitations standards for the secondary
aluminum industry on April 8, 1974 as Subpart C of 40 CFR Part
421.  Pollutants regulated by these standards are aluminum,
copper, chemical oxygen demand, ammonia, fluoride, TSS, and pH.
Unlike the current rulemaking, the BPT standards were developed
on the basis of two subdivisions of the secondary aluminum
process, not on the basis of individual wastewater streams.  BPT
standards were established for magnesium removal processes
(demagging using either chlorine or aluminum fluoride) and wet
residue processes. The effluent limitations established by the
BPT standards are as listed below:

     (a)  The following limitations establish the quantity or
          quality of pollutants or pollutant properties, which
          may be discharged by a point source subject to the
          provisions of this subpart and which uses water for
          metal cooling, after application of the best practi-
          cable control technology currently available:  There
          shall be no discharge of process wastewater pollutants
          to navigable waters.

     (b)  The following limitations establish the quantity or
          quality of pollutants or pollutant properties which may
          be discharged by a point source subject to the provi-
          sions of this subpart and which uses aluminum fluoride
          in its magnesium removal process ("demagging process"),
          after application of the best practicable control
          technology currently available:  There shall be no
          discharge of process wastewater pollutants to navi-
          gable waters.

     (c)  The following limitations establish the quantity or
          quality of pollutants or pollutant properties con-
          trolled by this section, which may be discharged by
          a point source subject to the provisions of this
          subpart and which uses chlorine in its magnesium
          removal process, after application of the best
          practicable control technology currently available:
                               821
-------
                               Effluent Limitations
   Effluent        Average of daily values for 30 consecutive
Characteristic	days shall not exceed	

                   Metric units (kilograms per 1,000 kg
                             magnesium removed)
                   English units (Ibs per 1,000 Ibs
                   	magnesium removed)	

TSS                                  175
COD                                    6.5
pH                        Within the range of 7.5 to 9,0

     (d)  The following limitations establish the quantity or
          quality of pollutants or pollutant properties which
          may be discharged by a point source subject to the
          provisions of this subpart and which processes resi-
          dues by wet methods, after application of the best
          practical control technology currently available:

                   	Effluent Limitations	

   Effluent        Average of daily values for 30 consecutive
Characteristic	days shall not exceed	

                   Metric units (kilograms per 1,000 kg
                             magnesium removed)
                   English units (Ibs per 1,000 Ibs
                   	magnesium removed)	

TSS                                    1.5
Fluoride                               0.4
Ammonia (as N)                         0.01
Aluminum                               1.0
Copper                                 0.003
COD                                    1.0
pH                       Within the range of 7.5 to 9.0
                               822
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                  SECONDARY ALUMINUM SUBCATEGORY

                            SECTION X

        BEST AVAILABLE TECHNOLOGY ECONOMICALLY ACHIEVABLE


The effluent limitations which must be achieved by July  1,  1984
are based on cne b^st control and treatment  technology used by a
specific point source within the industrial  category or  sub-
category, or by another industry where it is readily transfera-
ble.  Emphasis is placed on additional treatment techniques
applied at the end of the treatment systems  currently used  for
BPT, as well as reduction of the amount of water used and dis-
charged, process control, and treatment technology optimization.

The factors considered in assessing best available technology
economically achievable (BAT) include the age of equipment  and
facilities involved, the process used process changes, nonwater
quality environmental impacts (including energy requirements),
and the costs of application of such technology (Section 304(b)
(2) (B) of the Clean Water Act).  At a minimum, BAT represents the
best available technology economically achievable at plants of
various ages, sizes, processes, or other characteristics.   Where
the Agency has found the existing performance to be uniformly
inadequate, BAT may be transferred from a different subcategory
or  category.  BAT may include feasible process changes or
internal controls, even when not in common industry practice.

The required assessment of BAT considers costs, but does not
require a balancing of costs against effluent reduction  benefits
(see Weyerhaeuser v. Costle, 11 ERG 2149 (D.C. Cir. 1978)).
However, in assessing the proposed BAT, the Agency has given
substantial weight to the economic achievability of the
technology.

TECHNICAL APPROACH TO BAT

In pursuing this second round of effuent regulations, EPA
reviewed a wide range of technology options and evaluated the
available possibilities to ensure that the most effective and
beneficial technologies were used as the basis of BAT.   To
accomplish this, the Agency elected to examine three technology
alternatives which could be applied to the secondary aluminum
subcategory as BAT options.

In  summary, the treatment technologies considered for BAT are
presented below:
                              823
-------
Option A (Figure X-l) is based on

     o  Preliminary treatment with oil skimming (where required)
     o  Preliminary treatment of dross washing wastewater with
        ammonia steam stripping
     o  In-process flow reduction of direct chill casting contact
        cooling water and scrubber liquor resulting from scrap
        drying wet air pollution control
     o  Chemical precipitation and sedimentation

Option C (Figure X-2) is based on

     o  Preliminary treatment with oil skimming (where required)
     o  Preliminary treatment of dross washing wastewater with
        ammonia steam stripping
     o  In-process flow reduction of direct chill casting contact
        cooling water and scrubber liquor resulting from scrap
        drying wet air pollution control
     o  Chemical precipitation and sedimentation
     o  Multimedia filtration

Option F (Figure X-3) is based on

     o  Preliminary treatment with oil skimming (where required)
     o  Preliminary treatment of dross washing wastewater with
        ammonia steam stripping
     o  In-process flow reduction of direct chill casting contact
        cooling water and scrubber liquor resulting from scrap
        drying wet air pollution control
     o  Chemical precipitation and sedimentation
     o  Multimedia filtration
     o  Reverse osmosis and multiple-effect evaporation for
        complete recycle of treated water

The three options for BAT are discussed in greater detail below.
The first option considered is the same at the BPT treatment and
control technology.

OPTION A

Option A for the secondary aluminum subcategory is equivalent to
BPT treatment.  Option A requires control and treatment techolo-
gies to reduce the discharge of wastewater volume and pollutant
mass.   These measures include in-process changes, resulting in
the elimination of some wastewater streams and the concentration
of pollutants in other effluents.  As explained in Section VII of
the General Development Document, treatment of a more concen-
trated effluent allows achievement of a greater net pollutant
                               824
-------
removal and introduces the possible economic benefits associated
with treating a lower volume of wastewater.  Methods used  in
Option A to reduce process wastewater generation or discharge
rates include the following:

Recycle of Casting Contact Cooling Water Through Cooling Towers

The cooling and recycle of contact cooling water is practiced by
25 of the 38 plants reporting this wastewater.  The function of
casting contact cooling water is to quickly remove heat from the
newly formed ingot or bar.  Therefore, the principal requirements
of the water are that it be cool and not contain dissolved solids
at a concentration that would cause water marks or other surface
imperfections.   There is sufficient category experience with
casting contact cooling wastewaters to assure the success  of this
technology using cooling towers or heat exchangers (refer  to
Section VII of the General Development Document).  Although 22
plants have reported that they do not discharge any quench water
by reason of 100 percent recycle, a blowdown or periodic cleaning
is likely to be needed to prevent a buildup of dissolved and
suspended solids.  (EPA has determined that a blowdown of  10
percent of the water applied in a process is adequate.)

Recycle of Water Used in Wet Air Pollution Control

There are two wastewater sources associated with wet air
pollution control which are regulated under these effluent
limitations:

     1.  Scrap drying, and
     2.  Demagging.

Table X-l presents the number of plants reporting wastewater use
with these sources, the number of plants practicing recycle of
scrubber liquor, and the range of recycle values being used.

The Option A treatment scheme includes in-process flow reduction,
steam stripping preliminary treatment of wastewaters containing
ammonia at treatable concentrations and oil skimming, where
required.   Preliminary treatment is followed by chemical precipi-
tation and sedimentation (see Figure X-l).  Although oil and
grease is a conventional pollutant limited under best conven-
tional technology (BCT), oil skimming is needed for BAT to ensure
proper metals removal.  Oil and grease interferes with the chemi-
cal addition and mixing required for chemical precipitation
treatment.   Chemical precipitation is used to remove metals by
the addition of lime followed by gravity sedimentation.
Suspended solids are also removed from the process.
                               825
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OPTION C

Option C for the secondary aluminum subcategory builds upon  the
Option A control and treatment technology of in-process flow
reduction, oil skimming  (where required), ammonia steam strip-
ping, chemical precipitation, and sedimentation by adding multi-
media filtration technology at the end of the Option A treatment
scheme (see Figure X-2).  Multimedia filtration is used to remove
suspended solids, including precipitates of metals, beyond the
concentration attainable by gravity sedimentation.  The filter
suggested is of the gravity, mixed media type, although other
forms of filters, such as rapid sand filters or pressure filters,
would perform satisfactorily.

OPTION F

Option F for the secondary aluminum subcategory builds upon  the
Option C control and treatment technology of in-process flow
reduction, oil skimming  (where required), ammonia steam strip-
ping, chemical precipitation, sedimentation, and multimedia
filtration with the addition of reverse osmosis and evaporation
technology at the end of the Option C treatment train (see Figure
X-3).  Option F is used  for complete recycle of the treated
wastewater by controlling the concentration of dissolved solids.
Multiple-effect evaporation is used to dewater brines rejected
from reverse osmosis.

Other treatment technologies included additional in-process  flow
reduction (Option B), activated alumina adsorption (Option D),
and activated carbon adsorption (Option E).   These technologies
were not considered because they are not applicable to the
secondary aluminum subcategory.  Option B does not apply since
in-process wastewater flow reduction is part of the Option A
technology.   EPA believes that no additional in-process waste-
water flow reduction is  achievable for this subcategory.  Since
arsenic was not selected for consideration for limitation in the
secondary aluminum subcategory, activated alumina technology
(Option D) was not considered because it is not applicable.   (For
pollutant selection refer to Section VI, p.  787 .)  Since no
toxic organic pollutants were selected for consideration for
limitation in this subcategory, activated carbon technology
(Option E) also is not applicable.

INDUSTRY COST AND POLLUTANT REDUCTION BENEFITS

As a means of evaluating each technology option, EPA developed
estimates of the pollutant reduction benefits and the compliance
costs associated with each option.  The methodologies are
described below.
                               826
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POLLUTANT REDUCTION BENEFITS

A complete description of the methodology used  to  calculate  the
estimated pollutant reduction, or benefit, achieved by  the appli-
cation of the various treatment  options  is presented  in Section X
of the General Development Document.   In short, sampling data
collected during the field sampling program were used to charac-
terize the major waste streams considered for regulation.  At
each sampled facility, the sampling data was production normal-
ized for each unit operation (i.e., mass of pollutant generated
per mass of product manufactured).  This value, referred to  as
the raw waste, was used to estimate the  mass of toxic pollutants
generated within the secondary aluminum  subcategory.  By multi-
plying the total subcategory production  for a unit operation by
the corresponding raw waste value, the mass of pollutant
generated for that unit operation was  estimated.

The volume of wastewater discharged after the application of each
treatment option was estimated by multiplying the  regulatory flow
determined for each unit process by the  total subcategory produc-
tion.  The mass of pollutant discharged  was then estimated by
multiplying the achievable concentration values attainable by the
option (mg/1) by the estimated volume  of process wastewater  dis-
charged by the subcategory.  The mass  of pollutant removed,
referred to as the benefit, is simply  the difference  between the
estimated mass of pollutant generated  within the subcategory and
the mass of pollutant discharged after application of the treat-
ment option.

The Agency varied this procedure slightly in computing  estimated
BPT discharge in a subcategory where there is an existing BPT
limitation.  In this case, EPA took the  mass limits from the BPT
limitations (for all pollutants  limited  at BPT) and multiplied
these limits by the total subcategory  production (from  dcp).
(The assumption is that plants are discharging a volume equal to
their BPT allowance times their production.)  Where pollutants
are not controlled by existing BPT, EPA  used the achievable
concentration for the associated technology proposed  in this
document, and multiplied these concentrations by the  total
end-of-pipe discharge of process wastewater for the subcategory
(from dcp).  The total of both these calculations represents
estimated mass loadings for the subcategory.  The pollutant
reduction benefit estimates for direct dischargers in the
secondary aluminum subcategory are presented in Table X-2.

COMPLIANCE COSTS

In estimating subcategory-wide compliance costs, the  first step
was to develop uniformly-applicable cost curves, relating the
total costs associated with installation and operation  of waste-
water treatment technologies to plant  process wastewater dis-
charge.   EPA applied these curves on a per plant basis,  a plant's
                               827
-------
costs (both capital, and operating and maintenance) being deter-
mined by what treatment it has in-place and by its individual
process wastewater discharge (from dcp).   The final step was to
annualize the capital costs, and to sum the annualized capital
costs, and the operating and maintenance costs, yielding the cost
of compliance for the subcategory (see Table X-3).  These costs
were used in assessing economic achievability.

BAT OPTION SELECTION

EPA has selected Option C as the basis of BAT in this subcate-
gory.  The BAT treatment scheme proposed consists of flow reduc-
tion, oil skimming (where required), preliminary treatment of
ammonia steam stripping, lime precipitation, sedimentation, and
filtration for control of toxic metals.  The selected option
increases the removal of toxic pollutants from raw wastewater by
approximately 903 kg/yr and nonconventional pollutants by approx-
imately 541 kg/yr.  This option also removes approximately 17
kg/yr of toxic pollutants and 46 kg/yr of nonconventional pollu-
tants over the estimated BPT discharge.  The estimated capital
cost of proposed BAT is $1.6 million (1978 dollars) and the
annual cost is $1.35 million (1978 dollars).

Ammonia steam stripping is demonstrated in the nonferrous metals
manufacturing category.  One plant in the secondary aluminum sub-
category, one plant in the secondary lead subcategory, two plants
in the primary columbium-tantalum subcategory, and four plants in
the primary tungsten subcategory reported steam stripping in
place.

EPA believes that performance data from the iron and steel manu-
facturing category provide a valid measure of this technology's
performance on nonferrous metals manufacturing category waste-
water because raw wastewater concentrations of ammonia are of the
same order of magnitude in the respective raw wastewater
matrices.

Chemical analysis data were collected of raw waste (treatment
influent) and treated waste (treated effluent) from one coke
plant of the iron and steel manufacturing category.  A contractor
for EPA, using EPA sampling and chemical analysis protocols, col-
lected six paired samples in a two-month period.  These data are
the data base for determining the effectiveness of ammonia steam
stripping technology and are contained within the public record
supporting this document.  Ammonia treatment at this coke plant
consisted of two steam stripping columns in series with steam
injected countercurrently to the flow of the wastewater.  A lime
reactor for pH adjustment separated the two stripping columns.
                               828
-------
                    stewater samples  from the coke  facility  con-
                    ntrations of 599, 226, 819, 502, 984, and  797
                     wstewater samples  from the secondary alumi-
                    ained an ammonia  concentration  of 195 mg/1.

                    oves additional toxic and nonconventional
                    conomically achievable, it is included as
     v±. pvwpw^v- ~^~.  Filtration also  adds to the  treatment
system reliability by making it less  susceptible to operator
error and to sudden changes in raw wastewater flows and
concentrations.

Reverse osmosis (Option F) was considered for the purpose of
achieving zero discharge of process wastewater pollutants;
however, it was rejected because it is  not adequately demon-
strated in this subcategory nor is it clearly transferable from
another category.

WASTEWATER DISCHARGE RATES

Specific wastewater streams associated  with the secondary alumi-
num subcategory are generated from scrap drying air pollution
control, scrap screening and milling, dross washing, demagging
air pollution control, direct chill casting contact cooling, and
shot casting contact cooling.

Table X-4 lists the production normalized wastewater discharge
rates allocated at BAT for these wastewater streams.  The values
represent the best existing practices of the industry, as deter-
mined from the analysis of dcps.  Individual discharge rates from
the plants surveyed are presented in  Section V of this supplement
for each wastewater stream.

SCRAP DRYING WET AIR POLLUTION CONTROL  WASTEWATER

No BAT wastewater discharge allowance is provided for scrap
drying air pollution control.  Only three of 29 plants use
scrubbers to control emissions; the remaining 26 plants use
baghouses.  Two of the three plants with scrubbers  achieve zero
discharge by 100 percent recycle.  One  plant is a once-through
discharger with a rate of 1,057 1/kkg (253.5 gal/ton) of aluminum
scrap produced.  Wastewater rates are presented in  Section V
(Table V-l).  The BAT allowance is zero discharge of wastewater
pollutants based on the attainment of no discharge  by 28 of 29
plants including two of the three operations using wet air
pollution control.

SCRAP SCREENING AND MILLING

No BAT wastewater discharge rate is provided for scrap screening
and milling.  Both plants reporting this wastewater are zero
                               829
-------
dischargers because of 100 percent recycle or reuse.  Therefore,
the Agency believes that zero discharge is possible for all
secondary aluminum scrap screening and milling processes.

DROSS WASHING WASTEWATER

The BAT wastewater discharge rate is 10,868 1/kkg  (2,607 gal/ton)
of dross processed.  Four plants reported producing this waste-
water.  One plant discharges after 67 percent recycle and the BAT
rate is the discharge from this plant.  Two plants recycle 100
percent of the wastewater and the fourth plant evaporates 100
percent.  EPA considers the zero discharge practices for this
waste stream to be site-specific and not applicable on a nation-
wide basis.  Wastewater rates for dross washing are presented in
Section V (Table V-3).

DEMAGGING WET AIR POLLUTION CONTROL

The BAT wastewater discharge rate is 800 1/kkg (192 gal/ton) of
aluminum demagged.  This rate is allocated only for plants prac-
ticing wet air pollution control of demagging operations.  Of the
37 demagging operations reported, 19 use water for emissions con-
trol.  Nine plants using water reported no wastewater discharge,
achieved by recycle or reuse.  Eight of the nine plants com-
pletely recycle the wastewater, while one plant did not report a
recycle percentage.  Another plant practices a partial recycle of
40 percent.  Nine plants have once-through operations, eight of
these discharging 223.3 to 1,956.24 1/kkg (54.5 to 469.2 gal/
ton).  No flow data were provided by one of the discharging
plants.  A distribution of wastewater rates is presented in Table
V-5.  Industry comments on a draft of this document asserted that
the use of recirculation systems using treated water reduces
demagging scrubber efficiency.  Therefore, recycle of scrubber
liquor was not used as a basis for the BAT discharge rate for
demagging wet air pollution control.  The BAT discharge rate is
based on the average of the nine discharging plants.  Fifteen of
the 19 plants with demagging wet air pollution control meet the
BAT rate.

DIRECT CHILL CASTING CONTACT COOLING WATER

The BAT wastewater discharge rate for direct chill casting
contact cooling water is 1,999 1/kkg  (479.4 gal/ton) of aluminum
cast.  There is a trend in the secondary aluminum subcategory
toward converting to direct chill casting.  Direct chill casting
practices and the wastewater discharge from this operation are
similar in aluminum forming, primary aluminum reduction and
secondary aluminum plants.  The information available does not
indicate any significant difference in the amount of water
required for direct chill casting in a primary aluminum, second-
ary aluminum and aluminum forming plants.  For this reason,
                               830
-------
available wastewater data  from aluminum  forming  and  primary
aluminum plants were considered together in establishing BPT
effluent limitations.  No  data for  direct  chill  casting water  use
were provided by secondary aluminum plants

In all, 27 primary aluminum plants  and 61  aluminum forming plants
have direct chill casting  operations.  Recycle of the  contact
cooling water is practiced at 30 aluminum  forming and  18 primary
aluminum plants.  Of these, 12 plants indicated  that total recy-
cle of this stream made it possible to avoid any discharge of
wastewater; however, the majority of the plants  discharge a bleed
stream.  The discharge flow for this operation is based on the
average of the best, which is the average  normalized discharge
flow of the 29 plants that practice recycle.

STATIONARY CASTING CONTACT COOLING  WATER

No BAT wastewater discharge allowance is  provided for  stationary
casting cooling.  In the stationary casting method, molten alumi-
num is poured into cast iron molds  and then generally  allowed  to
air cool.  The Agency is aware of the use  of spray quenching to
quickly cool the surface of the molten aluminum  once it is cast
into the molds; however, this water evaporates on contact with
the molten aluminum.  As such, the  Agency  believes that there  is
no basis for a pollutant discharge  allowance.

SHOT CASTING CONTACT COOLING WATER

No BAT wastewater discharge allowance is provided for  shot
casting contact cooling.   In the secondary aluminum dcp summary,
22 of 35 plants reporting  casting contact  cooling water achieve
zero discharge through complete recycle  or evaporation.  EPA
believes zero discharge is feasible for  all secondary  aluminum
shot casting processes.

REGULATED POLLUTANT PARAMETERS

In implementing the terms of the Consent Agreement in  NRDC v.
Train, Op. Cit. , and 33 U.S.C. §1314(b)(2)(A and B)  (19T6J, the
Agency placed particular emphasis on the  toxic pollutants.  The
raw wastewater concentrations from  individual operations and the
subcategory as a whole were examined to  select certain pollutants
and pollutant parameters for consideration for limitation.  This
examination and evaluation, presented in Section VI, concluded
that eight pollutants and pollutant parameters are present in
secondary aluminum wastewaters at concentrations that  can be
effectively reduced by identified treatment technologies.  (Refer
to Section VI, p. 797).

However, the high cost associated with analysis  for toxic metal
pollutants has prompted EPA to develop an  alternative  method for
                               831
-------
regulating and monitoring toxic pollutant discharges from the
nonferrous metals manufacturing category.  Rather than developing
specific effluent mass limitations and standards for each of the
toxic metals found in treatable concentrations in the raw waste-
waters from a given subcategory, the Agency is proposing effluent
mass limitations only for those pollutants generated in the
greatest quantities as shown by the pollutant reduction benefit
analysis.  The pollutants selected for specific limitation are
listed below:

     122.  lead
     128.  zinc
           aluminum
           ammonia

By establishing limitations and standards for certain toxic metal
pollutants, dischargers will attain the same degree of control
over toxic metal pollutants as they would have been required to
achieve had all the toxic metal pollutants been directly limited.

This approach is technically justified since the treatable con-
centrations used for lime precipitation and sedimentation tech-
nology are based on optimized treatment for concommitant multiple
metals removal.  Thus, even though metals have somewhat different
theoretical solubilities, they will be removed at very nearly the
same rate in a lime precipitation and sedimentation treatment
system operated for multiple metals removal.  Filtration as part
of the technology basis is likewise justified because this tech-
nology removes metals non-preferentially.

The toxic metal pollutants selected for specific limitation in
the secondary aluminum subcategory to control the discharges of
toxic metal pollutants are lead and zinc.  Ammonia is also
selected for limitation since the methods used to control lead
and zinc are not effective in the control of ammonia.

The following toxic pollutant is excluded from limitation on the
basis that it is effectively controlled by the limitations
developed for lead and zinc:

     118.  cadmium

The conventional pollutant parameters oil and grease, TSS, and pH
will be limited by the best conventional technology (BCT) efflu-
ent limitations.  These effluent limitations and a discussion of
BCT are presented in Section XIII of this supplement.

EFFLUENT LIMITATIONS

The treatable concentrations achievable by application of the BAT
treatment are discussed in Section VII of the General Development
                               832
-------
Document and summarized there in Table VII-19.  The treatable
concentrations (both one day maximum and monthly average values)
are multiplied by the BAT normalized discharge flows summarized
in Table X-4 to calculate the mass of pollutants allowed to be
discharged per mass of product.  The results of these calcula-
tions in milligrams of pollutant per metric ton of product repre-
sent the BAT effluent limitations and are presented in Table X-5
for each waste stream.
                              833
-------
                           Table X-l

    CURRENT RECYCLE PRACTICES WITHIN  THE SECONDARY .ALUMINUM
                          SUBCATEGORY
                                       Number of
                         Number of       Plants        Range of
                        Plants With    Practicing     Recycle
    Waste Stream        Wastewater      Recycle       Values (%)

Scrap Drying Wet Air         3              2            100
 Pollution Control

Demagging Wet Air           19              9         40 -  100
 Pollution Control
                              834
-------
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                                              835
-------
                        Table X-3

COST OF COMPLIANCE FOR THE SECONDARY ALUMINUM SUBCATEGORY
                    DIRECT DISCHARGERS
                   Capital Cost       Annual Cost
       Option     (1978 Dollars)     (1978 Dollars)

         A          1,510,000          1,310,000

         C          1,600,000          1,350,000

         F          1,900,000          1,500,000
                           336
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                                         837
-------
                            Table X-5

 BAT EFFLUENT LIMITATIONS FOR THE SECONDARY ALUMINUM SUBCATEGORY


              Scrap Drying Wet Air Pollution Control

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

          Metric Units - mg/kkg of aluminum scrap dried
     English Units - Ibs/billion Ibs of aluminum scrap dried

Lead                                    0               0
Zinc                                    0               0
Aluminum                                0               0
Ammonia (as N)                          00


                   Scrap Screening and Milling

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

   Metric Units - mg/kkg of aluminum scrap screened and milled
    English Units - Ibs/billion Ibs of aluminum scrap screened
                            and milled

Lead                                    0               0
Zinc                                    0               0
Aluminum                                0               0
Ammonia (as N)                          00


                          Dross Washing

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

              Metric Units - mg/kkg of dross washed
         English Units - Ibs/billion Ibs of dross washed

Lead                                1,086.80          978.12
Zinc                               11,085.36        4,564.56
Aluminum                           32,930.04       13,476.32
Ammonia (as N)                  1,445,444.0       636,864.80
                               338
-------
                      Table X-5 (Continued)

 BAT EFFLUENT LIMITATIONS FOR THE SECONDARY ALUMINUM SUBCATEGORY


               Demagging Wet Air Pollution Control

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

            Metric Units - mg/kkg of aluminum demagged
       English Units - Ibs/billion Ibs of aluminum demagged

Lead                                   80.0            72.0
Zinc                                  816.0           336.0
Aluminum                            2,424.0           992.0
Ammonia (as N)                    106,400.0        46,880.0


               Direct Chill Casting Contact Cooling

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

      Metric Units - mg/kkg of aluminum product from direct
                          chill casting
     English Units - Ibs/billion Ibs of aluminum product from
                       direct chill casting

Lead                                  199.90          179.91
Zinc                                2,038.98          839.58
Aluminum                            6,056.97        2,478.76
Ammonia (as N)                    265,867.0       117,141.40


                Stationary Casting Contact Cooling

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

    Metric Units - mg/kkg of aluminum produced from stationary
                             casting
    English Units - Ibs/billion Ibs of aluminum produced from
                        stationary casting

Lead                                    0               0
Zinc                                    0               0
Aluminum                                0               0
Ammonia (as N)                          0               0
                              839
-------
                      Table X-5 (Continued)

 BAT EFFLUENT LIMITATIONS FOR THE SECONDARY ALUMINUM SUBCATEGORY


                   Shot Casting Contact Cooling

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

   Metric Units - mg/kkg of aluminum produced from shot casting
    English Units - Ibs/billion Ibs of aluminum produced from
                           shot casting


Lead                                    0               0
Zinc                                    0               0
Aluminum                                0               0
Ammonia (as N)                          0               0
                              840
-------
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                  SECONDARY ALUMINUM  SUBCATEGORY

                            SECTION XI

                 NEW SOURCE PERFORMANCE STANDARDS
INTRODUCTION
The basts for new source performance  standards  (NSPS) under Sec-
tion 306 of the Act if the best available demonstrated  technol-
ogy (BDT).  New plants have the opportunity to  design the best
and most efficient production processes and wastewater  treatment
technologies, without facing the added costs and restrictions
encountered in retrofitting an existing, plant.  Therefore, Con-
gress directed EPA to consider the best demonstrated process
changes, in-plant controls, and end-of-pipe treatment technolo-
gies which reduce pollution to the maximum extent  feasible.

This section describes the control technology for  treatment of
wastewater from new sources and presents mass discharge  limita-
tions of regulatory pollutants for NSPS in the  secondary aluminum
subcategory, based on the described control technology.

TECHNICAL APPROACH TO BDT

As discussed in the General Development Document,  all of the
treatment technology options applicable to a new source were
previously considered for the BAT options.  For this reason,
three options were considered for BDT, all identical to the BAT
options discussed in Section X.  The  treatment  technologies used
for the three BDT options are:

OPTION A

     o  Preliminary treatment with oil skimming (where required)
     o  Preliminary treatment of dross washing  wastewater with
        ammonia steam stripping
     o  In-process flow reduction of  direct chill  casting contact
        cooling water and scrubber liquor resulting from scrap
        drying wet air pollution control
     o  Chemical precipitation and sedimentation

OPTION C

     o  Preliminary treatment with oil skimming (where required)
     o  Preliminary treatment of dross washing  wastewater with
        ammonia steam stripping
     o  In-process flow reduction of  direct chill  casting contact
        cooling water and scrubber liquor resulting from scrap
        drying wet air pollution control
     o  Chemical precipitation and sedimentation
     o  Multimedia filtration
                              84.S
-------
OPTION F

     o  Preliminary treatment with oil skimming (where required)
     o  Preliminary treatment of dross washing wastewater with
        ammonia steam stripping
     o  In-process flow reduction of direct chill casting contact
        cooling water and scrubber liquor resulting from scrap
        drying wet air pollution control
     o  Chemical precipitation and sedimentation
     o  Multimedia filtration
     o  Reverse osmosis and multiple-effect evaporation for
        complete recycle of treated water

Partial or complete reuse and recycle of wastewater is an essen-
tial part of each option.  Reuse and recycle can precede or
follow end-of-pipe treatment.  A more detailed discussion of
these treatment options is presented in Section X.

BDT OPTION SELECTION

EPA promulgated the best available demonstrated technology for
the secondary aluminum subcategory on April 8, 1974 as Subpart C
of 40 CFR Part 421.  The promulgated NSPS prohibits the discharge
of process wastewater except for an allowance, if determined to
be necessary, which allows the discharge of process wastewater
from chlorine demagging.  In this respect, promulgated NSPS was
less stringent than promulgated BAT.  The Agency did this recog-
nizing that NSPS became effective on the data of promulgation and
did not believe that the dry chlorine demagging processes were
immediately available.  The Agency believes that they were
appropriate for BAT with its compliance date being 10 years
later.

EPA is proposing to modify the promulgated NSPS to allow for a
discharge from chlorine demagging and direct chill casting.  The
discharge allowances are identical to those proposed for BAT.
The technology basis is also identical to that of the proposed
BAT treatment consisting of in-process flow reduction, prelimi-
nary treatment by oil skimming and ammonia steam stripping, lime
precipitation, sedimentation and filtration (Option C).

Reverse osmosis is not demonstrated and is not clearly transfer-
able to nonferrous metals manufacturing wastewater.  The Agency
also does not believe that new plants could achieve any addi-
ional flow reduction for chlorine demagging and direct chill
casting beyond that proposed for BAT.
                               846
-------
REGULATED POLLUTANT PARAMETERS

The Agency has no reason to believe that the pollutants  that will
be found in treatable concentrations in processes within new
sources will be any different than with existing sources.
Accordingly, pollutants and pollutant parameters selected for
limitation under NSPS, in accordance with the rationale  of
Sections VI and X, are identical to those selected for BAT.  The
conventional pollutant parameters TSS, oil and grease, and pH are
also selected for limitation.

NEW SOURCE PERFORMANCE STANDARDS

The NSPS discharge flows for each wastewater source are the same
as the discharge rates for all the BAT options and are presented
in Table XI-1.  The mass of pollutant allowed to be discharged
per mass of product is calculated by multiplying the appropriate
achievable treatment concentration by the production normalized
wastewater discharge flows (1/kkg).  The treatable concentrations
are listed in Tables VII-19 of the General Development Document.
New source performance standards for the secondary aluminum
subcategory waste streams are presented in Table XI-2.
                              847
-------
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-------
                            Table XI-2

           NSPS FOR THE SECONDARY ALUMINUM SUBCATEGORY


              Scrap Drying Wet Air Pollution Control.

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

          Metric Units - mg/kkg of aluminum scrap dried
     English Units - Ibs/billion Ibs of aluminum scrap dried

Lead                                    0               0
Zinc                                    0               0
Aluminum                                0               0
Ammonia (as N)                          00
Oil and grease                          0               0
TSS                                     0               0
pH                                Within the range 7.5 to 10.0
                                          at all times


                   ScrapScreening and Milling

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

   Metric Units - mg/kkg of aluminum scrap screened and milled
    English Units - Ibs/billion Ibs of aluminum scrap screened
                            and milled

Lead                                    0               0
Zinc                                    0               0
Aluminum                                0               0
Ammonia (as N)                          00
Oil and grease                          0               0
TSS                                     0               0
pH                                    Within the range of 7.5
                                      to 10.0 at all times
                               849
-------
                      Table XI-2 (Continued)

           NSPS FOR THE SECONDARY ALUMINUM SUBCATEGORY


                          Dross Washing

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

              Metric Units - mg/kkg of dross washed
         English Units - Ibs/billion Ibs of dross washed

Lead                                1,086.80          978.12
Zinc                               11,085.36        4,564.56
Aluminum                           32,930.04       13,476.32
Ammonia (as N)                  1,445,444.0       636,864.80
Oil and grease                    108,680.0       108,680.0
TSS                               163,020.0       130,416.0
pH                                Within the range of 7.5 to 10.0
                                         at all times


               Demagging Wet Air Pollution Control

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

            Metric Units - mg/kkg of aluminum demagged
       English Units - Ibs/billion Ibs of aluminum demagged

Lead                                   80.0            72.0
Zinc                                  816.0           336.0
Aluminum                            2,424.0           992.0
Ammonia (as N)                    106,400.0        46,880.0
Oil and grease                      8,000.0         8,000.0
TSS                                12,000.0         9,600.0
pH                                 Within the range of 7.5 to
                                      10.0 at all times
                              850
-------
                      Table XI-2  (Continued)

           NSPS FOR THE SECONDARY ALUMINUM SUBCATEGORY


               Direct Chill Casting Contact Cooling

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

         Metric Units - mg/kkg of aluminum produced from
                       direct chill casting
    English Units - Ibs/billion Ibs of aluminum produced from
                       direct chill casting

Lead                                  199.90          179.91
Zinc                                2,038.98          839.58
Aluminum                            6,056.97        2,478.76
Ammonia (as N)                    265,867.0       117,141.40
Oil and grease                     19,990.0        19,990.0
TSS                                29,985.0        23,988.0
pH                                 Within the range of 7.5 to
                                    10.0 at all times


                Stationary Casting Contact Cooling

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

    Metric Units - mg/kkg of aluminum produced from stationary
                             casting
    English Units - Ibs/billion Ibs of aluminum produced from
                        stationary casting

Lead                                    0               0
Zinc                                    0               0
Aluminum                                0               0
Ammonia (as N)                          00
Oil and grease                          0               0
TSS                                     0               0
pH                                 Within the range of 7.5 to
                                    10.0 at all times
                              851
-------
                      Table XI-2 (Continued)

           NSPS FOR THE SECONDARY ALUMINUM SUBCATEGORY


                   Shot Casting Contact Cooling

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

    Metric Units - mg/kkg of aluminum produced from stationary
                             casting
    English Units - Ibs/billion Ibs of aluminum produced from
                        stationary casting

Lead                                    0               0
Zinc                                    0               0
Aluminum                                0               0
Ammonia (as N)                          00
Oil and grease                          0               0
TSS                                     0               0
pH                                 Within the range of 7.5 to
                                    10.0 at all times
                               852
-------
                  SECONDARY ALUMINUM SUBCATEGORY

                           SECTION XII

                      PRETREATMENT STANDARDS


Section 307(b) of the Act requires EPA to promulgate pretreatment
standards for existing sources (PSES), which must be achieved
within three years of promulgation.  PSES are designed to prevent
the discharge of pollutants which pass through, interfere with,
or are otherwise incompatible with the operation of publicly
owned treatment works (POTW).  The Clean Water Act of 1977
requires pretreatment for pollutants, such as heavy metals, that
limit POTW sludge management alternatives.  Section 307(c) of the
Act requires EPA to promulgate pretreatment standards for new
sources (PSNS) at the same time that it promulgates NSPS.  New
indirect discharge facilities, like new direct discharge facili-
ties, have the opportunity to incorporate the best available
demonstrated technologies, including process changes, in-plant
controls, and end-of-pipe treatment technologies, and to use
plant site selection to ensure adequate treatment system instal-
lation.  Pretreatment standards are to be technology based,
analogous to the best available technology for removal of toxic
pollutants.

This section describes the control technology for pretreatment of
process wastewaters from existing sources and new sources in the
secondary aluminum subcategory.  Pretreatment standards for regu-
lated pollutants are presented based on the described control
technology.

TECHNICAL APPROACH TO PRETREATMENT

Before proposing pretreatment standards, the Agency examines
whether the pollutants discharged by the subcategory pass through
the POTW of interfere with the POTW operation or its chosen
sludge disposal practices.  In determining whether pollutants
pass through a well-operated POTW, achieving secondary treatment,
the Agency compares the percentage of a pollutant removed by POTW
with the percentage removed by direct dischargers applying the
best available technology economically achievable.  A pollutant
is deemed to pass through the POTW when the average percentage
removed nationwide by well-operated POTW meeting secondary
treatment requirements, is less than the percentage removed by
direct dischargers complying with BAT effluent limitations
guidelines for that pollutant.  (see generally, 46 FR at 9415-16
(January 28, 1981).

This definition of pass through satisfies two competing objec-
tives set by Congress:  (1) that standards for indirect dis-
chargers be equivalent to standards for direct dischargers, while
                               853
-------
at the same time, (2) that the treatment capability and perfor-
mance of the POTW be recognized and taken into account in regula-
ting the discharge of pollutants from indirect dischargers.  The
Agency compares percentage removal rather than the mass or
concentration of pollutants discharged because the latter would
not take into account the mass of pollutants discharged to the
POTW from non-industrial sources nor the dilution of the pollu-
tants in the POTW effluent to lower concentrations due to the
addition of large amounts of non-industrial wastewater.

PRETREATMENT STANDARDS FOR EXISTING AND NEW SOURCES

Options for pretreatment of wastewaters from both existing and
new sources are based on increasing the effectiveness of end-of-
pipe treatment technologies.  All in-plant changes and applicable
end-of-pipe treatment processes have been discussed previously in
Sections X and XI.  The options for PSNS and PSES, therefore, are
the same as the BAT options discussed in Section X.  Although oil
and grease is a conventional pollutant compatible with treatment
provided by POTW, oil skimming is needed for the PSNS treatment
technology to ensure proper removal.  Oil and grease interferes
with the chemical addition and mixing required for chemical
precipitation and treatment.

A description of each option is presented in Section X, while a
more detailed discussion, including pollutants controlled by each
treatment process and achievable treatment concentrations is
presented in Section VII of the General Development Document.

Treatment technology options for the PSES and PSNS are:

OPTION A

     o  Preliminary treatment with oil skimming (where required)
     o  Preliminary treatment of dross washing wastewater with
        ammonia steam stripping
     o  In-process flow reduction of direct chill casting contact
        cooling water and scrubber liquor resulting from scrap
        drying wet air pollution control
     o  Chemical precipitation and sedimentation

OPTION C

     o  Preliminary treatment with oil skimming (where required)
     o  Preliminary treatment of dross washing wastewater with
        ammonia steam stripping
     o  In-process flow reduction of direct chill casting contact
        cooling water and scrubber liquor resulting from scrap
        drying wet air pollution control
     o  Chemical precipitation and sedimentation
     o  Multimedia filtration
                               854
-------
OPTION F

     o  Preliminary treatment with oil skimming  (where required)
     o  Preliminary treatment of dross washing wastewater with
        ammonia steam stripping
     o  In-process flow reduction of direct chill casting contact
        cooling water and scrubber liquor resulting  from scrap
        drying wet air pollution control
     o  Chemical precipitation and sedimentation
     o  Multimedia filtration
     o  Reverse osmosis and multiple-effect evaporation for
        complete recycle of treated water

INDUSTRY COST AND POLLUTANT REDUCTION BENEFITS

The industry cost and environmental benefits of each treatment
option were used to determine the most cost-effective option.
The methodology applied in calculating pollutant reduction
benefits and plant compliance costs is discussed in Section X.

Table XII-1 shows the estimated pollutant reduction benefits  for
indirect dischargers.  Compliance costs are presented in Table
XII-2.

FSES AND PSNS OPTION SELECTION

The technology basis for proposed PSES and PSNS is identical  to
BAT (Option C).  The treatment scheme consists of in-process  flow
reduction, preliminary treatment with ammonia steam stripping and
oil skimming (where required), followed by lime precipitation,
sedimentation, and filtration.  EPA knows of no demonstrated
technology that provides more efficient pollutant removal than
BAT technology.  No additional flow reduction for new sources is
feasible because the only other available flow reduction technol-
ogy, reverse osmosis (Option F) is not adequately demonstrated
nor is it clearly transferable for this subcategory.

Since the proposed PSNS does not increase costs compared to PSES
of BAT, it is not expected to prevent the entry of new plants
into the subcategory.  The selected option for proposed PSES
increases the removal of approximately 1,214 kg/yr of toxic
pollutants over the estimated raw discharge.  The estimated
capital cost of proposed PSES is $2.4 million (1978 dollars)  and
the annual cost is $1.6 million (1978 dollars).

REGULATED POLLUTANT PARAMETERS

Pollutants selected for regulation under PSES and PSNS are
identical to those selected for regulation for BAT.  The conven-
tional pollutants oil and grease, TSS, and pH are not limited
under PSES and PSNS because they are effectively controlled by
                               855
-------
POTW.  PSES and PSNS prevent the pass-through of lead, zinc, and
ammonia.  Aluminum is not limited because in its hydroxide form
it is used by POTW as a flocculant aid in the settling and
removal of suspended solids.  As such, aluminum in limited
quantities does not pass through or interfere with POTW; rather
it is a necessary aid to its operation.

PRETREATMENT STANDARDS

In proposing PSES and PSNS, the Agency considered whether to
propose exclusively mass-based standards, or to allow a POTW the
alternative of concentration or mass-based standards.  Mass-based
standards ensure that limitations are achieved by means of pollu-
tant removal rather than by dilution.  They are particularly
important when a limitation is based upon flow reduction because
pollutant limitations associated with the flow reduction cannot
be measured any way but as a reduction of mass discharged.
Mass-based standards, however, are harder to implement because a
POTW faces increased difficulties in monitoring.  A POTW also
must develop specific limits for each plant based on the unit
operations present and the production occurring in each opera-
tion.

EPA resolved these competing considerations by proposing mass-
based standards exclusively where the PSES and PSNS treatment
options include significant flow reductions or where significant
pollutant removals are attibutable to flow reductions.  Flow
reduction over current discharge rates is minimal (0.2 percent)
in the secondary aluminum subcategory.  For secondary aluminum,
EPA has concluded that the proposed PSES should provide alterna-
tive mass-based and concentration-based standards.

The Agency is not proposing alternative mass- and concentra-
tion-based PSNS for the secondary aluminum subcategory, since
PSNS include significant flow reduction (90 percent flow
reduction of direct chill casting).

The PSES and PSNS discharge flows for mass-based standards are
identical to the BAT discharge flows for all processes.  These
discharge flows are listed in Table XII-3.  The mass of pollutant
allowed to be discharged per mass of product is calculated by
multiplying the achievable treatment concentration (mg/1) by the
normalized wastewater discharge flow (1/kkg).  The achievable
treatment concentrations are presented in Table VII-19 of the
General Development Document.  Concentration-based PSES are iden-
tical to the achievable treatment concentrations.  Mass and con-
centration-based PSES are presented in Tables XII-4 and XII-5,
respectively.  PSNS are shown in Table XII-6.
                               856
-------
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-------
                       Table XII-2

COST OF COMPLIANCE FOR THE SECONDARY ALUMINUM SUBCATEGORY
                   INDIRECT DISCHARGERS
                   Capital Cost       Annual Cost
       Option     (1978 Dollars)     (1978 Dollars)

         A          2,200,000          1,500,000

         C          2,400,000          1,600,000

         F          3,080,000          1,900,000
                           858
-------
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-------
                           Table XII-4

           PSES FOR THE SECONDARY ALUMINUM SUBCATEGORY
                           (MASS-BASED)


              Scrap Drying Vet Air Pollution Control

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

          Metric Units - mg/kkg of aluminum scrap dried
     English Units - Ibs/billion Ibs of aluminum scrap dried

Lead                                    0               0
Zinc                                    0               0
Ammonia (as N)                          0               0


                   Scrap Screening and Milling

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

   Metric Units - mg/kkg of aluminum scrap screened and milled
    English Units - Ibs/billion Ibs of aluminum scrap screened
                            and milled

Lead                                    0               0
Zinc                                    0               0
Ammonia (as N)                          00


                          Dross Washing

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

              Metric Units - mg/kkg of dross washed
         English Units - Ibs/billion Ibs of dross washed

Lead                                1,086.80          978.12
Zinc                               11,085.36        4,564.56
Ammonia (as N)                  1,445,444.0       636,864.80
                              860
-------
                     Table XII-4 (Continued)

           PSES FOR THE SECONDARY ALUMINUM SUBCATEGORY
                           (MASS-BASED)


               Demagglng Wet Air Pollution Control

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

            Metric Units - mg/kkg of aluminum demagged
       English Units - Ibs/billion Ibs of aluminum demagged

Lead                                   80.0            72.0
Zinc                                  816.0           336.0
Ammonia (as N)                    106,400.0        46,880.0


               Direct ChillCasting Contact Cooling

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

         Metric Units - mg/kkg of aluminum produced from
                       direct chill casting
    English Units - Ibs/billion Ibs of aluminum produced from
                       direct chill casting

Lead                                  199.90          179.91
Zinc                                2,038.98          839.58
Ammonia (as N)                    265,867.0       117,141.40


                Stationary Casting Contact Cooling

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

         Metric Units - mg/kkg of aluminum produced from
                        stationary casting
       English Units - Ibs/billion Ibs of aluminum produced
                     from stationary casting

Lead                                    0               0
Zinc                                    0               0
Ammonia (as N)                          00
                              861
-------
                     Table XII-4 (Continued)

           PSES FOR THE SECONDARY ALUMINUM SUBCATEGORY
                           (MASS-BASED)


                   Shot Casting Contact Cooling

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

   Metric Units - mg/kkg of aluminum produced from shot casting
    English Units - Ibs/billion Ibs of aluminum produced from
                           shot casting

Lead                                    0               0
Zinc                                    0               0
Ammonia (as N)                          00
                               862
-------
                           Table XII-5

           PSES FOR THE SECONDARY ALUMINUM SUBCATEGORY
                      (CONCENTRATION-BASED)


                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

                       Metric Units - mg/1
                       English  Units -. ppm

Lead                                    0.10            0.09
Zinc                                    1.02            0.42
Ammonia (as N)                        133              58.6
                              863
-------
                           Table XII-6

           PSNS FOR THE SECONDARY ALUMINUM SUBCATEGORY


              Scrap Drying Wet Air Pollution Control

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

          Metric Units - mg/kkg of aluminum scrap dried
     English Units - Ibs/billion Ibs of aluminum scrap dried

Lead                                    0               0
Zinc                                    0               0
Ammonia (as N)                          00


                   Scrap Screening and Milling

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

   Metric Units - mg/kkg of aluminum scrap screened and milled
    English Units - Ibs/billion Ibs of aluminum scrap screened
                            and milled

Lead                                    0               0
Zinc                                    0               0
Ammonia (as N)                          00


                          Dross Washing

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

              Metric Units - mg/kkg of dross washed
         English Units - Ibs/billion Ibs of dross washed

Lead                                1,086.80          978.12
Zinc                               11,085.36        4,564.56
Ammonia (as N)                  1,445,444.0       636,864.80
                               864
-------
                     Table XII-6 (Continued)

           PSNS FOR THE SECONDARY ALUMINUM SUBCATEGORY


               Demagging Wet Air Pollution Control

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

            Metric Units - mg/kkg of aluminum demagged
       English Units - Ibs/billion Ibs of aluminum demagged

Lead                                   80.0            72.0
Zinc                                  816.0           336.0
Ammonia (as N)                    106,400.0        46,880.0


               Direct Chill Casting Contact Cooling

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

         Metric Units - mg/kkg of aluminum produced from
                       direct chill casting
    English Units - Ibs/billion Ibs of aluminum produced from
                       direct chill casting

Lead                                  199.90          179.91
Zinc                                2,038.98          839.58
Ammonia (as N)                    265,867.0       117,141.40


                Stationary Casting Contact Cooling

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

    Metric Units - mg/kkg of aluminum produced from stationary
                             casting
    English Units - Ibs/billion Ibs of aluminum produced from
                        stationary casting

Lead                                    0               0
Zinc                                    0               0
Ammonia (as N)                          00
                               365
-------
                     Table XII-6 (Continued)

           PSNS FOR THE SECONDARY ALUMINUM SUBCATEGORY


                   Shot Casting Contact Cooling

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

   Metric Units - mg/kke of aluminum produced from shot casting
    English Units - Ibs/billion Ibs of aluminum produced from
                           shot casting

Lead                                    0               0
Zinc                                    0               0
Ammonia (as N)                          00
                               866
-------
                  SECONDARY ALUMINUM SUBCATEGORY

                           SECTION XIII

          BEST CONVENTIONAL POLLUTANT CONTROL TECHNOLOGY
The 1977 amendments to the Clean Water Act added Section
301(b)(2)(E), establishing  "best conventional pollutant control
technology" (BCT) for discharge of conventional pollutants  from
existing industrial point sources.  Biochemical oxygen-demanding
pollutants  (BOD5), total suspended solids (TSS), fecal coli-
form, oil and grease (0&G), and pH have been designated as
conventional pollutants (see 44 FR 44501).

BCT is not an additional limitation, but replaces BAT for the
control of conventional pollutants.  In addition to the other
factors specified in SEction 304(b)(4)(B), the Act requires that
limitations for conventional pollutants be assessed in light of a
two-part cost-reasonableness test.  On October 29, 1982, the
Agency proposed a revised methodology for carrying out BCT  analy-
ses (47 FR 49176).  The purpose of the proposal was to correct
errors in the BCT methodology originally established in 1977.

Part 1 of the proposed BCT test requires that the cost and  level
of reduction of conventional pollutants by industrial discharges
be compared with the cost and level of reduction to remove  the
same type of pollutants by publicly-owned treatment works (POTW).
The POTW comparison figure has been calculated by evaluating the
change in costs and removals between secondary treatment (30 mg/1
BOD and 30 mg/1 TSS) and advanced secondary treatement (10  mg/1
BOD and 10 mg/1 TSS).  The difference in cost is divided by the
difference in pounds of conventional pollutants removed, result-
ing in an estimate of the "dollars per pound" of pollutant
removed, that is used as a benchmark value.  The proposed POTW
test benchmark is $0.30 per pound (1978 dollars).

Part 2 of the BCT test requires that the cost and level of
reduction of conventional pollutants by industrial dischargers be
evaluated internally to the industry.  In order to develop  a
benchmark that assesses a reasonable relationship between cost
and removal,  EPA has developed an industry cost ratio which
compares the dollar per pound of conventional pollutant removed
in going from primary to seondary treatment levels with that of
going from primary to secondary treatment levels with that  of
going from secondary to more advanced treatment levels.  The
basis of costs for the calculation of this ratio are the costs
incurred by a POTW.   EPA used these costs because: they reflect
the treatment technologies most commonly used to remove
conventional pollutants from wastewater; the treatment levels
associated with them compare readily to the levels considered for
                               867
-------
industral dischargers; and the costs are the most reliable for
the treatment levels under consideration.  The proposed industry
subcategory benchmark is 1.42.  If the industry figure for a
subcategory is lower than 1.43, the subcategory passes the BCT
test.

The Agency usually considers two conventional pollutants in the
cost test, TSS and an oxygen-demanding pollutant.  Although both
oil and grease and BOD5 are considered to be oxygen-demanding
substances by EPA (see 44 FR 50733), only one can be selected in
the cost analysis to conform to procedures used to develop POTW
costs.  Oil and grease is used rather than BOD5 in the cost
analysis performed for nonferrous metals manufacturing waste
streams due to the common use of oils in casting operations in
this industry.

BPT is the base for evaluating limitations on conventional
pollutants (i.e., it is assumed that BPT is already in place).
The test evaluates the cost and removals associated with
treatment and controls in addition to that specified as BPT.

If the conventional pollutant removal cost of the candidate BCT
is less than the POTW cost, Part 1 of the cost-reasonableness
test is passed and Part 2 (the internal industry test) of the
cost-reasonableness test must be performed.  If the internal
industry test is passed, then a BCT limitation is promulgated
equivalent to the candidate BCT level.  If all candidate BCT
technologies fail both parts of the cost-reasonableness test, the
BCT requirements for conventional pollutants are equal to BPT.

The BCT test was performed for the proposed BAT basis of lime
precipitation, sedimentation, in-process flow reduction, and
multimedia filtration.  The secondary aluminum subcategory failed
Part 1 of the test with a calculated cost of $15.68 per pound
(1978 dollars) of removal of conventional pollutants using BAT
technology.
                               868
-------
                           Table XIII-1

 BCT EFFLUENT LIMITATIONS FOR THE SECONDARY ALUMINUM SUBCATEGORY


              Scrap Drying Wet Air Pollution Control

                                  Maximum for      Maximum for
Pollutant or Pollutant Property   Any One Day	Monthly Average

          Metric Units - mg/kkg of aluminum scrap dried
     English Units - Ibs/billion Ibs of aluminum scrap dried

Oil and grease                         0                0
TSS                                    0                0
pH                                Within the range of 7.5 to 10.0
                                          all times


                   Scrap Screening and Milling

                                 Maximum for      Maximum for
Pollutant or Pollutant Property   Any One Day	Monthly Average

   Metric Units - mg/kkg of aluminum scrap screened and milled
    English Units - Ibs/billion Ibs of aluminum scrap screened
                            and milled

Oil and grease                         0                0
TSS                                    0                0
pH                                Within the range of 7.5 to 10.0
                                          all times


                          Dross Washing

                                  Maximum for      Maximum for
Pollutant or Pollutant Property   Any One Day	Monthly Average

              Metric Units - mg/kkg of dross washed
         English Units - Ibs/billion Ibs of dross washed

Oil and grease                   217,360.0        130,416.0
TSS                              445,588.0        217,360.0
pH                                Within the range of 7.5 to 10.0
                                          all times
                               869
-------
                     Table XIII-1 (Continued)

 BCT EFFLUENT LIMITATIONS FOR THE SECONDARY ALUMINUM SUBCATEGORY


               Demagging Wet Air Pollution Control

                                  Maximum for       Maximum for
Pollutant or Pollutant Property   Any One Day	Monthly Average

            Metric Units - mg/kkg of aluminum  demagged
       English Units - Ibs/billion Ibs of aluminum demagged

Oil and grease                    16,000.0          9,600.0
TSS                               32,800.0         16,000.0
pH                                Within the range of 7.5 to 10.0
                                          all  times


               Direct Chill Casting Contact Cooling

                                  Maximum for       Maximum for
Pollutant or Pollutant Property   Any One Day	Monthly Average

         Metric Units - mg/kkg of aluminum produced from
                       direct chill casting
    English Units - Ibs/billion Ibs of aluminum produced from
                       direct chill casting

Oil and grease                    39,980.0         23,988.0
TSS                               81,959.0         39,980.0
pH                                Within the range of 7.5 to 10.0
                                          all  times


                Stationary Casting Contact Cooling

                                  Maximum for       Maximum for
Pollutant or Pollutant Property   Any One Day	Monthly Average

         Metric Units - mg/kkg of aluminum produced from
                        stationary casting
       English Units - Ibs/billion Ibs of aluminum produced
                     from stationary casting

Oil and grease                         0                0
TSS                                    0                0
pH                                Within the range of 7.5 to 10.0
                                          all  times
                               870
-------
                     Table XIII-1 (Continued)

 BCT EFFLUENT LIMITATIONS FOR THE SECONDARY ALUMINUM SUBCATEGORY


                   Shot Casting Contact Cooling

                                  Maximum for      Maximum for
Pollutant or Pollutant Property   Any One Day	Monthly Average

         Metric Units - mg/kkg of aluminum produced from
                           shot casting
    English Units - Ibs/billion Ibs of aluminum produced from
                           shot casting

Oil and grease                         0                0
TSS                                    0                0
pH                                Within the range of 7.5 to 10.0
                                          all times
                               871
-------
                    SECONDARY LEAD SUBCATEGORY

                            SECTION I

                     SUMMARY AND CONCLUSIONS
On April 8, 1974, EPA promulgated technology-based effluent
limitations guidelines and performance standards for several sub-
categories of the Nonferrous Metals Manufacturing Point Source
Category.  These regulations included BPT, BAT, NSPS, and PSNS
limitations.  The main purpose of these effluent guidelines and
standards was to limit the quantities of total suspended solids,
arsenic, zinc, selenium, copper, cadmium, and oil and grease.
The allowable pH ranges for discharges was also limited.

Since 1974, implementation of the technology-based effluent limi-
tations and standards has been guided by a series of settlement
agreements into which EPA entered with several environmental
groups, the latest of which occurred in 1979.  NRDC v. Costie, 12
ERG 1833 (D.D.C. 1979), aff'd and remd'd, EOF v. Costle, 14 ERG
2161 (1980).  Under the settlement agreements, EPA was required
to develop BAT limitations and pretreatment and new source per-
formance standards for 65 classes of pollutants discharged from
specific industrial point source categories.  The list of 65
classes was subsequently expanded to a list of 129 specific toxic
pollutants, and now consists of 126 toxics.

Congress amended the Clean Water Act in 1977 to encompass many of
the provisions of the earlier settlement agreements, including
the list of 65 classes of pollutants.  As a result of the settle-
ment agreements and the Clean Water Act Amendments, EPA undertook
an extensive effort to develop technology-based BAT limitations
and pretreatment and new source performance standards for the
toxic pollutants.

The purpose of this proposed rulemaking is to create the secon-
dary lead subcategory and establish BPT, BAT, and BCT effluent
limitations and NSPS, and pretreatment standards for this sub-
category.  This is done pursuant to the provisions of the
Settlement Agreement and Sections 301, 304, 306, and 307 of the
Clean Water Act and its amendments.  This supplement provides a
compilation and analysis of the background material used to deve-
lop these effluent limitations and standards.

The secondary lead subcategory is comprised of 69 plants.  Of the
69 plants,  seven discharge directly to rivers, lakes,  or streams;
16 discharge to publicly owned treatment works (POTW); and 46 do
not discharge process wastewater.
                               873
-------
EPA first studied the secondary lead subcategory to determine
whether differences in raw materials, final products, manufactur-
ing processes, equipment, age and size of plants, and water
usage, required the development of separate effluent limitations
and standards for different segments of the subcategory.  This
involved a detailed analysis of wastewater discharge and treated
effluent characteristics, including  (1) the processes used (2)
the sources and volume of water used, (3) the sources of
pollutants and wastewaters in the plant; and (4) the constituents
(including toxic pollutants) and volume of wastewaters.

EPA also identified several distinct control and treatmemt tech-
nologies (both in-plant and end-of-pipe) applicable to the
secondary lead subcategory.  The Agency analyzed both historical
and newly generated data on the performance of these technolo-
gies, including their nonwater quality environmental impacts and
air quality, solid waste generation, and energy requirements.
EPA also studied various flow reduction techniques reported in
the data collection portfolios (dcp) and plant visits.

Engineering costs were prepared for each of the control and
treatment options considered for the category.  These costs were
then used by the Agency to estimate the impact of implementing
the various options on the subcategory.  For each control and
treatment option that the Agency found to be most effective and
technically feasible in controlling the discharge of pollutants,
the number of potential closures, number of employees affected,
and impact on price were estimated.  These results are reported
in a separate document entitled Economic Impact Analysis of
Proposed Effluent Standards and Limitations for the Nonferrous
Smelting and Refining Industry.

Based on consideration of the above factors, EPA identified vari-
ous control and treatment technologies which formed the basis for
BPT and selected control and treatment appropriate for each set
of standards and limitations.  The mass limitations and standards
for BPT, BAT, NSPS, PSES, PSNS, and BCT are presented in Section
II.

After examining the various treatment technologies, the Agency
has identified BPT to represent the average of the best existing
technology.  Metals removal based on lime precipitation and
sedimentation is the basis for the BPT limitations.  Wastewater
discharge rates used in developing BPT effluent limitations
represent the average of the subcategory discharge and usage for
process wastewater.  To meet the BPT effluent limitations based
on this technology, the secondary lead subcategory is estimated
to incur a capital cost of $0.470 million (1978 dollars) and an
annual cost of $0.228 million (1978 dollars).
                               874
-------
Due to current adverse structural economic changes that are not
reflected in EPA's current economic analysis, the Agency has
identified alternative technologies as a basis for BAT effluent
limitations.  For Alternative A, the Agency has built upon the
BPT basis of lime precipitation and sedimentation for metals
removed by adding in-process control technologies which include
recycle of process water from air pollution control and metal
contact cooling waste streams.  To meet the Alternative A BAT
effluent limitations, the secondary lead subcategory will incur
an estimated capital cost of $0.470 million (1978 dollars) and an
annual cost of $0.228 million (1978 dollars).  For Alternative B,
filtration is added as an effluent polishing step to the in-pro-
cess flow reduction, lime precipitation, and sedimentation tech-
nology considered in Alternative A.  To meet the Alternative B
BAT effluent limitations, the secondary lead subcategory will
incur an estimated capital cost of $2.12 million (1978 dollars)
and an annual cost of $1.36 million (1978 dollars).

The best demonstrated technology, BDT, which is the technical
basis of NSPS, is equivalent to BAT.  In selected BDT, EPA
recognizes that new plants have the opportunity to implement the
best and most efficient manufacturing processes and treatment
technology.  However, the technology basis of BAT has been
determined as the best demonstrated technology because no
additional process modifications or treatment technologies have
been identified that substantially improve BAT performance.

The Agency selected the same alternative technologies as BAT for
PSES.  To meet the Alternative A pretreatment standards for
existing sources, the secondary lead subcategory will incur an
estimated capital cost of $1.49 million (1978 dollars) and an
annual cost of $0.559 million (1978 dollars).

Alternative B pretreatment standards for existing sources are
estimated to result in a capital cost of $3.04 million (1978
dollars) and an annual cost of $1.94 million (1978 dollars).  For
pretreatment standards for new sources (PSNS), the Agency
selected end-of-pipe treatment and in-process flow reduction
control techniques equivalent to BDT.  As such, the PSNS are
identical to the NSPS for all waste streams.

The Agency is also proposing BCT effluent limitations at this
time.  The best conventional technology (BCT) replaces BAT for
the control of conventional pollutants.  The technology basis of
BCT is the BPT treatment of lime precipitation and sedimentation.
                               875
-------
                    SECONDARY LEAD SUBCATEGORY

                            SECTION II

                         RECOMMENDATIONS
 1.  EPA has divided the secondary lead subcategory into four
     subdivisions for the purpose of effluent limitations and
     standards.  These subdivisions are:

     (a)  Battery Cracking,
     (b)  Blast and Reverberatory Furnace Wet Air Pollution
          Control,
     (c)  Kettle Wet Air Pollution Control, and
     (d)  Casting Contact Cooling.

 2.  BPT is proposed based on the performance achievable by
     the application of chemical precipitation and sedimenta-
     tion (lime and settle) technology.  The following
     BPT effluent limitations are proposed:
     (a)  Battery Cracking
          BPT EFFLUENT LIMITATIONS
Pollutant or Pollutant Property
 Maximum for
 Any One Day
  Maximum  for
jlonthly Average
           Metric Units - mg/kkg of lead scrap produced
      English Units - Ibs/billion Ibs of lead scrap produced
Antimony
Arsenic
Lead
Zinc
Ammonia (as N)
Total Suspended Solids
pH
    2,697.80        1,193.80
    1,964.60          808.40
      141.0           122.20
    1,250.20          526.40
        0.0             0.0
   38,540.0        18,800.0
Within the range of 7.5 to 10.0
         at all times
                                877
-------
     (b)  Blast and Reverberatory Furnace Wet Air Pollution
          Control
          BPT EFFLUENT LIMITATIONS
Pollutant or Pollutant Property
 Maximum for
 Any One Day
  Maximum for
MonthlyAverage
       Metric Units - mg/kkg of lead produced from smelting
  English Units - Ibs/billion Ibs of lead produced from smelting
Antimony
Arsenic
Lead
Zinc
Ammonia (as N)
Total Suspended Solids
PH
    9,700.60
    7,064.20
      507.0
    4,495.40
        0.0
  138,580.0
    4,292.60
    2,906.80
      439.40
    1,892.80
        0.0
   67,600.0
Within the range of 7.5 to 10.0
         at all times
     (c)  Kettle Wet Air Pollution Control
          BPT EFFLUENT LIMITATIONS
Pollutant or Pollutant Property
 Maximum for
 Any One Day
  Maximum for
Monthly Average
   Metric Units - mg/kkg of lead produced from kettle furnaces
   English Units - Ibs/billion Ibs of lead produced from kettle
                             furnaces
Antimony
Arsenic
Lead
Zinc
Ammonia (as N)
Total Suspended Solids
pH
        0
        0
        0
        0
        0
        0
        0
        0
        0
        0
        0
        0
Within the range of 7.5 to 10.0
         at all times
                               878
-------
     (d)  Casting Contact Cooling
          BPT EFFLUENT LIMITATIONS
Pollutant or Pollutant Property
 Maximum for
 Any One Day
  Maximum for
Monthly Average
                  Metric Units - mg/kkg of lead cast
           English Units - Ibs/billion Ibs of lead cast
Antimony
Arsenic
Lead
Zinc
Ammonia (as N)
Total Suspended Solids
pH
      634.84          280.92
      462.31          190.23
       33.18           28.76
      294.20          123.87
        0.0             0.0
    9,069.20        4,424.0
Within the range of 7.5 to 10.0
         at all times
 3.  EPA is proposing two technology alternatives for BAT for the
     secondary lead subcategory.

     BAT Alternative A is proposed based on the performance
     achievable by the application of chemical precipitation
     and sedimentation (lime and settle) technology and in-
     process flow reduction control methods.  The follow-
     ing BAT effluent limitations are proposed for existing
     sources:
     (a)  Battery Cracking
          BAT EFFLUENT LIMITATIONS
Pollutant or Pollutant Property
 Maximum for
 Any One Day
  Maximum for
Monthly Average
           Metric Units - mg/kkg of lead scrap produced
      English Units - Ibs/billion Ibs of lead scrap produced
Antimony
Arsenic
Lead
Zinc
Ammonia (as N)
    1,931.51
    1,406.57
      100.95
      895.09
        0.0
      854.71
      578.78
       87.49
      376.88
        0.0
                               379
-------
     (b)   Blast and Reverberatory Furnace Wet Air Pollution
           Control
           BAT EFFLUENT LIMITATIONS

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

       Metric Units - mg/kkg of lead produced from smelting
  English Units - Ibs/billion Ibs of lead produced from smelting

Antimony                              7,490.7         3,314.7
Arsenic                               5,454.9         2,244.6
Lead                                    391.5           339.3
Zinc                                  3,471.30        1,461.6
Ammonia (as N)                            0.0             0.0

     (c)  Kettle Wet Air Pollution Control
          BAT EFFLUENT LIMITATIONS

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

   Metric Units - mg/kkg of lead produced from kettle furnaces
   English Units - Ibs/billion Ibs of lead produced from kettle
                             furnaces

Antimony                                  0               0
Arsenic                                   0               0
Lead                                      0               0
Zinc                                      0               0
Ammonia (as N)                            00

     (d)  Casting Contact Cooling
          BAT EFFLUENT LIMITATIONS

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

                  Metric Units - mg/kkg of lead cast
           English Units - Ibs/billion Ibs of lead cast

Antimony                                 63.43           28.07
Arsenic                                  46.19           19.01
Lead                                      3.32            2.87
Zinc                                     29.39           12.38
Ammonia (as N)                            0.0             0.0
                               880
-------
     BAT Alternative B is proposed based on the performance
     achievable by the! application of chemical precipitation
     sedimentation, an|d multimedia filtration  (lime, settle,
     and filter) technology and in-process flow reduction
     control methods.  The following BAT effluent  limitations
     are proposed for existing sources:

     (a)  Battery Cracking
          BAT EFFLUENT LIMITATIONS

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

           Metric Units - mg/kkg of lead scrap produced
      English Units - Ibs/billion Ibs of lead scrap produced

Antimony                               1298.89          578.78
Arsenic                                 935.47          383.61
Lead                                     67.30           60.57
Zinc                                    686.46          282.66
Ammonia (as N)                            0.0             0.0

     (b)  Blast and Reverberatory Furnace Wet Air
          Pollution Control
          BAT EFFLUENT LIMITATIONS

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

       Metric Units - mg/kkg of lead produced from smelting
  English Units - Ibs/billion Ibs of lead produced from smelting

Antimony                              5,037.30        2,244.60
Arsenic                               3,627.90        1,487.70
Lead                                    261.0           234.90
Zinc                                  2,662.20        1,096.20
Ammonia (as N)                            0.0             0.0

     (c)  Kettle Wet Air Pollution Control
          BAT EFFLUENT LIMITATIONS

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

   Metric Units - mg/kkg of lead produced from kettle furnaces
   English Units - Ibs/billion Ibs of lead produced from kettle
                             furnaces

Antimony                                  0               0
Arsenic                                   0               0
Lead                                      0               0
Zinc                                      0               0
Ammonia (as N)                            00

                               881
-------
     (d)  Casting Contact Cooling
          BAT EFFLUENT LIMITATIONS
Pollutant or Pollutant Property
 Maximum for
 Any One Day
  Maximum for
Monthly Average
                  Metric Units - mg/kkg of lead cast
           English Units - Ibs/billion Ibs of lead cast
Antimony
Arsenic
Lead
Zinc
Ammonia (as N)
       42.65
       30.72
        2.21
       22.54
        0.0
       19.01
       12.60
        1.99
        9.28
        0.0
 4.  NSPS are proposed based on the performance achievable
     by the application of chemical precipitation, sedimentation
     and multimedia filtration (lime, settle, and filter)
     technology and in-process flow reduction control methods.
     The following effluent standards are proposed for new
     sources:
     (a)  Battery Cracking NSPS
Pollutant or Pollutant Property
 Maximum for
 Any One Day
  Maximum for
Monthly Average
           Metric Units - mg/kkg of lead scrap produced
      English Units - Ibs/billion Ibs of lead scrap produced
Antimony
Arsenic
Lead
Zinc
Ammonia (as N)
Total Suspended Solids
pH
    1,298.89          578.78
      935.47          383.61
       67.30           60.57
      686.46          282.66
        0.0             0.0
   10,095.0         8,076.0
Within the range of 7.5 to 10.0
         at all times
                               882
-------
      (b)  Blast and Reverberatory Furnace Wet Air Pollution
          Control NSPS
Pollutant or Pollutant Property
 Maximum for
 Any One Day
  Maximum for
Monthly Average
       Metric Units - mg/kkg of lead produced from smelting
  English Units - Ibs/billion Ibs of lead produced from smelting
Antimony
Arsenic
Lead
Zinc
Ammonia (as N)
Total Suspended Solids
PH
    5,037.30
    3,627.90
      261.0
    2,662.0
        0
   39,150.0
    2,244.60
    1,487.70
      234.90
    1,096.20
        0
   31,320.0
Within the range of 7.5 to 10.0
         at all times
      (c)  Kettle Wet Air Pollution Control NSPS
Pollutant or Pollutant Property
 Maximum for
 Any One Day
  Maximum for
Monthly Average
   Metric Units - mg/kkg of lead produced from kettle furnaces
   English Units - Ibs/billion Ibs of lead produced from kettle
                             furnaces
Antimony
Arsenic
Lead
Zinc
Ammonia (as N)
Total Suspended Solids
PH
        0
        0
        0
        0
        0
        0
        0
        0
        0
        0
        0
        0
Within the range of 7.5 to 10.0
         at all times
     (d)  Casting Contact Cooling NSPS
Pollutant or Pollutant Property
 Maximum for
 Any One Day
  Maximum for
Monthly Average
                  Metric Units - mg/kkg of lead cast
           English Units - Ibs/billion Ibs of lead cast
Antimony
Arsenic
Lead
Zinc
Ammonia (as N)
Total Suspended Solids
PH
       42.65           19.01
       30.72           12.60
        2.21            1.99
       22.54            9.28
        0.0             0.0
      331.50          265.20
Within the range of 7.5 to 10.0
         at all times
                               883
-------
 5.  EPA is proposing two technology alternatives for PSES for
     the secondary lead subcategory.

     PSES Alternative A is proposed based on the performance
     achievable by the application of chemical precipitation
     and sedimentation (lime and settle) technology and in-
     process flow reduction control methods.  The follow-
     ing pretreatment standards are proposed:

     (a)  Battery Cracking PSES

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

           Metric Units - mg/kkg of lead scrap produced
      English Units - Ibs/billion Ibs of lead scrap produced

Antimony                              1,931.51          854.71
Arsenic                               1,406.57          578.78
Lead                                    100.95           87.49
Zinc                                    895.09          376.88
Ammonia (as N)                            0.0             0.0

     (b)  Blast and Reverberatory Furnace Wet Air Pollution
          Control PSES

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

       Metric Units - mg/kkg of lead produced from smelting
  English Units - Ibs/billion Ibs of lead produced from smelting

Antimony                              7,490.7    -     3,314.7
Arsenic                               5,454.9         2,244.6
Lead                                    391.5           339.3
Zinc                                  3,471.30        1,461.6
Ammonia (as N)                            0.0             0.0

     (c)  Kettle Wet Air Pollution Control PSES

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

   Metric Units - mg/kkg of lead produced from kettle furnaces
   English Units - Ibs/billion Ibs of lead produced from kettle
                             furnaces

Antimony                                  0               0
Arsenic                                   0               0
Lead                                      0               0
Zinc                                      0               0
Ammonia (as N)                            00


                               884
-------
     (d)  Casting Contact Cooling PSES

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

                  Metric Units - mg/kkg of lead cast
           English Units - Ibs/billion Ibs of lead cast

Antimony                                 63.43           28.07
Arsenic                                  46.19           19.01
Lead                                      3.32            2.87
Zinc                                     29.39           12.38
Ammonia (as N)                            0.0             0.0

     PSES Alternative B is proposed based on the performance
     achievable by the application of chemical precipitation,
     sedimentation, and multimedia filtration (lime, settle,
     and filter) technology and in-process flow reduction
     control methods.  The following pretreatment standards
     are proposed:

     (a)  Battery Cracking PSES

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

           Metric Units - mg/kkg of lead scrap produced
      English Units - Ibs/billion Ibs of lead scrap produced

Antimony                              1,298.89          578.78
Arsenic                                 935.47          383.61
Lead                                     67.30           60.57
Zinc                                    686.46          282.66
Ammonia (as N)                            0.0             0.0

     (b)  Blast and Reverberatory Furnace Wet Air Pollution
          Control PSES

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

       Metric Units - mg/kkg of lead produced from smelting
  English Units - Ibs/billion Ibs of lead produced from smelting

Antimony                              5,037.30        2,244.60
Arsenic                               3,627.90        1,487.70
Lead                                    261.0           234.90
Zinc                                  2,662.20        1,096.20
Ammonia (as N)                            0.0             0.0
                               885
-------
     (c)  Kettle Wet Air Pollution Control PSES

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

   Metric Units - mg/kkg of lead produced from kettle furnaces
   English Units '- Ibs/billion Ibs of lead produced from kettle
                             furnaces

Antimony                                  0               0
Arsenic                                   0               0
Lead                                      0               0
Zinc                                      0               0
Ammonia (as N)                            0               0

     (d)  Casting Contact Cooling PSES

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

                  Metric Units - mg/kkg of lead cast
           English Units - Ibs/billion Ibs of lead cast

Antimony                                 42.65           19.01
Arsenic                                  30.72           12.60
Lead                                      2.21            1.99
Zinc                                     22.54            9.28
Ammonia (as N)                            0.0             0.0

 6.  PSNS are proposed based on the performance achievable
     by the application of chemical precipitation, sedimentation
     and multimedia filtration (lime, settle, and filter)
     technology and in-process flow reduction control methods.
     The following pretreatment standards are proposed:

     (a)  Battery Cracking PSNS

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

           Metric Units - mg/kkg of lead scrap produced
      English Units - Ibs/billion Ibs of lead scrap produced

Antimony                              1,298.89          578.78
Arsenic                                 935.47          383.61
Lead                                     67.30           60.57
Zinc                                    686.46          282.66
Ammonia (as N)                            0.0             0.0
                               886
-------
     (b)  Blast and Reverberatory Furnace Wet Air Pollution
          Control PSNS'

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

       Metric Units - mg/kkg of lead produced from smelting
  English Units - Ibs/billion Ibs of lead produced from smelting

Antimony                              5,037.3         2,244.6
Arsenic                               3,627.9         1,487.7
Lead                                    261.0           234.9
Zinc                                  2,662.2         1,096.2
Ammonia (as N)                            0               0

     (c)  Kettle Wet Air Pollution Control PSNS

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

   Metric Units - mg/kkg of lead produced from kettle furnaces
   English Units - Ibs/billion Ibs of lead produced from kettle
                             furnaces

Antimony                                  0               0
Arsenic                                   0               0
Lead                                      0               0
Zinc                                      0               0
Ammonia (as N)                            00

     (d)  Casting Contact Cooling PSNS

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

                  Metric Units - mg/kkg of lead cast
           English Units - Ibs/billion Ibs of lead cast

Antimony                                 42.65           19.01
Arsenic                                  30.72           12.60
Lead                                      2.21            1.99
Zinc                                     22.54            9.28
Ammonia (as N)                            0.0             0.0
                              887
-------
 7.  BCT is proposed based on the performance achievable by the
     application of chemical precipitation and sedimentation
     (lime and settle) technology. BCT is not an additional set
     of effluent limitations, but replaces BAT in the control
     of conventional pollutants. The following BCT effluent
     limitations are proposed:

     (a)  Battery Cracking
          BCT EFFLUENT LIMITATIONS

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

           Metric Units - mg/kkg of lead scrap produced
      English Units - Ibs/billion Ibs of lead scrap produced

Total Suspended Solids               38,540.0        18,800.0
pH                                Within the range of 7.5 to 10.0
                                           at all times

     (b)  Blast and Reverberatory Furnace Wet Air Pollution
          Control
          BCT EFFLUENT LIMITATIONS

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

       Metric Units - mg/kkg of lead produced from smelting
  English Units - Ibs/billion Ibs of lead produced from smelting

Total Suspended Solids              138,580.0        67,600.0
pH                                Within the range of 7.5 to 10.0
                                           at all times

     (c)  Kettle Wet Air Pollution Control
          BCT EFFLUENT LIMITATIONS

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

   Metric Units - mg/kkg of lead produced from kettle furnaces
   English Units - Ibs/billion Ibs of lead produced from kettle
                             furnaces

Total Suspended Solids                    0               0
pH                                Within the range of 7.5 to 10.0
                                           at all times
                               888
-------
     (d)  Casting Contact Cooling
          BCT EFFLUENT LIMITATIONS

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

                  Metric Units - mg/kkg of lead cast
           English Units - Ibs/billion Ibs of lead cast

Total Suspended Solids                9,069.20        4,424.0
pH                                Within the range of 7.5 to 10.0
                                           at all times
                               839
-------
                    SECONDARY LEAD SUBCATEGORY

                           SECTION III

                         INDUSTRY PROFILE
This section of the secondary lead supplement describes  the  raw
materials and processes used in converting  lead-bearing  scrap  to
metallic lead and lead-based alloys and presents a profile of  the
secondary lead plants  identified  in this  study.  For  a discussion
of the purpose, authority, and methodology  for this study and  a
general description of the nonferrous metals manufacturing cate-
gory, refer to Section III of the General Development Document.

DESCRIPTION OF SECONDARY LEAD PRODUCTION

There are three major  phases involved in  the secondary lead  sub-
category scrap pretreatment, smelting, and  refining and  casting.
Figure III-l is a block flow diagram depicting the various pro-
cess steps involved in secondary  lead manufacture.  The  following
discussion summarizes  the raw materials used and the processes
with emphasis on the steps where water may  be used. It should  be
pointed out that not all secondary lead plants perform all of  the
process steps described.

RAW MATERIALS

The principal raw materials used  in the secondary lead subcate-
gory are battery storage plates and other scrap reclaimed from
discarded products containing lead.  Minor  amounts of solder,
babbitt, cable coverings, type metal, soft  lead, and antimonial
lead, as well as drosses and residues generated as a result  of
operations within the  secondary lead plant, are also utilized.

SCRAP PRETREATMENT

The scrap pretreatment phase may involve crushing or cutting used
batteries to allow separation of the lead from the battery case,
crushing of drosses and oversize scrap, and sweating of  lead
scrap containing other metals.  The general crushing operations
reduce the layer pieces of scrap to a suitable size using machin-
ery such as jaw crushers.  Sweating involves charging scrap  to a
furnace where the lead value is separated by selective melting.
The molten lead is collected and cast and the residue is removed
from the furnace.   Reverberatory furnaces are used for this
operation.  Particulate emissions can be controlled with a
baghouse, a scrubber,   or both.

There are a number of  different approaches used in battery break-
ing.  Each method of battery breaking is described below.
                              891
-------
Battery Breaking by Shear or Saw

Many smelters dismantle batteries in a hand operation in which
employees (1) separate plastic and rubber batteries, (2) cut the
top of the battery off, and (3) empty the contents of the battery
onto a pile.  Typically, front-end loaders then move the battery
parts to storage and disposal.

Hammer-Mill Battery-Breaking

In order to speed up the process, remove employees from exposure
and utilize plastic battery cases for fuel or resale, some plants
use hammer mills to break batteries.  Unfortunately, this
approach continues to require hand separation of plastic and
rubber cased batteries and manual handling of rubber cased
batteries.

Flotation-Type Separators

A number of flotation-type battery-breakers are currently used in
today's smelters.  The technique uses a combination of shears,
saws, and hammer mills to reduce battery scrap to small pieces.
The separator produces output streams of hard lead (grids and
posts), oxide and sulfate sludge, plastic, and rubber. The
advantages of this system are (1) positive control of furnace
feed enables use of more sophisticated furnaces, e.g., rotary,
and (2) separate recycling of plastic case material.

Low-Energy Shredders

At least five secondary smelters have (or, have had) low-energy
shredders installed for breaking batteries.  This system uses a
low-rpm, low-energy shredding device to slowly shred batteries
into chargeable or separable pieces.

Whole Battery Charging

This technique, developed by the Bergsoe smelter in Denmark,
purposely utilizes as little battery breaking as possible (only
about 20 percent of the battery mass needs to be broken).  The
acid is drained from the battery before charging.  The unbroken
batteries are mixed with other charge materials on concrete beds
using a rubber-tired front end loader.  After the charge is
prepared, it is loaded into the furnace with a front-end loader.

The battery cracking operation may be performed either on- or
off-site.  Spent electrolyte, along with saw or shredder cooling
water and wash water, constitutes a major source of wastewater at
plants where battery cracking is performed.
                              892
-------
SMELTING OPERATIONS

The smelting operation takes place  in either  a  reverberatory  or  a
blast furnace.  In the reverberatory furnace, heat  is  radiated
from the burner flame and the furnace roof  and  walls onto  the
melt.  It is usually one of the least expensive furnaces to oper-
ate because the flame and hot combustion products come in  direct
contact with the melt.

Reverberatory smelting partially purifies and compacts lead
scrap.  The charge to the furnace can be untreated  scrap (where
the sweating and smelting operations are combined), treated
scrap, or a mixture of both.  The process steps for this opera-
tion are:  (1) charging the scrap to the furnace, (2)  melting the
scrap, (3) allowing the slag to rise to the surface of the metal,
(4) tapping the slag as feed for the blast  furnace, and (5) tap-
ping the molten lead.  The product  lead can then be sent either
to the refining and casting operation, cast into semisoft  or  hard
lead ingots, or converted to various forms  of lead  oxide using
kettle (Barton pot) or reverberatory oxidation  methods.

The secondary lead blast furnace is a refractory-lined steel  cyl-
inder with air ports known as tuyeres located at the bottom,
through which air is supplied by a  blower.  Coke, used as  fuel,
is placed in the shaft in alternating layers  along  with scrap,
slag, and limestone (a flux).  One  of the most  important control
variables is the addition rate of combustion  air through the
tuyeres.  Preheating the combustion air may increase the
efficiency of the furnace.

The product of the blast furnace is semisoft  or hard (antimonial)
lead produced from pretreated scrap, reverberatory  slag, and
recycled blast furnace slag (rerun  slag).   A  typical charge for
the blast furnace is composed of 4.5 percent  rerun  slag, 4.5
percent scrap cast iron, 3.0 percent limestone,  5.5 percent coke,
which serves both as a fuel and as  a reducing agent, and 82.5
percent lead oxides, drosses, scrap, and reverberatory slags
obtained from other smelting and refining operations.

Emissions from reverberatory and blast furnaces are usually con-
trolled with baghouses, although wet scrubbers  may  be  used.   Most
secondary lead plants which practice wet scrubbing  of  furnace
emissions utilize some degree of recycle of the scrubbing  liquor.

REFINING AND CASTING

Softening, alloying, and refining processes take place in  kettle
furnaces which are larger versions  of pot furnaces.  Kettles  may
be cylindrical or rectangular in shape and  are  normally used  to
melt metals with melting points below 760°C.  They  are usually
                              893
-------
poured by tilting, dipping, or pumping.  These large pot or ket-
tle furnaces may have many small burners along all sides.  They
are usually natural gas or oil fired.

The product of the kettle softening and refining process is soft,
high purity lead.  The process steps involved are (a) charging
the preheated kettle furnace with an intermediate semisoft or
hard lead obtained from the smelting operation, (b) melting the
charge, (c) fluxing and agitating the molten charge, (d) skimming
the slag, and (e) pouring and casting the soft lead into ingots.

Fluxes which may be used include sodium hydroxide, sodium
nitrate, aluminum, aluminum chloride, sawdust, sulfur, and air.
Sodium hydroxide, sodium nitrate, or air may be used to reduce
the antimony content.  Aluminum reacts preferentially with anti-
mony, copper, and nickel to form drosses, as does sulfur with
copper.  Adding sawdust to the molten metal forms carbon which
produces elemental lead by the reduction of lead oxide.  This
process is known as dry dressing.

The operating temperatures of refining kettles range between 371°
to 482°C.  Emissions are normally collected by using a hood over
the kettle and are usually sent to a baghouse, although wet
scrubbing also may be used.  Solid wastes, consisting of drosses
and skimmings along with baghouse dust, are generally recycled to
the blast furnace.

The alloying and refining process utilizes the same types furnace
as the kettle softening and refining operation and involves
treatment and adjustment of the composition of the lead to
produce the desired alloy.  Antimony, arsenic, copper, silver,
and tin are commonly used for lead alloys.

Cooling of lead or lead alloy castings is usually done with
indirect (noncontact) cooling water in closed loop recirculating
systems.  Contact cooling may also produce a small volume dis-
charge stream.

PROCESS WASTEWATER SOURCES

In summary, the principal uses of wastewater in secondary lead
production are:

    (1).  Battery cracking,
    (2).  Wet air pollution control of blast and reverberatory
          furnaces,
    (3).  Wet air pollution control of refining (kettle)
          furnaces, and
    (4).  Casting contact cooling water.
                               894
-------
OTHER WASTEWATER SOURCES

There are other waste streams associated with the production of
secondary lead. The principal wastewater source is maintenace and
cleanup water.

This waste stream is not considered as part of this rulemaking.
EPA believes that the flows and pollutant loadings associated
with this waste stream is insignificant relative to the waste
streams selected, or is best handled by the appropriate permit
authority on a case-by-case basis under the authority of Section
403(a) of the Clean Water Act.

AGE. PRODUCTION, AND PROCESS PROFILE

Figure III-2 shows the location of the 69 secondary lead plants
operating in the United States.  These plants are predominantly
located in or near major urban centers where most of the raw
materials are readily available.  Of the 69 secondary plants
shown, 21 plants (30 percent) are located west of the Mississippi
River.  The remaining 48 plants are located in two bands east of
the Mississippi, around the Great Lakes and in the South.

As seen from Figure III-2, plants discharging indirectly to POTW
(indirect dischargers) and zero discharge plants (zero dis-
chargers) are found in all areas, while plants discharging
directly to receiving waters are found in the East and South.

Table III-l shows that the median age of secondary lead plants is
within a span of 25 to 44 years.  Table III-2 shows that, for the
58 plants providing lead production data, only nine produced over
20,000 tons in 1976.  Most secondary lead plants are relatively
small operations; roughly two-thirds produced under 15,000 tons
per year in 1976.

Table III-3 provides a summary of the number of plants in the
secondary lead industry which utilize the various process
operations discussed previously, and the number of plants which
generate wastewater associated with each process.  All plants
practicing battery cracking generate wastewater.  For the other
processes, most plants avoid producing wastewater by utilizing
dry air pollution control methods (e.g., baghouses) where con-
trols are implemented.
                               895
-------























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-------
                    Table III-2
PRODUCTION RANGES FOR THE SECONDARY LEAD SUBCATEGORY

    Production Ranges
   for 1976 (Tons/Year)          Number of Plants
        0 -  2,500                      16
    2,501 -  5,000                       4
    5,001 - 10,000                       8
   10,001 - 15,000                      11
   15,001 - 20,000                      10
   20,001 - 30,000                       5
   30,001 +                              4
   Not Reported                         1JL
   Total Number of                      69
   Plants in Survey
                        897
-------
                           Table III-3

         SUMMARY OF SECONDARY LEAD SUBCATEGORY PROCESSES
                   AND ASSOCIATED WASTE STREAMS
         Process

  Battery Cracking

  Lead Dross Preparation

  Smelting

  Lead Oxide Production

  Refining and Alloying

  Casting
Number of
 Plants
  With
 Process

   32

    5

   47

   12

   67

   66
  Number of Plants
Generating Wastewater*

         32

          0

          6

          1

          9

         11
*Through reuse or evaporation practices, a plant may "generate"
 a wastewater from a particular process but not discharge it.
                               898
-------







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                    SECONDARY LEAD SUBCATEGORY

                            SECTION IV

                        SUBCATEGORIZATION
As discussed in Section IV of the General Development Document,
the nonferrous metals manufacturing category has been subcatego-
rized to take into account pertinent industry characteristics,
manufacturing process variations, wastewater characteristics, and
a number of other factors which affect the ability of the facili-
ties to achieve effluent limitations.  This section summarizes
the factors considered during the designation of the secondary
lead subcategory and its related subdivisions.

FACTORS CONSIDERED IN SUBCATEGORIZATION

The following factors were evaluated for use in determining
appropriate subcategories for the nonferrous metals industry:

      1.  Metal products, co-products, and by-products;
      2.  Raw materials;
      3.  Manufacturing processes;
      4.  Product form;
      5.  Plant location;
      6.  Plant age;
      7.  Plant size;
      8.  Air pollution control methods;
      9.  Meteorological conditions;
     10.  Treatment costs;
     11.  Nonwater quality aspects;
     12.  Number of employees;
     13.  Total energy requirements; and
     14.  Unique plant characteristics.

Evaluation of all factors that could warrant subcategorization
resulted in the designation of the secondary lead subcategory.
Three factors were particularly important in establishing these
classifications:  the type of metal produced, the nature of raw
materials used, and the manufacturing processes involved.

In Section IV of the General Development Document, each of these
factors is described, and the rationale for selecting metal prod-
ucts, manufacturing processes, and raw materials as the principal
factors used for subcategorization is discussed.  On the basis of
these factors, the nonferrous metals manufacturing category
(phase I) was divided into 12 subcategories, one of them being
secondary lead.
                               901
-------
The purpose of this rulemaking is to propose the creation of the
secondary lead subcategory and the establishment of BPT and BAT
effluent limitations, and NSPS, PSES, and PSNS for this subcate-
gory.

FACTORS CONSIDERED IN SUBDIVIDING THE SECONDARY LEAD SUBCATEGORY

The factors listed previously were each evaluated when consider-
ing subdivision of the secondary lead subcategory.   In the
discussion that follows, the factors will be described as they
pertain to this particular subcategory.

The rationale for considering further subdivision of the second-
ary lead subcategory is based primarily on the production process
used.   Within this subcategory, a number of different operations
are performed, which may or may not have a water use or dis-
charge, and which may require the establishment of separate
effluent limitations and standards.  While secondary lead produc-
tion is still considered a single subcategory, a more thorough
examination of the production processes, water use and discharge
practices, and pollutant generation rates has illustrated the
need for limitations and standards based on a specific set of
waste streams, in accord with the building block approach adopted
for all nonferrous metal subcategories.  Limitations and
standards will be based on specific flow allowances for the
following subdivisions:

     1.  Battery cracking,
     2.  Blast and reverberatory furnace wet air pollution
         control,
     3.  Kettle wet air pollution control, and
     4.  Casting contact cooling.

OTHER FACTORS

The other factors considered in this evaluation either supported
the establishment of the secondary lead subcategory and its sub-
divisions or were shown to be inappropriate bases for subcatego-
rization.  Air pollution control methods, treatment costs,
nonwater quality aspects, and total energy requirements were each
shown to be functions of the selected subcategorization factors--
metal product, raw materials, and production processes.  As such,
they support the method of subcategorization which has been
applied.  As discussed in Section IV of the General Development
Document, such other factors as plant age, plant size, and the
number of employees were also evaluated and determined to be
inappropriate for use as bases for subcategorization of
nonferrous metal plants.
                               902
-------
PRODUCTION NORMALIZING PARAMETERS

The effluent limitations and standards developed in this document
establish mass limitations on the discharge of specific pollutant
parameters.  To allow these regulations to be applied to plants
with various production capacities, the mass of pollutant dis-
charged must be related to a unit of production.  This factor is
known as the production normalizing parameter (PNP).  In general,
the amount of lead produced by the respective manufacturing pro-
cess is used as the PNP.  This is based on the premise that the
amount of water generated is proportional to the amount of prod-
uct made.  Variations in the association between the amount of
water generated and the amount of product made are not felt to be
significant enough to prevent the establishment of effluent limi-
tations and standards.  The PNP's for the secondary lead subdivi-
sion are as follows:
        Subdivision

1.  Battery cracking

2.  Blast and reverberatory
     furnace wet air pollu-
     tion control

3.  Kettle wet air pollution
     control

4.  Casting contact cooling
     water
           PNP

kkg of lead scrap produced

kkg of lead produced from
 blast and reverberatory
 furnace smelting

kkg of lead produced from
 kettle furnaces

kkg of lead cast
                               903
-------
                    SECONDARY LEAD SUBCATEGORY

                            SECTION V

             WATER USE AND WASTEWATER CHARACTERISTICS
This section describes the characteristics of wastewater associ-
ated with the secondary lead subcategory.  Data used to quantify
wastewater flow and pollutant concentrations are presented, sum-
marized, and discussed.  The contribution of specific production
processes to the overall wastewater discharge from secondary lead
plants is identified whenever possible.

Section V of the General Development Document contains a detailed
description of the data sources and methods of analysis used to
characterize wastewater from the nonferrous metals category.  To
summarize this information briefly, two principle data sources
were used:  data collection portfolios (dcp) and field sampling
results.  Data collection portfolios contain information
regarding wastewater flows and production levels.

In order to quantify the pollutant discharge from secondary lead
plants, a field sampling program was conducted.  A complete list
of the pollutants considered and a summary of the techniques used
in sampling and laboratory analyses are included in Section V of
the General Development Document.  Wastewater samples were col-
lected in two phases: screening and verification.  The first
phase, screen sampling, was to identify which toxic pollutants
were present in the wastewaters from production of the various
metals.  Screening samples were analyzed for 128 of the 129 toxic
pollutants and other pollutants deemed appropriate.  (Because the
analytical standard for TCDD was judged to be too hazardous to be
made generally available, samples were never analyzed for this
pollutant.  There is no reason to expect that TCDD would be pre-
sent in nonferrous metals manufacturing wastewater.)  A total of
10 plants were selected for screen sampling in the nonferrous
metals manufacturing category, one of them being a secondary lead
facility.  In general, the samples were analyzed for three
classes of pollutants:  toxic organic pollutants, toxic metal
pollutants, and criteria pollutants (which includes both
conventional and nonconventional pollutants).

As described in Section IV of this supplement, the secondary lead
subcategory has been furthet categorized into four subdivisions,
so that the proposed regulation contains mass discharge limita-
tions and standards for four unit processes discharging process
wastewater.  Differences in the wastewater characteristics asso-
ciated with these subdivisions are to be expected.  For this
reason, wastewater streams corresponding to each subdivision are
addressed separately in the discussions that follow.
                              905
-------
WASTEWATER SOURCES, DISCHARGE RATES, AND CHARACTERISTICS

The wastewater data presented in this section were evaluated in
light of production process information compiled during this
analysis.  From this information it was possible to identify the
principal wastewater sources in the secondary lead subcategory.
These are:

     1.  Battery cracking,
     2.  Blast and reverberatory furnace wet air pollution
         control,
     3.  Kettle wet air pollution control, and
     4.  Casting contact cooling water.

Data supplied by dcp responses were evaluated and two flow-to-
production ratios were calculated for each stream.  These two
ratios, normalized water use and normalized wastewater discharge
flow rate, differ by the water flow rates used in their calcula-
tion.  Water use is defined as the volume of water or other fluid
(e.g., battery electrolyte) required for or generated in a given
process per mass of lead produced by the process and is therefore
based on the sum of recycle and makeup flows to a given process.
The production normalized discharge flow rate is defined as the
volume of wastewater actually discharged from a given process for
further treatment, disposal, or discharge per mass of lead pro-
duced.  Differences between the water use and discharge flows
associated with a given stream may result from combinations of
recycle, evaporation, and carryover on the product.  The pro-
duction values used in calculating these ratios correspond to the
production normalizing parameter (PNP) assigned to each stream,
as discussed in Section IV of this supplement.  The production
normalized flows were compiled by stream type.  An attempt was
made to identify factors that could account for variations in the
water use from plant to plant.  This information is summarized in
this section.  A similar analysis of factors affecting the
normalized wastewater flow rates is presented in Sections X, XI,
and XII where representative BAT, BDT, and pretreatment discharge
flows are selected for use in calculating effluent limitations.

In order to quantify the concentrations of pollutants present in
wastewaters from secondary lead plants, wastewater samples were
collected at six plants, representing 26 percent of the dis-
charging secondary lead plants.  Block diagrams indicating the
locations of sampling points and the production processes
involved for each of these six plants are given in Figures V-l
through V-6 (at the end of this section).

Raw wastewater sampling data for the secondary lead industry are
presented in Tables V-2, V-4, V-6, and V-8 (at the end of this
section).  Treated wastewater sampling data are shown in Tables
V-9 through V-13 (at the end of this section).  The stream codes
                              906
-------
displayed in the tables may be used to identify the  location  of
each of the samples on the process flow diagrams  in  Figures V-l
through V-6.  Where no data are listed for a specific day of  sam-
pling, the wastewater samples for the stream were not collected.
If the analysis did not detect a pollutant in a waste stream, the
pollutant was omitted from the table.

The data tables include some samples measured at  concentrations
considered not quantifiable.  The base neutral extractables,  acid
extractables, and volatile organics are considered not
quantifiable at concentrations equal to or less than 0.010 mg/1.
Below this concentration, organic analytical results are not
quantitatively accurate; however, the analyses are useful to
indicate the presence of a particular pollutant.  The pesticide
fraction is not considered quantifiable below concentrations  of
0.005 mg/1. Nonquantifiable results are designated in the tables
with an asterisk (double asterisk for pesticides).

These detection limits shown on the data tables are  not the same
in all cases as the published detection limits for these pollu-
tants by the same analytical methods.  The detection limits used
were reported with the analytical data and hence  are the appro-
priate limits to apply to the data.  Detection limit variation
can occur as a result of a number of laboratory-specific,
equipment-specific, and daily operator-specific factors.  These
factors can include day-to-day differences in machine calibra-
tion, variation in stock solutions, and variation in operators.

The statistical analysis of data includes some samples measured
at concentrations considered not quantifiable.  Data reported as
an asterisk are considered as detected but below  quantifiable
concentrations, and a value of zero is used for averaging.  Toxic
organic, nonconventional, and conventional data reported with a
"less than" sign are considered as detected, but not further
quantifiable.  A value of zero is also used for averaging.  If a
pollutant is reported as not detected, it is excluded in calcu-
lating the average.  Finally, toxic metal values reported as  less
than a certain value were considered as not detected, and a value
of zero was used in the calculation of the average.  For example,
three samples reported as ND, *, and 0.021 mg/1 have an average
value of 0.010 mg/1.  In selecting pollutants and pollutant
parameters for specific regulation, individual samples were used
rather than average values.

The method by which each sample was collected and composited  is
indicated on the data tables by a code number, as follows:
                               907
-------
     1     one-time grab
     2     24-hour manual composite
     3     24-hour automatic composite
     4     48-hour manual composite
     5     48-hour automatic composite
     6     72-hour manual composite
     7     72-hour automatic composite

In the data collection portfolios, the secondary lead plants
which discharge were asked to specify the presence or absence of
the toxic pollutants in their effluent.  Of the 69 secondary lead
plants, 22 responded to this portion of the questionnaire.  All
plants responding to the organic compounds portion reported that
all toxic organic pollutants were known to be absent or believed
to be absent from their wastewater.

The responses for the toxic metals are summarized below.

                   Known      Believed     Believed     Known
    Pollutant     Present     Present       Absent      Absent

    Antimony        13           5             4
    Arsenic          97             6          -
    Cadmium          76             63
    Chromium         3           5            10          4
    Copper          12           2             71
    Lead            17           4             -          -
    Mercury          2           4            13          3
    Nickel           64            11          1
    Silver           23            17          -
    Thallium         1           6            18          3
    Zinc            10           6             6          -

BATTERY CRACKING

Plants utilizing lead-acid batteries as a source of process raw
materials produce a wastewater stream associated with the battery
cracking operation.  Battery cracking involves the breaking of
battery cases by any of a number of methods described in Section
III.  Wastewater may be generated in the form of electrolyte
drained from the battery cases, by the use of saw or breaker
cooling water, and by area wash water.  All 32 plants having
battery cracking operations generate wastewater.  Table V-l
summarizes the normalized electrolyte, blowdown, and ultimate
discharge flows for these plants in terms of liters per metric
ton of lead scrap produced (recovered) from battery cracking
operations.  Differences from plant to plant in the specific
method and equipment used for battery cracking may be responsible
for variations in these flow rates.
                              903
-------
Table V-2 summarizes the field sampling data  for  the  toxic,  con-
ventional, and nonconventional pollutants detected.   This waste
stream contains quantifiable concentrations of  toxic  organics.
The metals antimony, arsenic, cadmium, copper,  lead,  and zinc  are
generally present in concentrations  from 1 to 100 mg/1.  Treat-
able concentrations of total suspended solids,  and oil and
grease, and low pH  (less than 2) also characterize this stream.

BLAST AND REVERBERATOR/ FURNACE WET  AIR POLLUTION CONTROL

Blast and reverberatory furnaces used in the  smelting operation
in secondary lead plants generally require some type  of air
pollution control to limit emissions, especially  of particulates
and sulfur oxide compounds.  Out of  47'plants having  smelting
operations, six use wet air pollution control;  41 use dry air
pollution control.  Table V-3 summarizes the  water use and
discharge rates for these plants.  Limited sampling and analy-
tical data were obtained on furnace  scrubbing liquor.  As shown
in Table V-4, treatable concentrations of lead  and total
suspended solids were found for the  single sample analyzed.

KETTLE WET AIR POLLUTION CONTROL

Kettles used in the refining and alloying operations  in secondary
lead plants may also produce air pollutants,  especially particu-
late matter, which may require control.  Nine of  the  67 plants
reporting the use of refining and alloying kettles use wet air
pollution control.  Table V-5 shows  the production normalized
water use and discharge rates for these plants.   Data obtained on
the kettle scrubber liquor at one of these plants (presented in
Table V-6) contained measurable concentrations  of ammonia and
treatable concentrations of total suspended solids, arsenic, and
lead (50 to 380 mg/1) with measurable concentrations  of other
metals.

CASTING CONTACT COOLING WATER

Contact cooling water may be used in the casting  operation.  The
cooling water is frequently recycled and may  be totally evapo-
rated,  but a small stream may be blown down to  limit  the buildup
of dissolved solids, which may cause surface  imperfections on the
cast metal.   Eleven plants, of the 66 reporting the use of a
casting operation, use direct contact cooling.  The normalized
water use and discharge data for these plants are summarized in
Table V-7.  No sampling data are available for  secondary lead
plant casting cooling water.  It is  expected  that this operation
may be similar to analogous operations in other nonferrous metals
manufacturing subcategories.  Organics, in the  form of oil and
grease, may be found when lubricants are used.  Total suspended
solids  may also be present in treatable concentrations.
                              909
-------
                          Table V-l

WATER USE AND DISCHARGE RATES FOR BATTERY CRACKING OPERATIONS
                (1/kkg of lead scrap produced)
 Plant Code

   222
   224
   223
   225
   227
   234
   236
   239
   244
   246
   248
   249
   250
   254
   263
   264
   265
   266
   271
   272
   273
   392
   391
   428
   652
   655
  4210
  4211
  9001
  9002
 26001
 26003
Percent
Recycle

   0
   0
   0
   0
   0
   0
   0
   0
   0
   0
   0
   0
   0
   0
   0
   0
   0
   0
   0
   0
   0
   0
   0
   0
   0
   0
   0
   0
   0
   0
   0
   0
Production
Normalized
Water Use

    139
    834
    775
    763
    384
    437
    142
    154
    306
    315
  1,618
    442
  1,984
    796
  1,046
  1,647
  1,084
  4,669
     81
  5,086
    286
    369
    922
    244
    429
    905
    671
    377
  1,063
    638
    705
    600
  Production
  Normalized
Discharge Rate

     139
     834
     775
     763
     384
     437
     142
     154
     306
     315
   1,618
     442
   1,984
     796
   1,046
   1,647
   1,084
   4,669
      81
   5,086
     286
     369
     922
     244
     429
     905
     671
     377
   1,063
     638
     705
     600
                             910
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-------
                            Table V-3

            WATER USE AND DISCHARGE RATES FOR BLAST AND
         REVERBERATORY FURNACE WET AIR POLLUTION CONTROL
               (1/kkg of  lead produced from smelting)
  Plant Code

     266
   26001
     272
     265  (a)
     265
     234
     222
 Percent
Recycle

    0
  100
   83.7
   83.3
   93.3
  100
   97.8
 Production
 Normalized
Water Use

  3,252
151/050
 40,411
 11,433
 25,507
    942
     NR
  Production
  Normalized
Discharge Rate

   3,252
       0
   6,587
   1,909
   1,776
       0
      NR
(a) Plant 265 controls air emissions on two furnaces with two
    different scrubbers.

NR = Present but data not reported in dcp.
                               915
-------
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-------
                            Table V-5

         WATER USE AND DISCHARGE RATES FOR KETTLE WET AIR
                        POLLUTION CONTROL
          (1/kkg of lead produced from kettle furnaces)


                                Production          Production
                 Percent        Normalized          Normalized
  Plant Code     Recycle        Water Use         Discharge Rate

  26001            100         151,050                   0
    655            100           3,071                   0
    391            100             361                   0
    273             91.7        21,900               1,818
    264             96           1,845                  74
    250              -           1,718                   0*
    225            100          11,373                   0
    224            100           5,724                   0
    223            100           7,089                   0
*100 percent of the wastewater is recycled to decasing washing.
                               917
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-------
                            Table V-7

    WATER USE AND DISCHARGE RATES FOR CASTING CONTACT  COOLING
                        (1/kkg of lead cast)
     Plant Code

      4211
      26001
       427
       422
       248
       244
       234
       046
       224
       247
       252
Percent
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  100 (a)
   100
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    0
    0
    0
    0
  100
    0
   NR
   NR
Production
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  171
  504
  120
  963
    5
  184
   22
  705
   33
  (b)
  (b)
  Production
  Normalized
Discharge Rate

     0
     0
    120
    963
      5
    184
     22
      0
     33
    (b)
    (b)
(a) 100 percent recycle or evaporation.

(b) Reported in dcp as "insignificant".

NR  - Not reported in dcp.
                               919
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                                      071
VOA BLANK
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  SAMPLING SITES AT  SECONDARY LEAD PLANT A
                          932
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176


FURNACE
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                     937
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                    SECONDARY LEAD SUBCATEGORY

                            SECTION VI

                     SELECTION OF POLLUTANTS  .
Section V of this supplement presented data from secondary lead
plant sampling visits and subsequent chemical analyses.  This
section examines that data and discusses the selection or exclu-
sion of pollutants for potential limitation.  The legal basis for
the exclusion of toxic pollutants under Paragraph 8(a) of the
Settlement Agreement is presented in Section VI of the General
Development Document.

Each pollutant selected for potential limitation is discussed in
Section VI of the General Development Document.  That discussion
provides information about where the pollutant originates (i.e.,
whether it is a naturally occurring substance, process metal, or
a manufactured compound); general physical properties and the
form of the pollutant; toxic effects of the pollutant in humans
and other animals; and behavior of the pollutant in POTW at the
concentrations expected in industrial discharges.

The discussion that follows describes the analysis that was per-
formed to select or exclude pollutants for further consideration
for limitations and standards.  Pollutants will be considered for
limitation if they are present in concentrations treatable by the
technologies considered in this analysis.  The concentrations
used for the toxic metals were the long-term performance values
achievable by lime precipitation, sedimentation, and filtration.
The concentrations used for the toxic organics were the long-term
performance values achievable by carbon adsorption (see Section
VII of the General Development Document - Combined Metals Data
Base).

CONVENTIONAL AND NONCONVENTIONAL POLLUTANTS

This study examined samples from the secondary lead subcategory
for three conventional pollutant parameters (oil and grease,
total suspended solids, and pH) and four nonconventional
pollutant parameters (ammonia, chemical oxygen demand, total
organic carbon, and total phenols).

CONVENTIONAL AND NONCONVENTIONAL POLLUTANT PARAMETERS SELECTED

The following conventional pollutant parameters were selected for
limitation in this subcategory:

     ammonia
     total suspended solids (TSS)
     pH


                               939
-------
Ammonia was found in all six samples analyzed in concentrations
ranging from 0.2 to 29 mg/1.  The values recorded are not above
the treatable concentration of 32 mg/1. Although none of the
concentrations are above the 32 mg/1 considered achievable with
ammonia steam stripping, ammonia is selected for limitation.
Only one kettle scrubber wastestream was sampled, and ammonia is
known to be present in this stream with concentrations of 22, 25,
and 29 mg/1.  Ammonia is selected for limitation because it is
known to be present in this wastestream and it may occur at
treatable concentrations in this wastestream at other facilities.

Total suspended solids ranged from 240 to 28,000 mg/1 in 14
samples.  All but two of the observed.concentrations are above
that considered achievable by treatment.  Further, most of the
methods used to remove toxic metals do so by converting these
metals to precipitates.  Meeting a limitation on total suspended
solids also helps ensure that removal of these precipitated toxic
metals has been effective.  For these reasons, total suspended
solids is considered for limitation in this subcategory.

The pH of a wastewater measures its relative acidity or alkalin-
ity.  In this study, the pH values observed ranged from 0.6 to
8.1.  Many harmful effects may be caused by extreme pH values or
by rapid changes in pH.  Therefore, pH is considered for limita-
tion in this subcategory.

TOXIC POLLUTANTS

The frequency of occurrence of the toxic pollutants in the waste-
water samples taken is presented in Table VI-1.  These data
provide the basis for the selection or exclusion of specific
pollutants, as discussed below.  Table VI-1 is based on the raw
wastewater data from streams 73, 75, 208, 106, 108, 151, 152, and
176 (see Section V).  Treatment plant sampling data were not used
in the frequency count.

TOXIC POLLUTANTS NEVER DETECTED

Paragraph 8(a)(iii) of the Revised Settlement Agreement allows
the Administrator to exclude from regulation those toxic pollu-
tants not detectable by Section 304(h) analytical methods or
other state-of-the-art methods.  The toxic pollutants listed
below were not detected in any wastewater samples from this sub-
category; therefore, they are not selected for consideration in
establishing limitations:

       1.  acenaphthene
       2.  acrolein
       3.  acrylonitrile
       4.  benzene
                               940
-------
 5.  benzidine
 6.  carbon tetrachloride
 8.  1,2,4-trichlorobenzene
 9.  hexachlorobenzene
10.  1,2-dtchloroethane
11.  1,1,1-trichloroethane
12.  hexachlorethane
13.  1,1-dichloroethane
14.  1,1,2-trichloroethane
15.  1,1,2,2-tetrachloroethane
16.  chloroethane
17.  DELETED
18.  bis(2-chloroethyl) ether
19.  2-chloroethyl vinyl ether
20.  2-chloronaphthalene
21.  2,4,6-trichlorophenol
22.  parachlorometa cresol
24.  2-chlorophenol
25.  1,2-dichlorobenzene
26.  1,3-dichlorobenzene
27.  1,4-dichlorobenzene
28.  3,3'-dichlorobenzidine
29.  1,1-dichloroethylene
30.  1,2-trans-dichloroethylene
31.  2,4-dichlorophenol
32.  1,2-dichloropropane
33.  1,3-dichloropropylene
34.  2,4-dimethylphenol
35.  2,4-dinitrotoluene
36.  2,6-dinitrotoluene
37.  1,2-diphenylhydrazine
38.  ethylbenzene
41.  4-bromophenyl phenyl ether
42.  bts(2-chloroisopropyl) ether
43.  bis(2-chloroethoxy) methane
44.  methylene chloride
45.  methyl chloride
46.  methyl bromide
48.  dichlorobromomethane
49.  DELETED
50.  DELETED
51.  chlorodibromomethane
52.  hexachlorobutadiene
53.  hexachlorocyclopentadiene
54.  isophorone
55.  naphthalene
57.  2-nitrophenol
58.  4-nitrophenol
59.  2,4-dinitrophenol
60.  4,6-dinitro-o-cresol
61.  N-nitrosodimethylamine
                        941
-------
      62.  N-nitrosodiphenylamine
      63.  N-nitrosodi-n-propylamine
      64.  pentachlorophenol
      65.  phenol
      67.  butyl benzyl phthalate
      72.  benzo(a)anthracene
      73.  benzo(a)pyrene
      74.  3,4-benzofluoranthene
      7 5.  benzo(k)fluoranthene
      79.  benzo(ghi)perylene
      80.  fluorene
      82.  dibenzo(a,h)anthracene
      83.  indeno(l,2,3-cd)pyrene
      85.  tetrachloroethylene
      86.  toluene
      87.  trichloroethylene
      88.  vinyl chloride
      89.  aldrin
      95.  alpha-endosulfan
      97.  endosulfan sulfate
     105.  delta-BHC
     113.  toxaphene
     116.  asbestos
     125.  selenium
     129.  2,3,7,8-tetrachlorodibenzo-p-dioxin (TCDD)

TOXIC POLLUTANTS NEVER FOUND ABOVE THEIR ANALYTICAL QUANTIFICA-
TION LIMIT

The provision of Paragraph 8(a)(iii) of the Revised Settlement
Agreement excluding from regulation those toxic pollutants which
are not detectable includes those pollutants whose concentrations
fall below EPA's nominal detection limit.  The toxic pollutants
listed below were never found above their analytical quantifica-
tion concentration in any wastewater samples from this subcate-
gory; therefore, they are not selected for consideration in
establishing limitations.

       7.  chlorobenzene
      40.  4-chlorophenyl phenyl ether
      70.  diethyl phthalate
      78.  anthracene     (a)
      81.  phenanthrene   (a)
      90.  dieldrin
      91.  chlordane
      92.  4,4'-DDT
      93.  4,4'-DDE
      94.  4,4'-DDD
      96.  beta-endosulfan
      98.  endrin
      99.  endrin aldehyde
     100.  heptachlor


                               942
-------
     101.  heptachlor epoxide
     102.  alpha-BHC
     103.  beta-BHC
     104.  gamma-BHC
     106.  PCB-1242       (b)
     107.  PCB-1254       (b)
     108.  PCB 1221       (b)
     109.  PCB-1232       (c)
     110.  PCB-1248       (c)
     111.  PCB-1260       (c)
     112.  PCB-1016       (c)

     (a),  (b), (c)  Reported together

TOXIC POLLUTANTS PRESENT  BELOW CONCENTRATIONS ACHIEVABLE  BY
TREATMENT

Paragraph  8(a)(ill) of the Revised Settlement Agreement also
allows the exclusion of toxic pollutants which were detected  in
quantities too small to be effectively reduced by  technologies
known to the Administrator.  The pollutants  listed below  are  not
selected for consideration in establishing limitations because
they were  not found in any wastewater samples from this subcate-
gory above concentrations considered achievable by existing or
identified treatment technologies.  These pollutants are
discussed  individually following the list.

      23.  chloroform
      47.  bromoform
      56.  nitrobenzene
      71.  dimethyl phthalate
     117.  beryllium
     123.  mercury

Chloroform was found above its analytical quantification  limit in
five of 10 samples analyzed, but the highest concentration
reported was 0.026 mg/1,  and identified treatment  can reduce  its
concentration only to 0.1 mg/1.  Chloroform  is thus not selected
for further consideration in establishing limitations.

Bromoform  was detected in only one of 10 samples,  and that one
was below  the concentration to which identified treatment can
reduce its concentration  (0.05 mg/1).  Bromoform is thus  not
selected for consideration for limitation.

Nitrobenzene concentrations exceeded the analytical quantifica-
tion limit in only one of eight samples, and that  one was 0.016
mg/1.  This value is below the 0.05 mg/1 concentration acheivable
by treatment. Therefore, nitrobenzene is not selected for
consideration for limitation.
                              943
-------
Dimethyl phthalate was not detected in seven of eight samples.
The one exception showed a concentration of 0.013 mg/1. This
value is below the 0.05 mg/1 concentration achievable by treat-
ment. Dimethyl phenol is thus not selected for consideration for
limitation.

Beryllium exceeded its analytical quantification limit in only
one of 11 samples, with a concentration of 0.03 mg/1.  This is
below the concentration to which available treatment can reduce
beryllium concentrations (0.20 mg/1), so beryllium is not
selected for consideration for limitation.

Mercury was detected in 11 of 13 samples; with all of these
values below the 0.036 mg/1 concentration achievable by treat-
ment.  Therefore, mercury is not selected for consideration for
limitation.

TOXIC POLLUTANTS DETECTED IN A SMALL NUMBER OF SOURCES

Paragraph 8(a)(iii) allows for the exclusion of a toxic pollutant
if it is detectable in the effluent from only a small number of
sources within the subcategory and it is uniquely related to only
those sources.  The following pollutants were not selected for
limitation on this basis.

      39.  fluoranthene
      66.  bis(2-ethylhexyl) phthalate
      68.  di-n-butyl phthalate
      69.  di-n-octyl phthalate
      76.  chrysene
      77.  ac enaphthy1ene
      84.  pyrene
     121.  cyanide

Although these pollutants were not selected for consideration in
establishing nationwide limitations, it may be appropriate, on a
case-by-case basis, for the local permitter to specify effluent
limitations.

Fluoranthene was detected in one of five samples analyzed, with a
concentration of 0.027 mg/1.  The concentration to which treat-
ment is effective is 0.01 mg/1.  Since fluoranthene was found in
only one waste stream, and since in the dcp all responding plants
indicated that this pollutant was known to be absent or believed
to be absent, it is not selected for consideration for
limitation.

Bis(2-ethylhexyl) phthalate was found above both its analytical
quantification limit and its treatable concentration (0.01 mg/1)
in five of eight samples, with a maximum concentration of 0.585
mg/1.  The presence of this pollutant is not attributable to
                                944
-------
materials or processes associated with the  secondary  lead
subcategory.  It is commonly used as a plasticizer  in laboratory
and field sampling equipment.  EPA suspects  sample  contamination
as the source of this pollutant.  Also, in  the dcp  all responding
plants indicated that this pollutant was known to be  absent  or
believed to be absent.  Therefore, bis(2-ethylhexyl)  phthalate  is
not selected for consideration for limitation.

Two of eight samples analyzed for di-n-butyl phthalate were  found
to contain concentrations above  its analytical quantification
limit, one of these above the 0.025 mg/1 concentration considered
achievable with treatment. The presence of  this pollutant  is not
attributable to materials or processes associated with the
secondary lead  subcategory.  It is commonly used as  a
plasticizer in laboratory and field sampling equipment. EPA
suspects sample contamination as the source of this pollutant.
Also, in the dcp all responding  plants indicated that this
pollutant was known to be absent or believed to be  absent.   It  is
thus not selected for consideration for limitation.

Di-n-octyl phthalate was found above its analytical quantifica-
tion limit (0.01 mg/1) in two of eight samples.  The  presence of
this pollutant is not attributable to materials or  processes
associated with the secondary lead subcategory.  It is commonly
used as a plasticizer in laboratory and field sampling equipment.
EPA suspects sample contamination as the source of  this pollu-
tant.  Also, in the dcp all responding plants indicated that this
pollutant was known to be absent or believed to be  absent.
Therefore, di-n-octyl phthalate  is not selected for consideration
for limitation.

Chrysene was reported present above its analytical  quantification
limit in two of eight samples.   The two reported concentrations
of chrysene were 0.139 and 0.545 mg/1, which are above the 0.001
mg/1 concentration considered attainable with treatment.   The
process waste stream that produced the 0.545 mg/1 value, also
produced five not detected values at two other facilities.
Chrysene is not considered characteristic of the subcategory
because it was found in only two samples from two different
process wastestreams, Therefore, chrysene is not selected  for
consideration for limitation.

Acenaphthylene occurred above its treatable concentration  (0.01
mg/1) in only one of eight samples, where it measured 0.035 mg/1.
Two other samples of this waste  stream at two different plants
were reported as not detected.  This site-specific  result  is not
sufficient to characterize the whole subcategory, so
acenaphthylene is not selected for consideration for  limitations.
                               945
-------
Pyrene exceeded its analytical quantification limit  (0.01 mg/1)
in only two of eight samples.  The two reported concentrations of
pyrene were 0.013 mg/1 and 0.038 mg/1.  These two values are  from
two different process wastestreams.  This site-specific result is
not sufficient to characterize the whole subcategory.  Also,  in
the dcp all responding plants indicated that this pollutant was
known to be absent or believed to be absent.  Therefore, pyrene
is not selected for consideration for limitation.

Cyanide was found at a treatable concentration in three of 11
samples, all at the same plant.  All three concentrations (3.0,
4.0, and 6.0 mg/1) that were reported above the 0.047 mg/1
concentration considered attainable are from the same plant.
Because of the site-specificity of this result, cyanide not
selected for consideration for limitation.

TOXIC POLLUTANTS SELECTED FOR FURTHER CONSIDERATION  FOR
LIMITATIONS

The toxic pollutants listed below were selected for  establishing
limitations and standards for this subcategory.  The toxic
pollutants selected are each discussed following the list.

     114.  antimony
     115.  arsenic
     118.  cadmium
     119.  chromium
     120.  copper
     122.  lead
     124.  nickel
     126.  silver
     127.  thallium
     128.  zinc

Eight of 11 samples analyzed for antimony exhibited  concentra-
tions over the treatable concentration (0.47 mg/1).  Most of
these were above 10 mg/1, with a maximum of 95 mg/1.  Antimony is
thus selected for further consideration for limitation.

Arsenic was found above its treatable concentration  (0.34 mg/1)
in all 10 samples analyzed.  Treatable concentrations ranged  from
0.6 to 16.0 mg/1.  Arsenic is thus selected for further consi-
deration for limitation.

Twelve of 13 samples analyzed for cadmium were found to have
concentrations in excess of the treatable concentration (0.049
mg/1).  Treatable concentrations ranged from 0.41 to 4.8 mg/1.
Therefore, cadmium is selected for further consideration for
limitation.
                               946
-------
Chromium was found to exceed its treatable concentration  (0.07
mg/1) in eight of 13 samples, with a maximum of 1 mg/1. There-
fore, chromium is selected for further consideration  for  limita-
tion.

Copper was found above its treatable concentration  (0.39  mg/1)  in
12 of 13 samples analyzed, with a maximum of 10 mg/1.  Therefore,
copper is selected for further consideration for limitation.

Lead was detected above its treatable concentration  (0.08 mg/1)
in 13 of 14 samples analyzed.  Treatable concentrations ranged
from 4.6 to 95.0 mg/1, with the majority above 10 mg/1.   Lead is
thus selected for further consideration for limitation.

Nine of 13 samples analyzed for nickel exhibited concentrations
exceeding its treatable concentration (0.22 mg/1).  Two sam-
ples had concentrations of 2 mg/1. Therefore, nickel  is selected
for further consideration for limitation.

Eleven samples were analyzed for silver.  Reported results
included concentrations of 0.16, 0.32, and 0.34 mg/1, all three
above the 0.07 mg/1 treatable concentration.  Therefore,  silver
is selected for further consideration for limitation.

Thallium, for which treatment is effective above 0.34 mg/1, was
found in three of 11 samples at 0.5, 0.8, and 1.0 mg/1.   There-
fore, thallium is selected for further consideration  for  limita-
tion.

Zinc was found above its treatable concentration (0.23 mg/1) in
10 of 13 samples analyzed.  Six of these were above 5 mg/1, with
a high of 20 mg/1.  Zinc is thus selected for further
consideration for limitation.
                               947
-------
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                                                          952
-------
                    SECONDARY LEAD SUBCATEGORY

                           SECTION VII

                CONTROL AND TREATMENT TECHNOLOGIES


The preceding sections of this supplement discussed the waste-
water sources, flows, and characteristics of the wastewaters  from
secondary lead plants.  This section summarizes the description
of these wastewaters and indicates the level of treatment which
is currently practiced by the secondary lead subcategory for  each
waste stream.

CURRENT CONTROL AND TREATMENT PRACTICES

Control and treatment technologies are discussed in general in
Section VII of the General Development Document.  The basic
principles of these technologies and the applicability to waste-
water similar to that found in this subcategory are presented
there.  This section presents a summary of the control and
treatment technologies that are currently applied to each of  the
sources generating wastewater in this subcategory.  As discussed
in Section V, wastewater associated with the secondary lead
subcategory is characterized by the presence of the toxic metal
pollutants and suspended solids.  This analysis is supported  by
the raw (untreated) wastewater data presented for specific
sources as well as combined waste streams in Section V.
Generally, these pollutants are present in each of the waste
streams at concentrations above treatability, so these waste
streams are commonly combined for treatment to reduce the
concentrations of these pollutants.  Construction of one
wastewater treatment system for combined treatment allows plants
to take advantage of economies of scale and, in some instances,
to combine streams of differing alkalinity to reduce treatment
chemical requirements.  Fourteen plants in this subcategory
currently have combined wastewater treatment systems, 10 have
lime precipitation and sedimentation, and seven have lime
precipitation, sedimentation and filtration.  As such, five
options have been selected for consideration for BPT, BAT, BDT,
BCT, and pretreatment in this subcategory, based on combined
treatment o£ these compatible waste streams.

BATTERY CRACKING

Wastewater from the battery cracking operation may result from
the following sources:

     1.  Waste battery electrolyte,
     2.  Saw or breaker cooiing water, and
     3.  Area washdown.

The combined wastewater from these sources has the characteris-
tics of the battery electrolyte; pollutant concentrations are


                               953
-------
dependent on the amount of dilution from the other water sources.
In general, this wastewater is characterized by treatable concen-
trations of suspended and dissolved solids, heavy metals, and
arsenic.  Of the 32 plants with battery cracking surveyed, four
do not currently have any control on this stream; they either
discharge it or use contract disposal.  The majority neutralize
the spent acid; 14 use ammonia, nine use lime, and two use
caustic to raise the wastewater pH.  Alkaline pH also favors the
precipitation of heavy metal salts.  Twenty plants provide for
settling of these solids and other suspended solids in sedi-
mentation equipment (e.g., clarifiers).  Six plants filter the
treated wastewater; in five of these plants the filtration step
occurs after sedimentation and in the other filtration is used
alone to remove suspended solids.  Several plants add polymer to
enhance the settling of this wastewater.  One plant combines
battery cracking wastewater with stormwater runoff, noncontact
cooling water, water softener backflush and sanitary wastes after
preliminary treatment, consisting of neutralization with ammonia
and sedimentation.  Approximately 20 percent of the combined
wastewater is evaporated in a cooling tower and recycled to the
plant process.  Cooling tower blowdown is treated by ion exchange
and then discharged.  This allows the plant to effectively
recycle or evaporate 90 percent of its wastewater.  Treated water
is recycled in four of the plants; others send it to ponds, or
discharge, it either directly or to a POTW.

BLAST AND REVERBERATORY FURNACE WET AIR POLLUTION CONTROL

Air emissions from the blast and reverberatory furnaces may
contain particulate matter which must be removed to meet air
emissions standards.  Either dry or wet methods may be used for
particulate control; of the 47 plants surveyed which have blast
reverberatory furnaces, 41 utilize baghouses or dry scrubbers,
while six plants have wet scrubbers to control furnace emissions.
The scrubbing solution contains treatable concentrations of
suspended solids and lead.  Five of the six plants with wet
scrubbers recycle a portion of the scrubber water; the average
recycle ratio is 93 percent.  Two plants indicate they recycle
100 percent of the scrubber water.  The four plants not using 100
percent recycle neutralize this wastewater using either ammonia
(three plants) or caustic (one plant).  Two follow this with
sedimentation or filtration.  The plant that does not recycle any
of this stream combines it with wastewater from other streams and
sends it to a pond.  Treated wastewater is discharged to a POTW
in the other plants not practicing total recycle.

KETTLE WET AIR POLLUTION CONTROL

Kettles used in the refining and alloying operation may produce a
gaseous stream which may require control, primarily to reduce
particulate emissions.  Of the plants surveyed, 39 do not control
                               954
-------
kettle emissions, 19 use dry  controls  (baghouses),  and  the
remaining nine use wet  scrubbers.  Kettle  scrubber  effluent
contains lead, arsenic, other alloying metals,  and  suspended
solids at treatable concentrations.  Eight of the nine  plants
with wet scrubbers recycle  the scrubber water;  the  average
recycle ratio is over 98 percent, with six plants reporting 100
percent recycle.  The remaining plant  utilizes  the  scrubber
wastewater in the battery cracking operation.   Of the two plants
not using total recycle, one  treats  the blowdown using  sodium
carbonate, sedimentation and  filtration, while  the  other does  not
treat the blowdown.  Both plants discharge the  blowdown to a
POTW.

CASTING CONTACT COOLING WATER

Water may be used in the casting operation to accelerate the
cooling of the cast metal.  Of the plants  surveyed, only 11 use
direct contact cooling.  Three plants  use  total recycle of the
cooling water, four rely on evaporation to eliminate the waste-
water, and the remainder discharge wastewater with  no treatment.

CONTROL AND TREATMENT OPTIONS  CONSIDERED

As the sampling and analytical data  in Section  V indicate, the
wastewaters from the secondary lead  subcategory contain various
types of contaminants.  The primary  constituents of concern are
dissolved metals, suspended solids,  dissolved solids, and pH
extremes or fluctuations.   The Agency  examined  five control and
treatment technology options  that are  applicable to the
wastewaters from the secondary lead  subcategory.

OPTION A

Option A for the secondary  lead subcategory requires treatment
technologies to reduce pollutant mass.  The Option A treatment
scheme consists of lime and settle treatment (chemical  precipita-
tion and sedimentation) applied to the combined streams of
battery cracking wastewater,  furnace smelting air pollution
scrubbing wastewater, and casting contact cooling water.  Chemi-
cal precipitation is used to remove metals by the addition of
lime, followed by gravity sedimentation.  Suspended solids are
also removed in the process.   This option also requires dry
control methods to control  air emissions from kettle refining  or
alternately,  100 percent recycle of kettle scrubber liquor.

OPTION B

Option B for the secondary  lead subcategory requires control and
treatment to reduce the discharge of wastewater volume  and pollu-
tant mass.   Option B includes  chemical precipitation and sedimen-
                               955
-------
tation requirements, plus wastewater flow reduction to reduce the
volume of wastewater discharged.  Water recycle and reuse are the
principal control mechanisms for flow reduction.

OPTION C

Option C for the secondary lead subcategory consists of Option B,
(in-process flow reduction, lime precipitation, and sedimenta-
tion) with the addition of multimedia filtration at the end of
Option B treatment.  Multimedia filtration is used to remove
suspended solids, including precipitated metals, below the
concentration attainable by gravity sedimentation.  The filter
suggested is of the gravity, mixed-media type, although other
forms of filters such as rapid sand filters or pressure filters
would perform satisfactorily.  The addition of filters also
provides for consistent removal during periods when there are
rapid increases in flows or loadings of pollutants to the
treatment system.

OPTION D

Option D for the secondary lead subcategory consists of Option C,
(in-process flow reduction, lime precipitation, sedimentation,
multimedia filtration) with the addition of activated alumina
technology at the end of Option C treatment.  The activated
alumina process is used to remove dissolved arsenic which remains
after lime precipitation.

OPTION F

Option F for the secondary lead subcategory consists of Option C,
(in-process flow reduction, lime precipitation, sedimentation,
multimedia filtration) with the addition of reverse osmosis and
multiple-effect evaporation technology at the end of Option C
treatment.  Option F is used for complete recycle of the treated
water by controlling the concentration of dissolved solids.
Multiple-effect evaporation is used to dewater brines rejected
from reverse osmosis.

In Section VI of this supplement, none of the toxic organic
pollutants were selected for further consideration in establish-
ing limitations for the secondary lead subcategory.  Therefore,
Option E, which includes activated carbon adsorption for organic
removal, is not applicable to this subcategory.
                               956
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                    SECONDARY LEAD SUBCATEGORY

                           SECTION VIII

           COSTS, ENERGY, AND NONWATER QUALITY ASPECTS
This section describes the method used to develop the  costs  asso-
ciated with the control and treatment technologies  discussed in
Section VII for wastewaters from secondary  lead plants.   The
energy requirements of the considered options as well  as  solid
waste and air pollution aspects are also discussed  in  this
section.  Section VIII of the General Development Document pro-
vides background on the capital and annual  costs for each of the
technologies discussed herein.

The wastewater streams associated with the  secondary lead sub-
category are combined into three groups for the purposes  of  this
section.  These three groups are as follows:

     1.  Battery cracking wastewater  (electrolyte and  saw water),
     2.  Smelting furnace and kettle wet air pollution control
         wastewaters, and
     3.  Casting contact cooling water.

These three groups are found in existing plants in  the three com-
binations shown below.  These three combinations are selected for
the purpose of cost estimation because they represent  the waste-
water combinations that occur most frequently in plants in the
secondary lead subcategory.
     Combination

          1
          2
          3
Battery
Cracking

     X
     X
     X
Casting
Contact
Cooling
     X
    Casting
Contact Cooling
or Wet Air Pol-
lution Control
Since the wastewater characteristics of combinations  2 and  3 are
similar, these two combinations are considered together  in  the
cost estimates.

TREATMENT OPTIONS COSTED FOR EXISTING SOURCES

As discussed in Section VII, five control and treatment  options
are considered for treating wastewater from the secondary lead
subcategory.  Cost estimates, in the form of annual cost curves,
have been developed for each of these control and treatment
options.  The control and treatment options are presented
schematically in Figures X-l through X-5, and summarized below.
                               957
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OPTION A

Option A for the secondary lead subcategory consists of  lime
preciptiation and sedimentation end-of-pipe technology.  Total
recycle of kettle wet air pollution control water is also
required for Option A.  The cost curves developed for Option A  do
not consider the cost for recycling kettle wet air pollution
control water.  Therefore, holding tank costs must be added to
the cost obtained from the Option A cost curves to determine the
total cost of Option A.

OPTION B

Option B for the secondary lead subcategory requires control and
treatment technologies to reduce the discharge of wastewater
volume and pollutant mass.  The recycle of casting contact cool-
ing water through cooling towers and the recycle of wet  air pol-
lution control water through holding tanks are the control
mechanisms for flow reduction.  The Option B end-of-pipe treat-
ment technology consists of lime precipitation and sedimentation.
The cost of Option B is determined by adding cooling tower and
holding tank costs (the holding tanks costs for Option B are only
for blast and reverberatory furnace scrubber water) to the cost
of Option A.

OPTION C

Option C for the secondary lead subcategory consists of  all the
control and treatment technologies of Option B (in-process flow
reduction through cooling towers and holding tanks; and  lime pre-
cipitation and sedimentation end-of-pipe treatment) with, the
addition of multimedia filtration to the end-of-pipe treatment
scheme.  The cost curves developed for Option C do not include
the cost of flow reduction.  Therefore, the total cost of Option
C is determined by adding cooling tower and holding tank costs  to
the costs obtained from the Option C cost curves.

OPTION D

Option D for the secondary lead subcategory consists of  all the
control and treatment technologies of Option C (in-process flow
reduction through cooling towers and holding tanks; and  lime pre-
cipitation, sedimentation, and multimedia filtration end-of-pipe
treatment) with the addition of activated alumina adsorption to
the end-of-pipe treatment scheme.  Flow reduction is not included
in the cost curves developed for Option D.  Therefore, holding
tank and cooling tower costs must be added to the costs  obtained
from the Option D cost curves to determine the total cost of
Option D.
                                958
-------
OPTION F

Option F for the secondary lead  subcategory  consists  of  all  the
control and treatment technologies of Option C  (in-process  flow
reduction through holding tanks  and  cooling  towers; and  lime pre-
cipitation, sedimentation, and multimedia  filtration  end-of-pipe
treatment) with the addition of  reverse  osmosis  and multiple-
effect evaporation followed by complete  recycle  to the end-of-
pipe treatment scheme.  Flow reduction is  not included in the
cost curves developed for Option F.  Therefore,  holding  tank and
cooling tower costs must be added to the costs  obtained  from the
Option F cost curves to determine the total  cost of Option  F.

The cost curves for the five options summarized  above are pre-
sented in the figures listed below.  The respective options  which
the curves are based on are also shown.

     Combination         Figure  VIII-         Options  Costed

          1                 1-4             A,  C, D, F

       2 and 3              5-8             A,  C, D, F

The holding tank and cooling tower cost  curves used to determine
flow reduction costs are presented in Figures VIII-9  and VIII-10,
respectively.

NONWATER QUALITY ASPECTS

A general discussion of nonwater quality aspects of the  control
and treatment alternatives considered for  the nonferrous metals
manufacturing category is contained  in Section VIII of the
General Development Document.  Nonwater  quality  impacts  specific
to the secondary lead subcategory including  energy requirements,
solid waste and air pollution are discussed  below.

ENERGY REQUIREMENTS

The methodology used for determining the energy  requirements  for
the various options is discussed in  Section  VIII of the  General
Development Document.  Briefly,  the  energy usage of the  options
is determined using the median wastewater  flow in the subcate-
gory.  The energy usage of the options is  then compared  to the
energy usage of the median secondary lead energy consumption
plant.  As shown in Table VIII-1, the most energy intensive
option is Option F with reverse  osmosis  and  multiple-effect
evaporation, which increases the median  energy consumption by
0.27 percent.
                               959
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SOLID WASTE

Sludges associated with the secondary lead subcategory will
necessarily contain additional quantities (and concentrations) of
toxic metal pollutants.

Wastes generated by secondary metal industries can be regulated
as hazardous.  However, the Agency examined the solid wastes that
would be generated at secondary lead plants by the suggested
treatment technologies and believes they are not hazardous wastes
under the Agency's regulations implementing Section 3001 of the
Resource Conservation and Recovery Act.  None of these wastes are
listed specifically as hazardous.  Nor are they likely to exhibit
a characteristic of hazardous waste.  This judgment is made based
on the recommended technology of lime precipitation, sedimenta-
tion and filtration.  By the addition of excess lime during
treatment, similar sludges, specifically toxic metal bearing
sludges, generated by other industries such as the iron and steel
industry passed the Extraction Procedure (EP) toxicity test.  See
40 CFR 261.24.  Thus, the Agency believes that the wastewater
sludges will similarly not be EP toxic if the recommended tech-
nology is applied.

Although it is the Agency's view that solid wastes generated as  a
result of these guidelines are not expected to be hazardous,
generators of these wastes must test the waste to determine if
the wastes meet any of the characteristics of hazardous waste
(see 40 CFR 262.11).

If these wastes should be identified or are listed as hazardous,
they will come within the scope of RCRA's "cradle to grave"
hazardous waste management program, requiring regulation from the
point of generation to point of final disposition.  EPA's genera-
tor standards would require generators of hazardous nonferrous
metals manufacturing wastes to meet containerization, labeling,
recordkeeping, and reporting requirements; if plants dispose of
hazardous wastes off-site, they would have to prepare a manifest
which would track the movement of the wastes from the generator's
premises to a permitted off-site treatment, storage, or disposal
facility.  See 40 CFR 262.20 45 FR 33142 (May 19, 1980), as
amended at 45 FR 86973 (December 31, 1980).  The transporter
regulations require transporters of hazardous wastes to comply
with the manifest system to assure that the wastes are delivered
to a permitted facility.  See 40 CFR 263.20 45 FR 33151 (May 19,
1980), as amended at 45 FR 86973 (December 31, 1980).  Finally,
RCRA Regulations establish standards for hazardous waste treat-
ment, storage, and disposal facilities allowed to receive such
wastes.  See 40 CFR Part 464 46 FR 2802 (January 12, 1981), 47 FR
32274 (July 26, 1982).
                                960
-------
Even if these wastes are not identified as hazardous, they  still
must be disposed of in compliance with the Subtitle  D open  dump-
ing standards, implementing 4004 of RCRA.  See 44 FR 53438
(September 13, 1979).  The Agency has calculated as part of the
costs for wastewater treatment the cost of hauling and disposing
of these wastes.  For more details, see Section VIII of the
General Development Document.

AIR POLLUTION

There is no reason to believe that any substantial air pollution
problems will result from implementation of chemical precipita-
tion, sedimentation, multimedia filtration, activated alumina
adsorption, and reverse osmosis.  These technologies transfer
pollutants to solid waste and do not involve air stripping  or any
other physical process likely to transfer pollutants to air.
Water vapor containing some particulate matter will be released
in the drift from cooling tower systems; however, the Agency does
not consider this impact to be significant.
                               961
-------
A
                 -a
                 £
                 m
                  o
                 £
                 CO
                 a)
                                CM
                           
-------
  10  er
c/i
o
<
-' A5
< '°
O
                        SLUDGE REMOVAL
                        CHEMICALS
                        ENERGY —
                        MATERIALS
                                                   LA30R
                                                   DEPRECIATION
                                                  CAPITAL
                                                                            . i
                                                                             -I

                                                                            1
                  0.01
                                 0-1  FLOW, mgd   '-°
         10.0
                      1 I 1111
                                                 I I I 1 I 11
                                                                           .  I
   10
 O
 o
 n
 »*•
 <
      L
      !
      !-
   10
            10
                         100           1,0 CO
                                  FLOW, cum/doy
                                 Figure VIII-1
10,000
100,000
                   SECONDARY LEAD  COMBINATION  1,  OPTION A
                       SLUDGE REMOVAL
                       CHEMICALS
                       ENERGY
                       MATERIALS-
                                                        LABOR
                                                        DEPRECIATION
                                                        CAPITAL
                             I  I I I lit
                   O.f!
                                  °J
                                     FLO'.V, ,-ngd
                                   Lilt Lit  __ i
          10.0
            10
                          100            1,000
                                   FLOW, cum
                                 Figure  VIII-2
 10,0^0
                    SECONDARY LEAD COMBINATION 1,  OPTION  C
                                       963
-------
                   SLUDGE  REMOVAL
                   CHEMICALS
                   ECiER
       °-CI            °! FLOW,  r.,Cd   '-°
     I  (  *  ! t M i !    1   !  ^ _ L L 'i i : 1    '   f  '- I ' I t I I
                                                             IOC
  10'
10             100            1,000         10,00'J
                       FLOW, cu m/doy
                      Figure  VIII-3

        SECONDARY LEAD COMBINATION 1,  OPTION D
                                                                 ioo,oco
                   SLUDGE REMOVAL
                   CHEMICALS
                   ENERGY
                   MATERIALS
  10°
CO
o
o
-I
o
                                                    LABOR
                                                    DEPRECIATION
                                                    CAPITAL
  IOH
                        A  1  i  1 1 1
                                ul
                  o.oi            o.i  _lrtvu        i.o
                                    FLOW, mgd
         11 111	i  i i  i i i 111	i   i i  i i i 111	i   i  i i i i
                                                   10.0
           10
               100            1,000
                        FLOW, cu m/doy
                      Figure VIII-4
IO.CJO
.00,000
                  SECONDARY  LEAD  COMBINATION  1, OPTION F
                                     964
-------
 10
 10  -
                                   SLUDGE' REMOVAL
                                   CHEMICALS
                                   ENERGY
                                                          LASCrt
                                                          DEPRECIATION
                                                          CAPITOL
                                   FLOW, mgd
                 i i  i t i ill	1—i  i j . i .. i    i  i  i .• i. 11
  10
                                      1,000
                                 FLOW, cu m/day
                                Figure VIII-5
                 SECONDARY  LEAD COMBINATION 2&3, OPTION A
  io6 t,
co
o
o
-J
O
  10
                                SLUDGE REMOVAL
                                CHEMICALS
                                ENERGY
                                MATERIALS
                                                          LABOR
                                                          DEPRECIATION
                                                          CAPITAL
                  0.01
         •'  FLOW, mgd  ''
           10
100            1,000
         FLOW, cum/day
        Figure  VIII-6
10,000
,00,000
                 SECONDARY LEAD  COMBINATION  2&3, OPTION C
                                     965
-------
  10
  10°
O
O
a
z
<
_l
o
  10
  10
                              I I I llf'    I  I   I I I I IIJ
                                SLUDGE REMOVAL
                                CHEMICALS
                                ENERGY 8
                                MATERIALS
                                                     i  i  i i i  i i
                                                          LABOR
                                                          DEPRECIATION
                                                          CAPITAL
              I  I, Mill!	1	1	1  I I I III	1- •   I I I I III    .  !  !	1
                                                                     '  I  I 1 1 I
                  0.01
                1  II I I I I 11
                                  '  FLOW, mgd
                                                             10.0
  10
            10
                         100           1,000
                                  FLOW, cu m/day
                                Figure VIII-7
                           10,000
100,000
                SECONDARY LEAD COMBINATIONS  2&3,  OPTION  D
  10   r
o
u
3
210
o
  to
                                SLUDGE REMOVAL
                                CHEMICALS
                                ENERGY
                                                           LABOR
                                                           DEPRECIATION!
                                                           CAPITAL
                  i > il
                   0.01
                   •  ' • '
        °J FLOW,
     i   i  i i i i i il    i
                                                              10'°
                                                           1 - 1 — I_J - L'J_
           10
100            1,000
         FLOW, cu m/doy
                                                     10.000
                                                                  100,000
                                 Figure  VIII-8

                SECONDARY  LEAD COMBINATIONS 2&3,  OPTION F
                                      966
-------
   10

   10
   10"
                                                        DEPRECIATION


                                                        CAPITAL
             t  T i i t t it
                         \   t <  I I >
Jll
                                                               iao
                                  Figure VIII-9


                                HOLDING  TANK COSTS
   10
   10'
at-
s
   10
a
                                       Labor and

                                       Material
                            Depreciation



                         Capital
                                                      t  »
                                                              iao
                                  Figure  VIII-10


                  COOLING TOWER COSTS CASTING CONTACT  COOLING
                                       967
-------
                    SECONDARY LEAD SUBCATEGORY

                            SECTION IX

                BEST PRACTICABLE CONTROL TECHNOLOGY
                        CURRENTLY AVAILABLE
This section defines the effluent characteristics attainable
through the application of best practicable control technology
currently available (BPT), Section 301(b)(a)(A).  BPT reflects
the existing performance by plants of various sizes, ages, and
manufacturing processes within the secondary lead subcategory, as
well as the established performance of the recommended BPT
systems.  Particular consideration is given to the treatment
already in place at plants within the data base.

The factors considered in identifying BPT include the total cost
of applying the technology in relation to the effluent reduction
benefits from such application, the age of equipment and facili-
ties involved, the manufacturing processes used, nonwater quality
environmental impacts (including energy requirements), and other
factors the Administrator considers appropriate.  In general, the
BPT level represents the average of the existing performances of
plants of various ages, sizes, processes, or other common
characteristics.  Where existing performance is uniformly
inadequate, BPT may be transferred from a different subcategory
or category.  Limitations based on transfer of technology are
supported by a rationale concluding that the technology is,
indeed, transferable, and a reasonable prediction that it will be
capable of achieving the prescribed effluent limits (see
Tanner's Council of America v. Train, 540 F.2d 1188 (4th Cir.
1176).BPT focuses on end-of-pipe treatment rather than process
changes or internal controls, except where such practices are
common subcategory practice.

TECHNICAL APPROACH TO BPT

The Agency studied the nonferrous metals manufacturing category
to identify the processes used, the wastewaters generated, and
the treatment processes installed.  Information was collected
from industry using data collection portfolios, and specific
plants were sampled and the wastewaters analyzed.  Some of the
factors which must be considered in establishing effluent limi-
tations based on BPT have already been discussed.  The age of
equipment and facilities, processes used, and raw materials were
taken into account in subcategorization and subdivision and are
discussed fully in Section IV.  Nonwater quality impacts and
energy requirements are considered in Section VIII.
                               969
-------
As explained in Section IV, the secondary lead subcategory has
been subdivided into four potential wastewater sources.  Since
the water use, discharge rates, and pollutant characteristics of
each of these wastewaters is potentially unique, effluent limita-
tions will be developed for each of the four subdivisions.

For each of the subdivisions, a specific approach was followed
for the development of BPT mass limitations.  To account for
production and flow variability from plant to plant, a unit of
production or production normalizing parameter (PNP) was deter-
mined for each waste stream which could then be related to the
flow from the process to determine a production normalized flow.
Selection of the PNP for each process element is discussed in
Section IV.  Each process within the subcategory was then ana-
lyzed to determine (1) whether or not operations included gener-
ated wastewater, (2) specific flow rates generated, and (3) the
specific production normalized flows for each process.  This
analysis is discussed in detail in Section V.  Nonprocess waste-
water such as rainfall runoff and noncontact cooling water is not
considered in the analysis.

Normalized flows were analyzed to determine which flow was to be
used as part of the basis for BPT mass limitations.  The selected
flow (sometimes referred to as a BPT regulatory flow or BPT
discharge rate) reflects the water use controls which are common
practices within the subcategory.  The BPT normalized flow is
based on the average of all applicable data.  Plants with normal-
ized flows above the average may have to implement some method of
flow reduction to achieve the BPT limitations.  In most cases,
this will involve improving housekeeping practices, better main-
tenance to limit water leakage, or reducing excess flow by
turning down a flow valve.  It is not believed that these
modifications would incur any costs for the plants.

For the development of effluent limitations, mass loadings were
calculated for each wastewater source or subdivision.  This cal-
culation was made on a stream-by-stream basis, primarily because
plants in this category may perform one or more of the operations
in various combinations.  The mass loadings (milligrams of pollu-
tant per metric ton of production unit - mg/kkg) were calculated
by multiplying the BPT normalized flow (1/kkg) by the concentra-
tion achievable using the BPT treatment system (mg/1) for each
pollutant parameter to be limited under BPT.

The mass loadings which are allowed under BPT for each plant will
be the sum of the individual mass loadings for the various waste-
water sources which are found at particular plants.  Accordingly,
all the wastewater generated within a plant may be combined for
treatment in a single or common treatment system, but the efflu-
ent limitations for these combined wastewaters are based on the
                              970
-------
various wastewater sources which actually  contribute  to  the  com-
bined flow.  This method accounts  for the  variety of  combinations
of wastewater sources and production processes which  may be  found
at secondary lead plants.

The Agency usually establishes wastewater  limitations  in terms  of
mass rather than concentration.  This approach prevents  the  use
of dilution as a treatment method  (except  for controlling pH).
The production normalized wastewater flow  (1/kkg) is  a link
between the production operations  and the  effluent  limitations.
The pollutant discharge attributable to each operation can be
calculated from the normalized flow and effluent concentration
achievable by the treatment technology and summed to  derive  an
appropriate limitation for each subcategory.

BPT effluent limitations are based on the  average of  the dis-
charge flow rates for each source; consequently, the  treatment
levels which are currently used by the lowest dischargers will  be
the treatment technologies most likely required to  meet  BPT
guidelines.  Section VII discusses the various treatment tech-
nologies which are currently in place for  each wastewater source.
In most cases, the current treatment levels consist of chemical
precipitation and sedimentation (lime and  settle technology) and
a combination of reuse and recycle to reduce flow.

The overall effectiveness of end-of-pipe treatment  for the
removal of wastewater pollutants is improved by the applica-
tion of water flow controls within the process to limit  the
volume of wastewater requiring treatment.   The controls  or in-
process technologies recommended under BPT include  only  those
measures which are commonly practiced within the subcategory and
which reduce flows to meet the production  normalized  flow for
each operation.

In making technical assessments of data, reviewing  manufacturing
processes, and assessing wastewater treatment technology options,
both indirect and direct dischargers have  been considered as a
single group.  An examination of plants and processes  did not
indicate any process differences based on  the type  of  discharge,
whether it be direct or indirect.

INDUSTRY COST AND POLLUTANT REDUCTION BENEFITS

In balancing costs in relation to effluent  reduction benefits,
EPA considers the volume and nature of existing discharges, the
volume and nature of discharges expected after application of
BPT, the general environmental effects of  the pollutants, and the
cost and economic impacts of the required  pollution control
level. The Act does not require or permit  consideration  of water
                               971
-------
quality problems attributable to particular point sources or
industries, or water quality improvements in particular water
quality bodies.  Accordingly, water quality considerations were
not the basis for selecting the proposed BPT.  See Weyerhaeuser
Company v. Costle, 590 F.2d 1011 (D.C. Cir. 1978).

The methodology for calculating pollutant reduction benefits and
plant compliance costs is discussed in Section X.  Tables X-2 and
XII-1 show the estimated pollutant reduction benefits for each
treatment option for direct and indirect dischargers.  Compliance
costs are presented in Table X-3.

BPT OPTION SELECTION

The BPT treatment scheme (Figure IX-1) selected consists of
complete recycle of kettle scrubber liquor, and chemical
precipitation and sedimentation (lime and settle) end-of-pipe
technology.  Dry air pollution control of air emissions from
kettle refining is required; or alternately, complete recycle of
kettle scrubber liquor may be used to achieve zero discharge of
wastewater pollutants.  The BPT treatment is equivalent to Option
A described in Section X. The proposed BPT will result in the
removal of approximately 14,350 kg/yr of toxic metal pollutants
and 5,398,900 kg/yr of conventional pollutants from the estimated
raw discharge.  The estimated capital cost of BPT is $470,000
(1978 dollars) and the estimated annual cost is $228,000 (1978
dollars).

WASTEWATER DISCHARGE RATES

A BPT discharge rate is calculated for each subdivision based on
the average of the flows of the existing plants, as determined
from analysis of the dcp.  The discharge rate is used with the
achievable treatment concentrations to determine BPT effluent
limitations.  Since the discharge rate may be different for each
wastewater source, separate production normalized discharge rates
for each of the four wastewater sources are discussed below and
summarized in Table IX-1.  The discharge rates are normalized on
a production basis by relating the amount of wastewater generated
to the mass of the intermediate product which is produced by the
process associated with the waste stream in question.  These pro-
duction normalizing parameters, or PNP's, are also listed in
Table IX-1.

BATTERY CRACKING

The BPT wastewater discharge rate for battery cracking is 940
1/kkg (225 gal/ton) of lead produced.  All 32 of the plants with
this process discharge this wastewater at rates ranging from 80.5
to 5,086 1/kkg (19.3 to 1,220 gal/ton).  A distribution of waste-
water rates for battery cracking wastewater is presented in
                               972
-------
Section V  (Table V-l).   None  of  the  plants  practice  recycle of
this wastewater, therefore  the BPT rate  is  the  average  discharge
rate of 32 plants.  Twenty-three plants  meet  the  BPT discharge
rate.

BLAST AND REVERBERATORY  FURNACE  WET  AIR  POLLUTION CONTROL

The BPT wastewater discharge  rate for blast and reverberatory
furnace wet air pollution control is 3,380  1/kkg  (811 gal/ton)  of
lead produced.  This rate is  allocated only for those plants
having wet air pollution control for smelting operations.   Of the
47 plants with this process,  seven use air  scrubbing devices.
One of the seven plants  did not  report sufficient production  data
to calculate a discharge rate but reported a  recycle rate  of  97.8
percent.  One plant discharges with  no recycle.   Three  plants
practice partial recycle, ranging from 83.3 to  93.3  percent.   Two
of the seven plants achieve zero discharge by 100 percent
recycle.  Extensive recycling is possible for this wastewater
stream, but a zero discharge  may not be  technically  feasible
unless (1) a recycle system controls dissolved  solids buildup;
(2) the wastewater is evaporated;  or (3) there  is a  production
operation that can accept the quality of treated  wastewater.
Some of these zero discharge  possibilities are  site-specific  and,
therefore, are not applicable to the secondary  lead  subcategory
as a whole.  The discharge rates from the four  discharging plants
range from 1,776 to 6,587 1/kkg  (426 to  1,580 gal/ton).   The
average of these four discharges is  the basis for the BPT  rate.
Five of six plants meet  the BPT  rate.  Wastewater rates  for blast
and reverberatory furnace wet air pollution control  are  presented
in Table V-3.

KETTLE WET AIR POLLUTION CONTROL

No BPT wastewater discharge allowance is provided for kettle
scrubbing wastewater.  Twenty-eight  plants control kettle  air
emissions; 19 use dry controls (baghouses), and nine use
scrubbers.  Six plants practice  complete recycle  of  the  scrubber
liquor and one plant uses the liquor in the battery  cracking  and
decasing operation.  The remaining two plants practice  recycle  of
91.7 and 96 percent. Since complete  recycle of kettle scrubber
wastewater is so widely  demonstrated in this  subcategory,  the
Agency believes that zero discharge  of wastewater pollutants  is
feasible for all secondary lead  kettle wet air  pollution control.

CASTING CONTACT COOLING  WATER

The BPT wastewater discharge  rate  for casting contact cooling
water is 221 1/kkg (53.1 gal/ton)  of lead cast.   Of  the  66
secondary lead plants with casting operations,  11  generate
wastewater from the process.  Three  plants practice  total  recycle
and two plants reported  discharging  insignificant"  amounts of
                               973
-------
wastewater. Six plants are once-through dischargers, with flow
rates ranging from 5 to 963 1/kkg  (1 to 231 gal/ton;. Wastewater
rates for casting contact cooling  are presented in Table V-7.
The BPT discharge rate is based on the average of the six dis-
charging plants.  Ten of the 11 plants using casting contact
cooling water meet the BPT discharge rate.

REGULATED POLLUTANT PARAMETERS

The raw wastewater concentrations  from individual operations and
the subcategory as a whole were examined to select certain pollu-
tants and pollutant parameters for consideration for limitation.
This examination and evaluation was presented in Section VI.  A
total of seven pollutants or pollutant parameters are selected
for limitation under BPT and are listed below:

     114.  antimony
     115.  arsenic
     122.  lead
     128.  zinc
           ammonia
           total suspended solids  (TSS)
           PH

EFFLUENT LIMITATIONS

The treatable concentrations achievable by the proposed BPT
treatment scheme are explained in  Section VII of General
Development Document and summarized there in Table VII-22.  The
treatable concentrations (both one day maximum and monthly
average values) are multiplied by  the BPT normalized discharge
flows summarized in Table IX-1 to  calculate the mass of
pollutants allowed to be discharged per mass of product.  The
results of these calculations in kilograms of pollutant per
metric ton of product represent the BPT effluent limitations and
are presented in Table IX-2 for each individual waste stream.
                               974
-------


































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                            Table IX-2

   BPT EFFLUENT LIMITATIONS FOR THE SECONDARY LEAD SUBCATEGORY
                         Battery Cracking

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

           Metric Units - mg/kkg of lead scrap produced
      English Units - Ibs/billion Ibs. of lead scrap produced
Ant imony
Arsenic
Lead
Zinc
Ammonia (as N)
Total Suspended Solids
pH
    2,697.80
    1,964.60
      141.0
    1,250.20
        0.0
   38,540.0
    1,193.80
      808.40
      122.20
      526.40
        0.0
   18,800.0
Within the range of 7.5 to 10.0
         at all times
    Blast and Reverberatory Furnace Wet Air Pollution Control
Pollutant or Pollutant Property
 Maximum for
 Any One Day
  Maximum for
Monthly Average
       Metric Units - mg/kkg of lead produced from smelting
  English Units - Ibs/billion Ibs of lead produced from smelting
Ant imony
Arsenic
Lead
Zinc
Ammonia (as N)
Total Suspended Solids
pH
    9,700.60
    7,064.20
      507.0
    4,495.40
        0.0
  138,580.0
    4,292.60
    2,906.80
      439.40
    1,892.80
        0.0
   67,600.0
Within the range of 7.5 to 10.0
         at all times
                                976
-------
                      Table IX-2 (Continued)

   BPT EFFLUENT LIMITATIONS FOR THE SECONDARY LEAD SUBCATEGORY
                 Kettle Wet Air Pollution Control

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

   Metric Units - mg/kkg of lead produced from kettle furnaces
   English Units - Ibs/billion Ibs of lead produced from kettle
                             furnaces
Antimony
Arsenic
Lead
Zinc
Ammonia (as N)
Total Suspended Solids
PH
        0
        0
        0
        0
        0
        0
        0
        0
        0
        0
        0
        0
Within the range of 7.5 to 10.0
         at all times
                     Casting Contact Cooling
Pollutant or Pollutant Property
 Maximum for
 Any One Day
  Maximum for
Monthly Average
                  Metric Units - mg/kkg of lead cast
           English Units - Ibs/billion Ibs of lead cast
Antimony
Arsenic
Lead
Zinc
Ammonia (as N)
Total Suspended Solids
PH
      634.84          280.92
      462.31          190.23
       33.18           28.76
      294.20          123.87
        0.0             0.0
    9,069.20        4,424.0
Within the range of 7.5 to 10.0
         at all times
                               977
-------
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    978
-------
                     SECONDARY LEAD  SUBCATEGORY

                             SECTION X

        BEST AVAILABLE TECHNOLOGY ECONOMICALLY ACHIEVABLE


The effluent limitations which must be  achieved by  July  1,  1984,
are based on the best control and treatment  technology used by  a
specific point source within the industrial  category  or  subcate-
gory, or by another  category where  it is  readily  transferable.
Emphasis is placed on additional treatment techniques applied at
the end of the treatment systems currently used,  as well as
reduction of the amount of water used and discharged, process
control, and treatment technology optimization.

The factors considered in assessing best  available  technology
economically achievable (BAT) include the age of  equipment  and
facilities involved, the process used,  process changes,  nonwater
quality environmental impacts (including  energy requirements),
and the costs of application of such technology (Section 304(b)
(2) (B) of the Clean  Water Act).  At a minimum, BAT  represents the
best available technology economically  achievable at  plants of
various ages, sizes, processes, or  other  characteristics.   Where
the Agency has found the existing performance to  be uniformly
inadequate, BAT may  be transferred  from a different subcategory
or category.  BAT may include feasible  process changes or
internal controls, even when not in commom subcategory practice.

The statutory assessment of BAT considers costs,  but  does not
require a balancing  of costs against effluent reduction  benefits
(see Weyerhaeuser v. Costle, 11 ERG 2149  (D.C. Cir. 1978)).
However, in assessing the proposed  BAT, the  Agency has given
substantial weight to the economic  achievability  of the
technology.

TECHNICAL APPROACH TO BAT

In pursuing this second round of effluent regulations, the  Agency
reviewed a wide range of technology options  and evaluated the
available possibilities to ensure that  the most effective and
beneficial technologies were used as the  basis of BAT.   To
accomplish this, the Agency elected to  examine five technology
options which could  be applied to the secondary lead  subcategory
as alternatives for  the basis of BAT effluent limitations.

In summary, the treatment technologies  considered for BAT are
presented below:
                                979
-------
Option A is based on:

     o  Chemical precipitation and sedimentation
     o  Dry air pollution control of kettle refining or alterna-
        tively, complete recycle of kettle scrubber liquor

Option B is based on:

     o  Chemical precipitation and sedimentation
     o  Dry air pollution control of kettle refining or alterna-
        tively, complete recycle of kettle scrubber liquor
     o  In-process flow reduction of casting contact cooling
        water, blast and reverberatory furnace scrubber liquor,
        and battery cracking wastewater

Option C is based on:

     o  Chemical precipitation and sedimentation
     o  Dry air pollution control of kettle refining or alterna-
        tively, complete recycle of kettle scrubber liquor
     o  In-process flow reduction of casting contact cooling
        water, blast and reverberatory furnace scrubber liquor,
        and battery cracking wastewater
     o  Multimedia filtration

Option D is based on:

     o  Chemical precipitation and sedimentation
     o  Dry air pollution control of kettle refining or alterna-
        tively, complete recycle of kettle scrubber liquor
     o  In-process flow reduction of casting contact cooling
        water, blast and reverberatory furnace scrubber liquor,
        and battery cracking wastewater
     o  Multimedia filtration
     o  Activated alumina adsorption

Option F is based on:

     o  Chemical precipitation and sedimentation
     o  Dry air pollution control of kettle refining or alterna-
        tively, complete recycle of kettle scrubber liquor
     o  In-process flow reduction of casting contact cooling
        water, blast and reverberatory furnace scrubber liquor,
        and battery cracking wastewater
     o  Multimedia filtration
     o  Reverse osmosis in conjunction with multiple-effect
        evaporation for complete recycle of treated water

The five options examined for BAT are discussed in greater detail
below.  The first option considered (Option A) is the same as the
BPT treatment technology which was presented in the previous
section.
                               980
-------
OPTION A

Option A for the secondary lead subcategory  is  equivalent  to  the
control and treatment technologies which were analyzed  for BPT  in
Section IX.  The BPT end-of-pipe treatment scheme  consists of
complete recycle of kettle scrubber liquor,  and chemical precipi-
tation and sedimentation  (lime and settle) end-of-pipe  technology
(see Figure X-l).  The discharge rates  for Option  A are equal to
the discharge rates allocated to each stream as a  BPT discharge
flow.  Dry air pollution  control of kettle refining air emissions
is required to achieve zero discharge of wastewater pollutants,
or alternatively, complete recycle of kettle scrubber liquor  may
be used.

OPTION B

Option B for the secondary lead subcategory  achieves lower
pollutant discharge by building upon the Option A  end-of-pipe
treatment technology.  Flow reduction measures  are added to
Option A treatment, chemical precipitation and  sedimentation  (see
Figure X-2).  These flow  reduction measures, including  in-process
changes, result in the elimination of some wastewater streams and
the concentration of pollutants in other effluents.  As explained
in Section VII of the General Development Document, treatment of
a more concentrated effluent allows achievement of a greater  net
pollutant removal and introduces the possible economic benefits
associated with treating  a lower volume of wastewater.

Methods used in Option B  to reduce process wastewater generation
and discharge rates include the following:

Recycle of Casting Contact Cooling Water Through Cooling Towers

The function of casting contact cooling water is to quickly
remove heat from the newly formed lead  ingots.  Therefore, the
principal requirements of the water are that it be cool and not
contain dissolved solids  at a concentration  that would  cause
water marks or other surface imperfections.  There is sufficient
experience within the category with the cooling and recycling of
casting contact cooling wastewater to assure the success of this
technology using cooling  towers or heat exchangers (refer  to
Section VII of the General Development  Document).  A blowdown or
periodic cleaning is likely to be needed to  prevent a build-up  of
dissolved and suspended solids.  (EPA has determined that  a
blowdown of 10 percent of the water applied  in a process is
adequate.)
                               981
-------
Recycle of Water Used in Wet Air Pollution Control

There are two wastewater sources associated with wet air
pollution control which are regulated under these effluent
limitations:

     --Blast and reverberatory furnace scrubber, and
     --Kettle scrubber.

Table X-l presents the number of plants reporting wastewater use
with these sources, the number of plants practicing recycle of
scrubber liquor, and the range of recycle values being used.
Although some plants report total recycle of their scrubber
water, a blowdown or periodic cleaning may be needed to prevent
the buildup of dissolved and suspended solids since the water
picks up particulates and fumes from the air.  Since the BPT
discharge rate for the kettle scrubber is zero, no further flow
reduction can be achieved at BAT.

OPTION C

Option C for the secondary lead subcategory consists of in-
process flow reduction, chemical precipitation, and sedimentation
treatment of Option B plus multimedia filtration technology added
at the end of Option B treatment (see Figure X-3).  Multimedia
filtration is used to remove suspended solids, including precipi-
tates of toxic metals, beyond the concentration attainable by
gravity sedimentation.  The filter suggested is of the gravity,
mixed media type, although other filters, such as rapid sand
filters or pressure filters, would perform satisfactorily.

OPTION D

Option D for the secondary lead subcategory consists of in-
process flow reduction, chemical precipitation, sedimentation,
and multimedia filtration treatment of Option C with the addition
of activated alumina technology at the end of the Option C treat-
ment.  The activated alumina process is used to remove dissolved
arsenic which remains after lime precipitation.

OPTION F

Option F for the secondary lead subcategory consists of in-
process flow reduction, chemical precipitation, sedimentation,
and multimedia filtration treatment of Option C with the addition
of reverse osmosis and multiple-effect evaporation technology at
the end of the Option C treatment (see Figure X-4).  Option F is
used for complete recycle of the treated water by controlling the
concentration of dissolved solids.  Multiple-effect evaporation
is used in dewater brines rejected by reverse osmosis.
                               982
-------
Another treatment technology, activated  carbon  adsorption  (Option
E) was not considered for this subcategory.   In Section  VI of
this supplement, none of the toxic organic pollutants were
selected for further consideration in establishing limitations
for the secondary lead subcategory.  Therefore,  Option E,  which
includes activated carbon adsorption for organic removal,  is not
applicable.

INDUSTRY COST AND POLLUTANT REDUCTION BENEFITS

As a means of evaluating each technology option, EPA developed
estimates of the pollutant reduction benefits and the compliance
costs associated with each option.  The  methodologies are
described below.

POLLUTANT REDUCTION BENEFITS

A complete description of the methodology used  to calculate the
estimated pollutant reduction, or benefit, achieved by the appli-
cation of the various treatment options  is presented in  Section X
of the General Development Document.  In short,  sampling data
collected during the field sampling program were used to charac-
terize the major waste streams considered for regulation.  At
each sampled facility, the sampling data was production  normal-
ized for each unit operation (i.e., mass of pollutant generated
per mass of product manufactured).  This value,  referred to as
the raw waste, was used to estimate the mass of toxic pollutants
generated within the secondary lead subcategory.  By multiplying
the total subcategory production for a unit operation by the
corresponding raw waste value, the mass of pollutant generated
for that unit operation was estimated.

The volume of wastewater discharged after the application  of each
treatment option was estimated by multiplying the regulatory flow
determined for each unit process by the total subcategory  produc-
tion.   The mass of pollutant discharged was then estimated by
multiplying the achievable concentration values  attainable by the
option (mg/1) by the estimated volume of process wastewater dis-
charged by the subcategory.  The mass of pollutant removed,
referred to as the benefit, is simply the difference between the
estimated mass of pollutant generated within the subcategory and
the mass of pollutant discharged after application of the  treat-
ment option.

The Agency varied this procedure slightly in computing estimated
BPT discharge in a subcategory where there is an existing  BPT
limitation.  In this case, EPA took the mass limits from the BPT
limitations (for all pollutants limited at BPT)  and multiplied
these limits by the total subcategory production (from dcp).
                               983
-------
(The assumption is that plants are discharging a volume equal to
their BPT allowance times their production.)  Where pollutants
are not controlled by existing BPT, EPA used the achievable
concentration for the associated technology proposed in this
document, and multiplied these concentrations by the total
end-of-pipe discharge of process wastewater for the subcategory
(from dcp).  The total of both these calculations represents
estimated mass loadings for the subcategory.  The pollutant
reduction benefit estimates for direct discharges in the second-
ary lead subcategory are presented in Table X-2.

COMPLIANCE COSTS

In estimating subcategory-wide compliance costs, the first step
was to develop uniformly-applicable cost curves, relating the
total costs associated with installation and operation of waste-
water treatment technologies to plant process wastewater dis-
charge.  EPA applied these curves on a per plant basis, a plant's
costs (both capital, and operating and maintenance) being deter-
mined by what treatment it has in-place and by its individual
process wastewater discharge (from dcp).  The final step was to
annualize the capital costs, and to sum the annualized capital
costs, and the operating and maintenance costs, yielding the cost
of compliance for the subcategory (see Table X-3) .  These costs
were used in assessing economic achievability.

BAT OPTION SELECTION

EPA has selected both Option B and Option C as the basis for
alternative BAT effluent limitations for the secondary lead sub-
category due to current adverse structural economic changes that
are not reflected in the Agency's current economic analysis.
These alternative limitations are based on lime precipitation,
sedimentation, and in-process control technologies to reduce the
volume of process wastewater discharged for Option B and the
addition of multimedia filtration for Option C.  The major
changes affecting the secondary lead market are an overall
stagnant demand, and a major shift by battery manufacturers to
low-antimony maintenance free (MF) batteries. A more detailed
explanation regarding this economic analysis can be found in the
Economic Impact Analysis of Proposed Effluent Standards and
Limitations for the Nonferrous Smelting and Refining Industry,
EPA 440/2-82-002.

The selected BAT Alternative A (Option B) increases the removal
of toxic metals by an estimated 132 kg/yr over the estimated BPT
discharge.  The estimated capital cost of proposed Alternative A
is $0.470 million (1978 dollars), and the annualized cost is
$0.228 million (1978 dollars).  The selected BAT Alternative B
(Option C) would remove approximately 14,602 kg/yr of toxic
metals and 495 kg/yr of ammonia from raw discharge and increases
                               984
-------
the removal of toxic metals by  an  estimated  189  kg/yr  over the
estimated BPT discharge.  The estimated  capital  cost of the
proposed Alternative B  is $2.12 million  (1978  dollars), and the
annualized cost is  $1.36 million  (1978 dollars).

Activated alumina  (Option D) was considered; however,  this tech-
nology was rejected because it  was not demonstrated in this
subcategory nor was it  clearly  transferable  to nonferrous
wastewater.  Reverse osmosis (Option  F)  was  considered for the
purpose of achieving zero discharge of process wastewater; how-
ever, the Agency ultimately rejected  this  technology because it
was determined that its performance for  this specific  purpose was
not adequately demonstrated in  this subcategory  nor was it
clearly transferable from another  subcategory  or category.

WASTEWATER DISCHARGE RATES

A BAT discharge rate was calculated for  each subdivision based
upon the flows of the existing  plants, as  determined from
analysis of the data collection portfolios.  The discharge rate
is used with the achievable treatment concentration to determine
BAT effluent limitations.  Since the  discharge rate may be
different for each  wastewater source, separate production
normalized discharge rates for  each of the four  wastewater
sources were determined and are summarized in  Table X-4.   The
discharge rates are normalized  on  a production basis by relating
the amount of wastewater generated to the  mass of the  interme-
diate product which is produced by the process associated  with
the waste stream in question.   These  production  normalizing
parameters (PNP) are also listed in Table  X-4.

The BAT wastewater  discharge rate  equals the BPT wastewater
discharge rate for  kettle wet air  pollution  control.   Since the
kettle scrubber regulatory discharge  rate  is zero, no  further
flow reduction is feasible.  Wastewater  streams  for which  BAT
discharge rates differ from BPT are discussed  below.

BATTERY CRACKING

The BAT wastewater  discharge rate  for battery  cracking is  673
1/kkg (162 gal/ton) of lead produced  from  battery cracking.   All
32 of the secondary lead plants with  this  process  discharge this
wastewater; none practice recycle.  The  BAT  rate  is predicated  on
the average of discharge rates  from 30 plants  with flow rates
ranging from 80.5 to 1,984 1/kkg (19.3 to  476  gal/ton).  Two
plants use significantly larger volumes  of wash water  than the
other facilities and thus were  excluded  from the  BAT flow
calculation.   Wastewater rates  for  battery cracking are  presented
in Section V (Table V-l).  Seventeen  of  the  32 plants  meet the
BAT discharge rate.
                                985
-------
BLAST AND REVERBERATORY FURNACE WET AIR POLLUTION CONTROL

The BAT wastewater discharge rate for smelting furnace wet air
pollution control is 2,610 1/kkg (626 gal/ton) of lead produced
from smelting.  This rate is based on 90 percent recycle of the
scrubber water used at four plants that discharge from this
process and is allocated only for those plants having wet air
pollution control for smelting operations.  (Refer to Section VII
of the General Development Document.)  Of the 47 plants with
smelting processes, seven use wet scrubbing devices.  One of the
seven did not provide sufficient production information in the
dcp to calculate a discharge rate but reported a recycle rate of
97.8 percent.  One plant is a once-through discharger, practicing
no recycle.  The recycle in three other plants ranges from 83.3
to 93.3 percent.  Two plants achieve zero discharge by 100
percent recycle.  Some zero discharge possibilities are
site-specific and thus, are not applicable on a nationwide basis.
The distribution of wastewater rates for this waste stream is
presented in Table V-3.  Four of the six plants reporting flow
data for this waste stream meet the BAT discharge rate.

CASTING CONTACT COOLING WATER

The BAT wastewater discharge rate is 22 1/kkg (5.3 gal/ton),
based on 90 percent recycle of the BPT discharge allowance (refer
to Section VII of the General Development Document).  Eleven of
the 66 plants with casting operations use contact cooling water.
Three plants achieve zero discharge through 100 percent recycle
or evaporation.  Six plants are once-through dischargers with
flow rates ranging from 5 to 963 1/kkg (1 to 231 gal/ton).  Seven
of the 11 plants using casting contact cooling water meet the BAT
discharge rate.

REGULATED POLLUTANT PARAMETERS

In implementing the terms of the Consent Agreement in NRDC v.
Train, Op. Cit., and 33 U.S.C. 1314(b)(2)(A and B) (197677 the
Agency placed particular emphasis on the toxic pollutants.  The
raw wastewater concentrations from individual operations and the
subcategory as a whole were examined to select certain pollutants
and pollutant parameters for consideration for limitation.  This
examination and evaluation, presented in Section VI, concluded
that 13 pollutants or pollutant parameters are present in second-
ary lead wastewaters at concentrations that can be effectively
reduced by identified treatment technologies.

The high cost associated with analysis for toxic metal pollutants
has prompted EPA to develop an alternative method for regulating
and monitoring toxic pollutant discharges from the nonferrous
metals manufacturing category.  Rather than developing specific
effluent mass limitations and standards for each of the toxic
metals found in treatable concentrations in the raw wastewater
                               986
-------
from a given  subcategory,  the Agency  is  proposing  effluent  mass
limitations only  for those pollutants  generated  in the  greatest
quantities as shown by the pollutant  reduction benefit  analysis.
The pollutants selected  for  specific  limitation  are listed  below:

     114.  antimony
     115.  arsenic
     122.  lead
     128.  zinc
           ammonia  (as N)

By establishing limitations  and  standards  for certain toxic metal
pollutants, dischargers  will attain the  same degree of  control
over toxic metal  pollutants  as they would  have been required to
achieve had all the toxic  metal  pollutants been  directly  limited.

This approach is  technically justified since the treatable  con-
centrations used  for lime  precipitation  and sedimentation tech-
nology are based  on optimized treatment  for concommitant  multiple
metals removal.   Thus, even  though metals  have somewhat different
theoretical solubilities,  they will be removed at  very  nearly the
same rate in a lime precipitation and  sedimentation treatment
system operated for multiple metals removal.  Filtration  as part
of the technology basis  is likewise justified because this  tech-
nology removes metals non-preferentially.

The toxic metal pollutants selected for  specific limitation in
the secondary lead subcategory to control  the discharges  of toxic
metal pollutants  are antimony, arsenic,  lead, and  zinc.   The
following toxic pollutants are excluded  from limitation on  the
basis that they are effectively  controlled by the  limitations
developed for the selected toxic metals:

     118.  cadmium
     119.  chromium (Total)
     120.  copper
     124.  nickel
     126.  silver
     127.  thallium

The conventional pollutant parameters  TSS  and pH will be  limited
by the best conventional technology (BCT)  effluent  limitations.
These effluent limitations and a discussion of BCT  are  presented
in Section XIII of this  supplement.

EFFLUENT LIMITATIONS

The treatable concentrations, achievable by application of  the
two BAT technologies (Options B and C) are summarized in Table
VII-19 of the General Development Document.  These  treatable con-
centrations (both one day maximum and  monthly average) are  multi-
plied by the BAT normalized discharge  flows summarized  in Table


                               987
-------
X-4 to calculate the mass of pollutants allowed to be discharged
per mass of product.  The results of these calculations in milli-
grams of pollutant per metric ton of product represent the BAT
effluent limitations for the secondary lead subcategory.  Two
sets of BAT effluent limitations, each based on one of the two
alternative BAT options, have been developed for the secondary
lead subcategory.  BAT effluent limitations based on Option B
(lime precipitation, sedimentation, and in-process flow reduc-
tion) are presented in Table X-5, while limitations based on
Option C (lime precipitation, sedimentation, in-process flow
reduction, and multimedia filtration) are presented in Table X-6,
                               988
-------
                            Table X-l
               CURRENT RECYCLE PRACTICES WITHIN THE
                    SECONDARY LEAD SUBCATEGORY
                         Number of      Number of
                         Plants         Plants         Range of
                         With           Practicing     Recycle
Waste Stream             Wastewater     Recycle        Values (%)

Blast and Reverberatory
 Furnace Wet Atr
 Pollution Control           7              6          83.7-100

Kettle Wet Air
 Pollution Control           9              8          91.7-100
                               989
-------

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                      Table X-3

      COST OF COMPLIANCE FOR THE SECONDARY LEAD
                     SUBCATEGORY
                             Direct Dischargers

                         Capital Cost    Annual Cost
Option                   (1978 Dollars)  (1978 Dollars)

   A                     470,000           288,000
   B                     470,000           228,000
   C                   2,116,000         1,358,000
   D                   2,486,000         1,642,000
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                            Table X-5

   BAT EFFLUENT LIMITATIONS FOR THE SECONDARY LEAD SUBCATEGORY
                       (BASED ON OPTION B)
                         Battery Cracking

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

           Metric Units - mg/kkg of lead scrap produced
      English Units - Ibs/billion Ibs of' lead scrap produced

Antimony                              1,931.51          854.71
Arsenic                               1,406.57          578.78
Lead                                    100.95           87.49
Zinc                                    895.09          376.88
Ammonia (as N)                            0.0             0.0


    Blast and Reverberatory Furnace Wet Air Pollution Control

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

       Metric Units - mg/kkg of lead produced from smelting
  English Units - Ibs/billion Ibs of lead produced from smelting

Antimony                              7,490.7         3,314.7
Arsenic                               5,454.9         2,244.6
Lead                                    391.5           339.3
Zinc                                  3,471.30        1,461.6
Ammonia (as N)                            0.0             0.0


                 Kettle Wet Air Pollution Control

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

   Metric Units - mg/kkg of lead produced from kettle furnaces
   English Units - Ibs/billion Ibs of lead produced from kettle
                             furnaces

Antimony                                  0               0
Arsenic                                   0               0
Lead                                      0               0
Zinc                                      0               0
Ammpnia (as N)                            00
                              994
-------
                      Table X-5 (Continued)

   BAT EFFLUENT LIMITATIONS FOR THE SECONDARY LEAD SUBCATEGORY
                       (BASED ON OPTION B)


                     Casting Contact Cooling

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

                  Metric Units - mg/kkg of lead cast
           English Units - Ibs/billion Ibs of lead cast

Antimony                                 63.43           28.07
Arsenic                                  46.19           19.01
Lead                                      3.32            2.87
Zinc                                     29.39           12.38
Ammonia (as N)                            0.0             0.0
                              995
-------
                            Table X-6

   BAT EFFLUENT LIMITATIONS FOR THE SECONDARY LEAD SUBCATEGORY
                       (BASED ON OPTION C)


                         Battery Cracking

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

           Metric Units - mg/kkg of lead scrap produced
      English Units - Ibs/billion Ibs of lead scrap produced

Antimony                              1,298.89          578.78
Arsenic                                 935.47          383.61
Lead                                     67.30           60.57
Zinc                                    686.46          282.66
Ammonia (as N)                            0.0             0.0


    Blast and Reverberatory Furnace Wet Air Pollution Control

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

       Metric Units - mg/kkg of lead produced from smelting
  English Units - Ibs/billion Ibs of lead produced from smelting

Antimony                              5,037.30        2,244.60
Arsenic                               3,627.90        1,487.70
Lead                                    261.0           234.90
Zinc                                  2,662.20        1,096.20
Ammonia (as N)                            0.0             0.0


                 Kettle Wet Air Pollution Control

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

   Metric Units - mg/kkg of lead produced from kettle furnaces
   English Units - Ibs/billion Ibs of lead produced from kettle
                             furnaces

Antimony                                  0               0
Arsenic                                   0               0
Lead                                      0               0
Zinc                                      0               0
Ammonia (as N)                            0               0
                               996
-------
                      Table X-6 (Continued)

   BAT EFFLUENT LIMITATIONS FOR THE SECONDARY LEAD SUBCATEGORY
                       (BASED ON OPTION C)


                     Casting Contact Cooling

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

                  Metric Units - mg/kkg of lead cast
           English Units - Ibs/billion Ibs of lead cast

Antimony                                 42.65           19.01
Arsenic                                  30.72           12.60
Lead                                      2.21            1.99
Zinc                                     22.54            9.28
Ammonia (as N)                            0.0             0.0
                               997
-------
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                     SECONDARY LEAD SUBCATEGORY

                             SECTION XI

                 NEW SOURCE  PERFORMANCE  STANDARDS


The basis  for new  source performance standards (NSPS)  under
Section 306 of the Act  is  the best available  demonstrated  tech-
nology (BDT).  New plants  have the opportunity to  design the  best
and most efficient production processes  and wastewater treatment
technologies, without facing the  added costs  and restrictions
encountered in retrofitting  an existing  plant.  Therefore,  Con-
gress directed EPA to consider the best  demonstrated process
changes, in-plant  controls,  and end-of-pipe treatment  technolo-
gies which reduce pollution  to the maximum extent  feasible.

This section describes  the control technology for  treatment of
wastewater from new  sources  and presents  mass discharge
limitations of regulatory  pollutants for  NSPS in the secondary
lead subcategory, based on the described  control technology.

TECHNICAL APPROACH TO BDT

As discussed in the  General  Development  Document,  all  of the
treatment technology options  applicable  to a  new source were
previously considered for  the BAT options.  For this reason,  five
options were considered for  BDT,  all identical, with one
exception, to the BAT options discussed  in Section X.   It  is
proposed that the kettle wet  air  pollution control waste stream
be eliminated under  BDT through the  use  of dry air pollution
control.   Dry scrubbing is widely demonstrated  for controlling
emissions from kettle smelting.   Of  the  28 plants  with kettle air
pollution control, 19 use  dry scrubbing.  The Agency also
considered proposing dry scrubbing for controlling emissions  from
blast and reverberatory furnaces,  but the nature of these
emissions precludes  the use  of dry scrubbing.  Exhaust  gases  from
blast and reverberatory furnaces  contain hot  particu-  late
matter, as well as sulfur  dioxide fumes, which requires wet air
pollution scrubbing.

The treatment technologies used for  the five  BDT options are:

OPTION A

     o  Chemical precipitation  and  sedimentation
     o  Dry air pollution  control  of kettle refining,  or alter-
        nately,  complete recycle  of  kettle scrubber liquor
                               1003
-------
OPTION B

     o
     o
Chemical precipitation and sedimentation
Dry air pollution control of kettle refining, or alter-
nately, complete recycle of kettle scrubber liquor
In-process flow reduction of casting contact cooling
water, blast and reverberatory furnace scrubber liquor,
and battery cracking wastewater
OPTION C
        Chemical precipitation and sedimentation
        Dry air pollution control of kettle refining, or alter-
        nately, complete recycle of kettle scrubber liquor
        In-process flow reduction of casting contact cooling
        water, blast and reverberatory furnace scrubber liquor,
        and battery cracking wastewater
        Multimedia filtration
OPTION D
     o  Chemical precipitation and sedimentation
     o  Dry air pollution control of kettle refining, or alter-
        nately, complete recycle of kettle scrubber liquor
     o  In-process flow reduction of casting contact cooling
        water, blast and reverberatory furnace scrubber liquor,
        and battery cracking wastewater
     o  Multimedia filtration
     o  Activated alumina adsorption
OPTION F

     o  Chemical precipitation and sedimentation
     o  Dry air pollution control of kettle refining, or alter-
        nately, complete recycle of kettle scrubber liquor
     o  In-process flow reduction of casting contact cooling
        water, blast and reverberatory furnace scrubber liquor,
        and battery cracking wastewater
     o  Multimedia filtration
     o  Reverse osmosis in conjunction with multiple-effect
        evaporation for complete recycle of treated water

Partial or complete reuse and recycle of wastewater is an
essential part of each option.  Reuse and recycle can precede or
follow end-of-pipe treatment.  A more detailed discussion of
these treatment options is presented in Section X.
                               1004
-------
BDT OPTION SELECTION

EPA is proposing that the best available demonstrated technology
for the secondary lead subcategory be equivalent to BAT technol-
ogy Alternative B (Option C).  The selected option consists of
dry kettle air pollution control methods (or alternately, com-
plete recycle of kettle scrubber liquor), in-process flow reduc-
tion, chemical precipitation, sedimentation, and multimedia fil-
tration.

The Agency recognizes that new sources have the opportunity to
implement more advanced levels of treatment without incurring the
costs of retrofit equipment, the costs of partial or complete
shutdown necessary for installation of the new equipment, and the
costs of startup and stabilization of the treatment system that
existing plants would have.  Specifically, the design of new
plants can be based on recycle of contact cooling waters, recycle
of air pollution control scrubber liquor, and use of dry air
pollution equipment.

Water conservation and advanced wastewater treatment are demon-
strated in the secondary lead subcategory, and they form the
technical basis of BAT.  Therefore, new source performance stan-
dards are equivalent to BAT Alternative B (Option C).  Control of
particulate matter from kettle smelting has been demonstrated
with dry methods, but emissions from blast and reverberatory fur-
naces may not be controlled with a dry method.  Emissions from
these latter two furnaces contain varying concentrations of sul-
fur dioxide which is removed most efficiently with a wet scrub-
ber.  Review of the subcategory indicates that no additional flow
reduction over and above BAT is achievable with currently demon-
strated technology.  Activated alumina and reverse osmosis are
not demonstrated in this subcategory, and are not clearly trans-
ferable to nonferrous metals manufacturing wastewater.

REGULATED POLLUTANT PARAMETERS

The Agency has no reason to believe that the pollutants that will
be found in treatable concentrations in processes within new
sources will be any different than with existing sources.
Accordingly, pollutants and pollutant parameters selected for
limitation under NSPS, in accordance with the rationale of
Sections VI and X, are identical to those selected for BAT.  The
conventional pollutant parameters TSS, and pH are also selected
for limitation.
                               1005
-------
NEW SOURCE PERFORMANCE STANDARDS

The NSPS discharge flows for each wastewater source are the same
as the discharge rates for BAT and are presented in Table XI-1.
The mass of pollutant allowed to be discharged per mass of
product is calculated by multiplying the appropriate achievable
treatment concentration by the production normalized wastewater
discharge flows (1/kkg).  These concentrations are listed in
Table VII-19 of the General Development Document. New source
performance standards are presented in Table XI-2.
                               1006
-------
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                            Table XI-2

             NSPS FOR THE SECONDARY LEAD SUBCATEGORY
                         Battery Cracking
Pollutant or Pollutant Property
 Maxinmm for
 Any One Day
  Maximum for
Monthly Average
           Metric Units - mg/kkg of lead scrap produced
      English Units - Ibs/billion Ibs of lead scrap produced
Antimony
Arsenic
Lead
Zinc
Ammonia (as N)
Total Suspended Solids
PH
    1,298.89          578.78
      935.47          383.61
       67.30           60.57
      686.46          282.66
        0.0             0.0
   10,095.0         8,076.0
Within the range of 7.5 to 10.0
         at all times
    Blast and Reverberatory Furnace Wet Air Pollution Control
Pollutant or Pollutant Property
 Maximum for
 Any One Day
  Maximum for
Monthly Average
       Metric Units - mg/kkg of lead produced from smelting
  English Units - Ibs/billion Ibs of lead produced from smelting
Antimony
Arsenic
Lead
Zinc
Ammonia (as N)
Total Suspended Solids
pH
    5,037.30
    3,627.90
      261.0
    2,662.0
        0
   39,150.0
    2,244.60
    1,487.70
      234.90
    1,096.20
        0
   31,320.0
Within the range of 7.5 to 10.0
         at all times
                            1008
-------
                      Table XI-2  (Continued)

             NSPS FOR THE SECONDARY LEAD SUBCATEGORY
                 Kettle Wet Air Pollution Control
Pollutant or Pollutant Property
 Maximum for
 Any One Day
  Maximum for
Monthly Average
   Metric Units - mg/kkg of lead produced from kettle furnaces
   English Units - Ibs/billion Ibs of lead produced from kettle
                             furnaces
Antimony
Arsenic
Lead
Zinc
Ammonia (as N)
Total Suspended Solids
pH
        0
        0
        0
        0
        0
        0
        0
        0
        0
        0
        0
        0
Within the range of 7.5 to 10.0
         at all times
                     Casting Contact Cooling
Pollutant or Pollutant Property
 Maximum for
 Any One Day
  Maximum for
Monthly Average
                  Metric Units - mg/kkg of cast
           English Units - Ibs/billion Ibs of lead cast
Antimony
Arsenic
Lead
Zinc
Ammonia (as N)
Total Suspended Solids
pH
       42.65
       30.72
        2.21
       22.54
        0.0
      331.50
Within the range of 7.5 to 10.0
         at all times
       19.01
       12.60
        1.99
        9.28
        0.0
      265.20
                             1009
-------
                    SECONDARY LEAD SUBCATEGORY

                           SECTION XII

                      PRETREATMENT STANDARDS


Section 307(b) of the Act requires EPA to promulgate pretreatment
standards for existing sources  (PSES), which must be achieved
within three years of promulgation.  PSES are designed to prevent
the discharge of pollutants which pass through, interfere with,
or are otherwise inco^palible with the operation of publicly
owned treatment works '(POxW) .  The Clean Water Act of 1977
requires pretreatment for pollutants, such as heavy metals, that
limit POTW sludge management alternatives.  Section 307(c) of the
Act requires EPA to promulgate pretreatment standards for new
sources (PSNS) at the same time that it promulgates NSPS.  New
indirect discharge facilities, like new direct discharge facili-
ties, have the opportunity to incorporate the best available
demonstrated technologies, including process changes, in-plant
controls, and end-of-pipe treatment technologies, and to use
plant site selection to ensure adequate treatment system instal-
lation.  Pretreatment standards are to be technology based,
analogous to the best available technology for removal of toxic
pollutants.

This section describes the control and treatment technologies for
pretreatment of process wastewaters from existing sources and new
sources in the secondary lead subcategory.  Pretreatment
standards for regulated pollutants are presented based on the
selected control and treatment technologies.

TECHNICAL APPROACH TO PRETREATMENT

Before proposing pretreatment standards, the Agency examines
whether the pollutants discharged by the industry pass through
the POTW or interfere with the POTW operation or its chosen
sludge disposal practices.  In determining whether pollutants
pass through a well-operated POTW achieving secondary treatment,
the Agency compares the percentage of a pollutant removed by POTW
with the percentage removed by direct dischargers applying the
best available technology economically achievable.  A pollutant
is deemed to pass through the POTW when the average percentage
removed nationwide by well-operated POTW meeting secondary
treatment requirements, is less than the percentage removed by
direct dischargers complying with BAT effluent limitations
guidelines for that pollutant.  (See generally, 46 FR 9415-16
(January 28,  1981).)

This definition of pass through satisfies two competing objec-
tives set by Congress:  (1) that standards for indirect dis-
chargers be equivalent to standards for direct dischargers, while

                              1011
-------
at the same time, (2) that the treatment capability and perfor-
mance of the POTW be recognized and taken into account in regu-
lating the discharge of pollutants from indirect dischargers.
The Agency compares percentage removal rather than the mass or
concentration of pollutants discharged because the latter would
not take into account the mass of pollutants discharged to the
POTW from non-industrial sources nor the dilution of the pollu-
tants in the POTW effluent to lower concentrations due to the
addition of large amounts of non-industrial wastewater.

PRETREATMENT STANDARDS FOR EXISTING AND NEW SOURCES

The treatment technology options for PSES and PSNS are the same
as the BAT Options discussed in Section X.  It is proposed for
PSNS that the kettle furnace air scrubbing waste stream be
eliminated through the use of dry air pollution control. A more
detailed discussion, including pollutants controlled by each
treatment process and achievable treatment concentration for each
option, is presented in Section VII of the General Development
Document.

Treatment technologies considered for PSES and PSNS:

OPTION A

     o  Chemical precipitation and sedimentation
     o  Dry air pollution control of kettle refining, or alter-
        nately, complete recycle of kettle scrubber liquor

OPTION B

     o  Chemical precipitation and sedimentation
     o  Dry air pollution control of kettle refining, or alter-
        nately, complete recycle of kettle scrubber liquor
     o  In-process flow reduction of casting contact cooling
        water, blast and reverberatory furnace scrubber liquor,
        and battery cracking wastewater

OPTION C

     o  Chemical precipitation and sedimentation
     o  Dry air pollution control of kettle refining, or alter-
        nately, complete recycle of kettle scrubber liquor
     o  In-process flow reduction of casting contact cooling
        water, blast and reverberatory furnace scrubber liquor,
        and battery cracking wastewater
     o  Multimedia filtration
                               1012
-------
OPTION D
     o  Chemical precipitation and sedimentation
     o  Dry air pollution control of kettle refining, or alter-
        nately, complete recycle of kettle scrubber  liquor
     o  In-process flow reduction of casting contact cooling
        water, blast and reverberatory furnace scrubber liquor,
        and battery cracking wastewater
     o  Multimedia filtration
     o  Activated alumina adsorption

OPTION F

     o  Chemical precipitation and sedimentation
     o  Dry air pollution control of kettle refining, or alter-
        nately, complete recycle of kettle scrubber  liquor
     o  In-process flow reduction of casting contact cooling
        water, blast and reverberatory furnace scrubber liquor,
        and battery cracking wastewater
     o  Multimedia filtration
     o  Reverse osmosis in conjunction with multiple-effect
        evaporation for complete recycle of treated water

INDUSTRY COST AND POLLUTANT REDUCTION BENEFITS

The industry cost and pollutant reduction benefits of each treat-
ment option were used to determine the most cost-effective
option.  The methodology applied in calculating pollutant
reduction benefits and plant compliance costs is discussed in
Section X.  Table XII-1 shows the estimated pollutant reduction
benefits for indirect dischargers.  Compliance costs are
presented in Table XII-2.

PSES OPTION SELECTION

EPA has selected both Option B and Option C as the basis for
alternative PSES for the secondary lead subcategory.  This selec-
tion follows the rationale used in reflecting the alternative
options as the basis for BAT.  (Refer to Section X.)  The Option
B treatment consists of in-process flow reduction, chemical pre-
cipitation, and sedimentation.  The Option C treatment consists
of dry kettle air pollution control, in-process flow reduction,
chemical precipitation, sedimentation, and multimedia filtration.
This selection flows the rationale used in selected the alterna-
tive options as the basis for BAT.  (Refer to Section X.)
                               1013
-------
The proposed PSES Alternative A (Option B) would remove approxi-
mately 17,130 kg/yr of toxic metal pollutants over the raw dis-
charge and approximately 11,527 kg/yr of ammonia.  The estimated
capital cost of proposed Alternative A is $1.49 million (1978
dollars) and the estimated annual cost is $0.559 million  (1978
dollars).  The proposed PSES Alternative B (Option C) would
remove approximately 17,290 kg/yr of toxic metal pollutants over
raw discharge and approximately 1,527 kg/yr of ammonia.   The
estimated capital cost Alternative B is $3.04 million  (1978
dollars) and the annual cost is $1.94 million (1978 dollars).

Activated alumina (Option D) was considered; however, this tech-
nology was rejected because it was not demonstrated in this
subcategory nor was it clearly transferable to nonferrous waste-
water.  Reverse osmosis (Option F) was considered for the purpose
of achieving zero discharge of process wastewater; however, the
Agency ultimately rejected this technology because it was deter-
mined that its performance for this specific purpose was  not
adequately demonstrated in this subcategory nor was it clearly
transferable from another subcategory.

PSNS OPTION SELECTION

The technology basis for proposed PSNS is identical to NSPS.
The PSNS treatment consists of in-process flow reduction, chemi-
cal precipitation, sedimentation, and multimedia filtration.
The Agency recognizes that new sources have the opportunity to
implement more advanced levels of treatment without incurring the
costs of retrofitting and the costs of partial or complete shut-
down necessary for installation of the new equipment that exist-
ing plants should have.  Therefore, PSNS will be based on the
Option C technology only, rather than considering two alterna-
tives (Options B and C) as in PSES.

EPA knows of no demonstrated technology that provides more
efficient pollutant removal than NSPS technology.  Activated
alumina was considered; however, this technology was rejected
because it was not demonstrated in this subcategory nor was it
clearly transferable to nonferrous wastewater.  No additional
flow reduction for new sources is feasible because the only other
available flow reduction technology, reverse osmosis (Option F) ,
is not demonstrated in the subcategory nor is it clearly
transferable to nonferrous wastewater.
                               1014
-------
REGULATED POLLUTANT PARAMETERS

Pollutants and pollutant parameters selected  for  limitation  in
accordance with the rationale of Sections VI  and  X, are  identical
to those selected for limitation for BAT.  EPA is proposing  PSES
and PSNS for ammonia, antimony, arsenic, lead, and zinc  to pre-
vent pass-through.  The conventional pollutants are not  limited
under PSES and PSNS because they are effectively  controlled  by
POTW.

PRETREATMENT STANDARDS

The PSES and PSNS discharge flows are identical to the BAT dis-
charge flows for all processes.  These discharge  flows are listed
in Table XII-3.  The mass of pollutant allowed to be discharged
per mass of product is calculated by multiplying  the achievable
treatment concentration (mg/1) by the normalized  wastewater  dis-
charge flow (1/kkg).  The achievable treatment concentrations are
presented in Table VII-19 of the General Development Document.
Pretreatment standards for existing and new sources, as  de-
termined from the above procedure, are shown  in Tables XII-4
through XII-6 for each waste stream.
                              1015
-------
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-------
                          Table XII-2

                   COST OF COMPLIANCE FOR THE
                  SECONDARY LEAD SUBCATEGORY
                               Indirect Dischargers

                            Capital Cost       Annual Cost
Option                      (1978 Dollars)     (1978 Dollars)
  A                            1,240,000          558,000
  B                            1,485,000          559,000
  C                            3,037,000        1,944,000
  D                   -         3,910,000        2,310,000
                             1018
-------





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-------
                           Table XII-4

             PSES FOR THE SECONDARY LEAD SUBCATEGORY
                       (BASED ON OPTION B)


                         Battery Cracking

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

           Metric Units - mg/kkg of lead scrap produced
      English Units - Ibs/billion Ibs of lead scrap produced

Antimony                              1,931.51          854.71
Arsenic                               1,406.57          578.78
Lead                                    100.95           87.49
Zinc                                    895.09          376.88
Ammonia (as N)                            0.0             0.0


Blast and Reverberatory Furnace Wet Air Pollution Control

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

       Metric Units - mg/kkg of lead produced from smelting
  English Units - Ibs/billion Ibs of lead produced from smelting

Antimony                              7,490.7         3,314.7
Arsenic                               5,454.9         2,244.6
Lead                                    391.5           339.3
Zinc                                  3,471.30        1,461.6
Ammonia (as N)                            0.0             0.0


                 Kettle Wet Air Pollution Control

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

   Metric Units - mg/kkg of lead produced from kettle furnaces
   English Units - Ibs/billion Ibs of lead produced from kettle
                             furnaces

Antimony                                  0               0
Arsenic                                   0               0
Lead                                      0               0
Zinc                                      0               0
Ammonia (as N)                            00
                             1020
-------
                     Table XII-4 (Continued)

             PSES FOR THE SECONDARY LEAD SUBCATEGORY
                       (BASED ON OPTION B)


                     Casting Contact Cooling

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

                  Metric Units - mg/kkg of lead cast
           English Units - Ibs/billion Ibs of lead cast

Antimony                                 63.43           28.07
Arsenic                                  46.19           19.01
Lead                                      3.32            2.87
Zinc                                     29.39           12.38
Ammonia (as N)                            0.0             0.0
                             1021
-------
                           Table XII-5

             PSES FOR THE SECONDARY LEAD SUBCATEGORY
                       (BASED ON OPTION C)


                         Battery Cracking

                                   Maximum for      Maximum for
Pollutant or Pollutant Property	Any One Day	Monthly Average

           Metric Units - mg/kkg of lead scrap produced
      English Units - Ibs/billion Ibs of lead scrap produced

Antimony                              1,298.89          578.78
Arsenic                                 935.47          383.61
Lead                                     67.30           60.57
Zinc                                    686.46          282.66
Ammonia (as N)                            0.0             0.0


    Blast and Reverberatory Furnace Wet Air Pollution Control

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

       Metric Units - mg/kkg of lead produced from smelting
  English Units - Ibs/billion Ibs of lead produced from smelting

Antimony                              5,037.30        2,244.60
Arsenic                               3,627.90        1,487.70
Lead                                    261.0           234.90
Zinc                                  2,662.20        1,096.20
Ammonia (as N)                            0.0             0.0


                 Kettle Wet Air Pollution Control

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

   Metric Units - mg/kkg of lead produced from kettle furnaces
   English Units - Ibs/billion Ibs of lead produced from kettle
                             furnaces

Antimony                                  0               0
Arsenic                                   0               0
Lead                                      0               0
Zinc                                      0               0
Ammonia (as N)                            00
                             1022
-------
                     Table XII-5 (Continued)

             PSES FOR THE SECONDARY LEAD SUBCATEGORY
                       (BASED ON OPTION C)


                     Casting Contact Cooling

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Pay    Monthly Average

                  Metric Units - mg/kkg of lead cast
           English Units - Ibs/billion Ibs of lead cast

Antimony                                 42.65           19.01
Arsenic                                  30.72           12.60
Lead                                      2.21            1.99
Zinc                                     22.54            9.28
Ammonia (as N)                            0.0             0.0
                             1023
-------
                           Table XII-6

             PSNS FOR THE SECONDARY LEAD SUBCATEGORY


                         Battery Cracking

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

           Metric Units - mg/kkg of lead scrap produced
      English Units - Ibs/billion Ibs of lead scrap produced

Antimony                              1,298.89          578.78
Arsenic                                 935.47          383.61
Lead                                     67.30           60.57
Zinc                                    686.46          282.66
Ammonia (as N)                            0.0             0.0


    Blast and Reverberatory Furnace Wet Air Pollution Control

                                   Maximum for      Maximum for
Pollutantor Pollutant Property    Any One Day    Monthly Average

       Metric Units - mg/kkg of lead produced from smelting
  English Units - Ibs/billion Ibs of lead produced from smelting

Antimony                              5,037.30        2,244.60
Arsenic                               3,627.9         1,487.7
Lead                                    261.0           234.9
Zinc                                  2,662.2         1,096.2
Ammonia (as N)                            0               0


                 Kettle Wet Air Pollution Control

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

   Metric Units - mg/kkg of lead produced from kettle furnaces
   English Units - Ibs/billion Ibs of lead produced from kettle
                             furnaces

Antimony                                  0               0
Arsenic                                   0               0
Lead                                      0               0
Zinc                                      0               0
Ammonia (as N)                            0               0
                              1024
-------
                     Table XII-6 (Continued)

             PSNS FOR THE SECONDARY LEAD SUBCATEGORY


                     Casting Contact Cooling

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

                  Metric Units - mg/kkg of lead cast
           English Units - Ibs/billion Ibs of lead cast

Antimony                                 42.65           19.01
Arsenic                                  30.72           12.60
Lead                                      2.21            1.99
Zinc                                     22.54            9.28
Ammonia (as N)                            0.0             0.0
                             1025
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                    SECONDARY LEAD SUBCATEGORY

                           Section XIII

            Best Conventional Pollutant Control Technology


The 1977 amendments to the Clean Water Act added Section
301(b)(2)(E), establishing "best conventional pollutant control
technology" (BCT) for discharge of conventional pollutants  from
existing industrial point sources.  Biochemical oxygen-demanding
pollutants (6005), total suspended solids  (TSS), fecal coli-
form, oil and grease (OScG), and pH have been designated as
conventional pollutants  (see 44 FR 44501).

BCT is not an additional limitation, but replaces BAT for the
control of conventional pollutants.  In addition to the other
factors specified in Section 304(b)(4)(B), the Act requires that
limitations for conventional pollutants be assessed in light of a
two-part cost-reasonableness test.  On October 29, 1982, the
Agency proposed a revised methodology for carrying out BCT  analy-
ses (47 FR 49176).  The purpose of the proposal was to correct
errors in the BCT methodology originally established in 1977.

Part 1 of the proposed BCT test requires that the cost and  level
of reduction of conventional pollutants by industrial dischargers
be compared with the cost and level of reduction to remove  the
same type of pollutants by publicly-owned treatment works (POTW).
The POTW comparison figure has been calculated by evaluating the
change in costs and removals between secondary treatment (30 mg/1
BOD and 30 mg/1 TSS) and advanced secondary treatment (10 mg/1
BOD and 10 mg/1 TSS).  The difference in cost is divided by the
difference in pounds of conventional pollutants removed, result-
ing in an estimate of the "dollars per pound" of pollutant
removed, that is used as a benchmark value.  The proposed POTW
test benchmark is $0.30 per pound (1978 dollars).

Part 2 of the BCT test requires that the cost and level of  reduc-
tion of conventional pollutants by industrial dischargers be
evaluated internally to the industry.  In order to develop  a
benchmark that assesses a reasonable relationship between cost
and removal,  EPA has developed an industry cost ratio which
compares the dollar per pound of conventional pollutant removed
in going from primary to secondary treatment levels with that of
going from secondary to more advanced treatment levels.  The
basis of costs for the calculation of this ratio are the costs
incurred by a POTW.  EPA used these costs because:  they reflect
the treatment technologies most commonly used to remove conven-
tional pollutants from wastewater; the treatment levels associ-
ated with them compare readily to the levels considered for
industrial dischargers; and the costs are the most reliable for
the treatment levels under consideration.  The proposed industry


                              1027
-------
subcategory benchmark is 1.42.  If the industry figure for a
subcategory is lower than 1.43, the subcategory passes the BCT
test.

The Agency usually considers two conventional pollutants in the
cost test, TSS and an oxygen-demanding pollutant.  Although both
oil and grease and BOD5 are considered to be oxygen-demanding
substances by EPA (see 44 FR 50733), only one can be selected in
the cost analysis to conform to procedures used to develop POTW
costs.  Oil and grease is used rather than BOD5 in the cost
analysis performed for nonferrous metals manufacturing waste
streams due to the common use of oils in casting operations in
this industry.

BPT is the base for evaluating limitations on conventional
pollutants (i.e., it is assumed that BPT is already in place).
The test evaluates the cost and removals associated with treat-
ment and controls in addition to that specified as BPT.

If the conventional pollutant removal cost of the candidate BCT
is less than the POTW cost, Part 1 of the cost-reasonableness
test is passed and Part 2 (the internal industry test) of the
cost-reasonableness test must be performed.  If the internal
industry test is passed, then a BCT limitation is promulgated
equivalent to the candidate BCT level.  If all candidate BCT
technologies fail both parts of the cost-reasonableness test, the
BCT requirements for conventional pollutants are equal to BPT.

The BCT test was performed for the proposed BAT basis of lime
precipitation, sedimentation, in-process flow reduction, and
multimedia filtration.  The secondary lead subcategory failed
Part 1 of the test with a calculated cost of $179.94 per pound
(1978 dollars) of removal of conventional pollutants using BAT
technology.  The intermediate flow reduction option was also
examined, but it too failed with a cost of $15.34 per pound (1978
dollars) of conventional removal.
                               1028
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                           Table XIII-1

   BCT EFFLUENT LIMITATIONS FOR THE SECONDARY LEAD SUBCATEGORY


                         Battery Cracking

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

           Metric Units - mg/kkg of lead scrap produced
      English Units - Ibs/billion Ibs of lead scrap produced

Total Suspended Solids               38,540.0        18,800.0
pH                                Within the range of 7.5 to 10.0
                                           at all times


    Blast and Reverberatory Furnace Wet Air Pollution Control

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day	Monthly Average

       Metric Units - mg/kkg of lead produced from smelting
  English Units - Ibs/billion Ibs of lead produced from smelting

Total Suspended Solids              138,580.0        67,600.0
pH                                Within the range of 7.5 to 10.0
                                           at all times


                 Kettle Wet Air Pollution Control

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

   Metric Units - mg/kkg of lead produced from kettle furnaces
   English Units - Ibs/billion Ibs of lead produced from kettle
                             furnaces

Total Suspended Solids                    0               0
pH                                Within the range of 7.5 to 10.0
                                           at all times
                              1029
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                     Table XIII-1 (Continued)

   BCT EFFLUENT LIMITATIONS FOR THE SECONDARY  LEAD SUBCATEGORY


                     Casting Contact Cooling

                                   Maximum for      Maximum for
Pollutant or Pollutant Property    Any One Day    Monthly Average

                  Metric Units - mg/kkg of lead cast
           English Units - Ibs/billion Ibs of  lead cast

Total Suspended Solids                9,069.20        4,424.0
pH                                Within the range of 7.5 to 10.0
                                           at  all times
                               1030
-------