United States       Effluent Guidelines Division

Envi,— Protection  .  , VH K      EPA-440/ 1-84-019-B 02/84
Water and Waste Management
Development      Proposed
Document for
Effluent Limitations
Guidelines and
Standards for the
IMonferrous Metals
Forming and Iron and Steel,
Copper Forming,
Aluminum Metal
Powder Production and
Powder Metallurgy
Point Source Category

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USB
         \
          APR
              UNiTED STATES
    ENVIRONMENTAL PROTECTION AGENCY
                 REGION 5
            230 SOUTH DEARBORN ST
1984         CHICAGO. ILLINOIS 60604
Re:  Proposed Development Document on Effluent
     Guidelines for the Nonferrous Metals Forming
     and Iron and Steel/Copper/Al uminum Metal
     Powder Production and Powder Metallurgy
     Industrial Category
     (EPA 440/1-84/019-B)

To:  See Below
                                                                    REPLY TO ATTENTION OF
                                                                        5WQP-11
   Enclosed for your information  and  use  is  a  copy  of  the  proposed Development

   Document published by  the  U.S.  EPA Effluent  Guidelines  Division for the

   Nonferrous Metals Forming  and  Iron and Steel/Copper/Aluminum Metal

   Powder Production and  Powder Metallurgy industrial  category.   If you

   have any questions, please call  Lorraine  Kosik at  (312) 886-6108.

   Sincerely,
Lorraine Kosik
Regional Effluent Guidelines Specialist

Enclosure
Addressees:
(w/enclosure)
Mr. Thomas McSwiggin, IEPA
Mr. Larry Kane, ISPCB
Mr. William McCracken, MDNR (5)
Mr. Curtis Sparks, MPCA
Mr. Robert Phelps, OEPA (5)
Mr. Mike Witt, WDNR
Ms. Angela Tin, IEPA
Mr. Lon Brumfield, ISPCB
Mr. Bruce Moore, MDNR
Mr. Randy Dunnette, MPCA
Mr. Mehmet Tin, OEPA
Mr. Stan Kleinert, WDNR

bcc:  (w/enclosure)
      Tilley/Library
      Eastern District Office
      Central District Office

      (w/o enclosure)
      Librarian, EPS, Toronto
      Eastern District Office
        (Grosse lie)
                                              bcc:   (w/o  enclosure)
                                                    Sutfi n/Bryson
                                                    Cayer/Horn
                                                    Fenner
                                                    Mustard/DiDornenico
                                                    Marizardo
                                                    Dzikowski
                                                    Newman
                                                    Clemens
                                                    Poloncsik
                                                    Ross/CRL
                                                    Pratt
                                                    Barney
                                                    Gierczak
                                                    Robichaud
                                                    Jones
                                                    Diks
                                                    Barriball
                                                    LeBlanc
                                                    Duckman
                                                    Argi roff
                                                    Henry
                                                    Kosik
                                                    Waldron

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            DEVELOPMENT DOCUMENT
                     for

EFFLUENT LIMITATIONS GUIDELINES AND  STANDARDS
                   for the
NONFERROUS METALS FORMING AND  IRON AND STEEL/
   COPPER/ALUMINUM METAL POWDER PRODUCTION
 AND POWDER METALLURGY POINT SOURCE  CATEGORY
            William D.  Ruckelshaus
                Adminis trator


                Jack E. Ravan
      Assistant Administrator  for Water
          Steven Schatzow,  Director
  Office of Water Regulations  and Standards
                  \mj
          Jeffery D.  Denit, Director
         Effluent Guidelines Division
           G.  Edward Stigall, Chief
          Inorganic Chemicals Branch
               Thomas  Fielding
          Technical  Project Officer


                February  1984
     U.S.  Environmental  Protection Agency
               Office of Water
  Office of Water Regulations and Standards
         Effluent Guidelines Division
           Washington, D.C.  20460

   U.S. Environ--'-'-I - '^io
   Region '-'. ' .'•'•"'•-    _ ..^
   230 So^-..•'

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Ut6. Environment':! Prelection Agency

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                        TABLE OF CONTENTS


Section                                                      Page

          LIST OF FIGURES 	

          LIST OF TABLES	

          ACKNOWLEDGEMENT 	

I         SUMMARY AND CONCLUSIONS 	       1

II        RECOMMENDATIONS 	       5

          SUBPART A.  BPT MASS LIMITATIONS FOR THE
          BERYLLIUM FORMING SUBCATEGORY  	       5

          SUBPART B.  BPT MASS LIMITATIONS FOR THE
          LEAD/TIN/BISMUTH FORMING SUB CATEGORY	       8

          SUBPART C.  BPT MASS LIMITATIONS FOR THE
          MAGNESIUM FORMING SUBCATEGORY  	     13

          SUBPART D.  BPT MASS LIMITATIONS FOR THE
          NICKEL/COBALT FORMING SUBCATEGORY 	     16

          SUBPART E.  BPT MASS LIMITATIONS FOR THE
          PRECIOUS METALS FORMING SUBCATEGORY 	     25

          SUBPART F.  BPT MASS LIMITATIONS FOR THE
          REFRACTORY METALS FORMING SUBCATEGORY 	     36

          SUBPART G.  BPT MASS LIMITATIONS FOR THE
          TITANIUM FORMING SUBCATEGORY	     47

          SUBPART H.  BPT MASS LIMITATIONS FOR THE
          URANIUM FORMING SUBCATEGORY 	     54

          SUBPART I.  BPT MASS LIMITATIONS FOR THE
          ZINC FORMING SUBCATEGORY	     58

          SUBPART J.  BPT MASS LIMITATIONS FOR THE
          ZIRCONIUM/HAFNIUM FORMING SUBCATEGORY 	     62

          SUBPART K.  BPT MASS LIMITATIONS FOR THE
          IRON AND STEEL/COPPER/ALUMINUM METAL POWDER
          PRODUCTION AND POWDER METALLURGY SUBCATEGORY.  .     68

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                  TABLE OF CONTENTS (Continued)
Section                                                     Page

II        SUBPART A.  BAT MASS LIMITATIONS FOR THE
          BERYLLIUM FORMING SUBCATEGORY 	     72

          SUBPART B.  BAT MASS LIMITATIONS FOR THE
          LEAD/TIN/BISMUTH FORMING SUBCATEGORY	     74

          SUBPART C.  BAT MASS LIMITATIONS FOR THE
          MAGNESIUM FORMING SUBCATEGORY 	     77

          SUBPART D.  BAT MASS LIMITATIONS FOR THE
          NICKEL/COBALT FORMING SUBCATEGORY 	     80

          SUBPART E.  BAT MASS LIMITATIONS FOR THE
          PRECIOUS METALS FORMING SUBCATEGORY 	     88

          SUBPART F.  BAT MASS LIMITATIONS FOR THE
          REFRACTORY METALS FORMING SUBCATEGORY 	     95

          SUBPART G.  BAT MASS LIMITATIONS FOR THE
          TITANIUM FORMING SUBCATEGORY	    105

          SUBPART H.  BAT MASS LIMITATIONS FOR THE
          URANIUM FORMING SUBCATEGORY 	    110

          SUBPART I.  BAT MASS LIMITATIONS FOR THE
          ZINC FORMING SUBCATEGORY	    113

          SUBPART J.  BAT MASS LIMITATIONS FOR THE
          ZIRCONIUM/HAFNIUM FORMING SUBCATEGORY 	    117

          SUBPART K.  BAT MASS LIMITATIONS FOR THE
          IRON AND STEEL/COPPER/ALUMINUM METAL POWDER
          PRODUCTION AND POWDER METALLURGY SUBCATEGORY.  .    121

          SUBPART A.  NSPS FOR THE BERYLLIUM FORMING
          SUBCATEGORY	    124

          SUBPART B.  NSPS FOR THE LEAD/TIN/BISMUTH
          FORMING SUBCATEGORY 	    126

          SUBPART C.  NSPS FOR THE MAGNESIUM FORMING
          SUBCATEGORY	    126
                              IV

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                  TABLE OF CONTENTS (Continued)


Section                                                     Page

II        SUBPART D.  NSPS FOR THE NICKEL/COBALT
          FORMING SUBCATEGORY 	      127

          SUBPART E.  NSPS FOR THE PRECIOUS METALS
          FORMING SUBCATEGORY 	      127

          SUBPART F.  NSPS FOR THE REFRACTORY METALS
          FORMING SUBCATEGORY 	      137

          SUBPART G.  NSPS FOR THE TITANIUM FORMING
          SUBCATEGORY	      148

          SUBPART H.  NSPS FOR THE URANIUM FORMING
          SUBCATEGORY	      148

          SUBPART I.  NSPS FOR THE ZINC FORMING
          SUBCATEGORY	      148

          SUBPART J.  NSPS FOR THE ZIRCONIUM/HAFNIUM
          FORMING SUBCATEGORY 	      152

          SUBPART K.  NSPS FOR THE IRON AND STEEL/
          COPPER/ALUMINUM METAL POWDER PRODUCTION
          AND POWDER METALLURGY SUBCATEGORY 	      158

          SUBPART A.  PSES FOR THE BERYLLIUM FORMING
          SUBCATEGORY	    158

          SUBPART B.  PSES FOR THE LEAD/TIN/BISMUTH
          FORMING SUBCATEGORY 	    158

          SUBPART C.  PSES FOR THE MAGNESIUM FORMING
          SUBCATEGORY	    158

          SUBPART D.  PSES FOR THE NICKEL/COBALT
          FORMING SUBCATEGORY 	      158

          SUBPART E.  PSES FOR THE PRECIOUS METALS
          FORMING SUBCATEGORY 	      159

          SUBPART F.  PSES FOR THE REFRACTORY METALS
          FORMING SUBCATEGORY 	      159

          SUBPART G.  PSES FOR THE TITANIUM FORMING
          SUBCATEGORY	      159

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                  TABLE OF CONTENTS (Continued)
Section
II        SUBPART A.  BCT MASS LIMITATIONS FOR THE
          BERYLLIUM FORMING SUBCATEGORY 	    162

          SUBPART B.  BCT MASS LIMITATIONS FOR THE
          LEAD/TIN/BISMUTH FORMING SUBCATEGORY	    162

          SUBPART C.  BCT MASS LIMITATIONS FOR THE
          MAGNESIUM FORMING SUBCATEGORY 	    167

          SUBPART D.  BCT MASS LIMITATIONS FOR THE
          NICKEL/COBALT FORMING SUBCATEGORY 	    169

          SUBPART E.  BCT MASS LIMITATIONS FOR THE
          PRECIOUS METALS FORMING SUBCATEGORY 	    177

          SUBPART F.  BCT MASS LIMITATIONS FOR THE
          REFRACTORY METALS FORMING SUBCATEGORY 	    177

          SUBPART G.  BCT MASS LIMITATIONS FOR THE
          TITANIUM FORMING SUBCATEGORY	    177

          SUBPART H.  BCT MASS LIMITATIONS FOR THE
          URANIUM FORMING SUBCATEGORY 	    182

          SUBPART I.  BCT MASS LIMITATIONS FOR THE
          ZINC FORMING SUBCATEGORY	    185

          SUBPART J.  BCT MASS LIMITATIONS FOR THE
          ZIRCONIUM/HAFNIUM FORMING SUBCATEGORY 	    185

          SUBPART K.  BCT MASS LIMITATIONS FOR THE
          IRON AND STEEL/COPPER/ALUMINUM METAL POWDER
          PRODUCTION AND POWDER METALLURGY SUBCATEGORY. .    189

          SUBPART A.  ALTERNATE BAT MASS LIMITATIONS
          FOR THE BERYLLIUM FORMING SUBCATEGORY 	    192

          SUBPART B.  ALTERNATE BAT MASS LIMITATIONS
          FOR THE LEAD/TIN/BISMUTH FORMING SUBCATEGORY. .    194

          SUBPART C.  ALTERNATE BAT MASS LIMITATIONS
          FOR THE MAGNESIUM FORMING SUBCATEGORY 	    198

          SUBPART D.  ALTERNATE BAT MASS LIMITATIONS
          FOR THE NICKEL/COBALT FORMING SUBCATEGORY .   . .    200
                              VI

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                  TABLE OF CONTENTS (Continued)


Section                                                     Page

II        SUBPART E.  ALTERNATE BAT MASS LIMITATIONS
          FOR THE PRECIOUS METALS FORMING SUBCATEGORY  .  .    208

          SUBPART F.  ALTERNATE BAT MASS LIMITATIONS
          FOR THE REFRACTORY METALS FORMING SUBCATEGORY  .    216

          SUBPART G.  ALTERNATE BAT MASS LIMITATIONS
          FOR THE TITANIUM FORMING SUBCATEGORY	    226

          SUBPART H.  ALTERNATE BAT MASS LIMITATIONS
          FOR THE URANIUM FORMING SUBCATEGORY 	    230

          SUBPART I.  ALTERNATE BAT MASS LIMITATIONS
          FOR THE ZINC FORMING SUBCATEGORY	    234

          SUBPART J.  ALTERNATE BAT MASS LIMITATIONS
          FOR THE ZIRCONIUM/HAFNIUM FORMING SUBCATEGORY  .    237

          SUBPART K.  ALTERNATE BAT MASS LIMITATIONS
          FOR THE IRON AND STEEL/COPPER/ALUMINUM METAL
          POWDER PRODUCTION AND POWDER METALLURGY
          SUBCATEGORY	    243

          SUBPART A.  ALTERNATE NSPS FOR THE BERYLLIUM
          FORMING SUBCATEGORY 	    246

          SUBPART B.  ALTERNATE NSPS FOR THE LEAD/TIN/
          BISMUTH FORMING SUBCATEGORY 	    248

          SUBPART C.  ALTERNATE NSPS FOR THE MAGNESIUM
          FORMING SUBCATEGORY 	    253

          SUBPART D.  ALTERNATE NSPS FOR THE NICKEL/
          COBALT FORMING SUBCATEGORY	    257

          SUBPART E.  ALTERNATE NSPS FOR THE PRECIOUS
          METALS FORMING SUBCATEGORY	    266

          SUBPART F.  ALTERNATE NSPS FOR THE REFRACTORY
          METALS FORMING SUBCATEGORY	    277

          SUBPART G.  ALTERNATE NSPS FOR THE TITANIUM
          FORMING SUBCATEGORY 	    288

          SUBPART H.  ALTERNATE NSPS FOR THE URANIUM
          FORMING SUBCATEGORY 	    294
                              Vll

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                  TABLE OF CONTENTS (Continued)


Section                                                     Page

II        SUBPART I.  ALTERNATE NSPS FOR THE ZINC
          FORMING SUBCATEGORY ... 	    299

          SUBPART J.  ALTERNATE NSPS FOR THE ZIRCONIUM/
          HAFNIUM FORMING SUBCATEGORY 	    303

          SUBPART K.  ALTERNATE NSPS FOR THE IRON AND
          STEEL/COPPER/ALUMINUM METAL POWDER PRODUCTION
          AND POWDER METALLURGY SUBCATEGORY 	    304

          SUBPART A.  ALTERNATE PSES FOR THE BERYLLIUM
          FORMING SUBCATEGORY 	    308

          SUBPART B.  ALTERNATE PSES FOR THE LEAD/TIN/
          BISMUTH FORMING SUBCATEGORY 	    308

          SUBPART C.  ALTERNATE PSES FOR THE MAGNESIUM
          FORMING SUBCATEGORY 	    308

          SUBPART D.  ALTERNATE PSES FOR THE NICKEL/
          COBALT FORMING SUBCATEGORY	    308

          SUBPART E.  ALTERNATE PSES FOR THE PRECIOUS
          METALS FORMING SUBCATEGORY	    308

          SUBPART F.  ALTERNATE PSES FOR THE REFRACTORY
          METALS FORMING SUBCATEGORY	    308

          SUBPART G.  ALTERNATE PSES FOR THE TITANIUM
          FORMING SUBCATEGORY 	    308

          SUBPART H.  ALTERNATE PSES FOR THE URANIUM
          FORMING SUBCATEGORY 	    308

          SUBPART I.  ALTERNATE PSES FOR THE ZINC
          FORMING SUBCATEGORY 	    309

          SUBPART J.  ALTERNATE PSES FOR THE ZIRCONIUM/
          HAFNIUM FORMING SUBCATEGORY 	    309

          SUBPART K.  ALTERNATE PSES FOR THE IRON AND
          STEEL/COPPER/ALUMINUM METAL POWDER PRODUCTION
          AND POWDER METALLURGY SUBCATEGORY 	    309
                             viii

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                  TABLE OF CONTENTS  (Continued)


Section                                                      Page

II        SUBPART A.  ALTERNATE PSNS FOR THE BERYLLIUM
          FORMING SUBCATEGORY  	     310

          SUBPART B.  ALTERNATE PSNS FOR THE LEAD/TIN/
          BISMUTH FORMING SUBCATEGORY  	     310

          SUBPART C.  ALTERNATE PSNS FOR THE MAGNESIUM
          FORMING SUBCATEGORY  	     310

          SUBPART D.  ALTERNATE PSNS FOR THE NICKEL/
          COBALT FORMING SUBCATEGORY	     310

          SUBPART E.  ALTERNATE PSNS FOR THE PRECIOUS
          METALS FORMING SUBCATEGORY	     310

          SUBPART F.  ALTERNATE PSNS FOR THE REFRACTORY
          METALS FORMING SUBCATEGORY	     310

          SUBPART G.  ALTERNATE PSNS FOR THE TITANIUM
          FORMING SUBCATEGORY  	     311

          SUBPART H.  ALTERNATE PSNS FOR THE URANIUM
          FORMING SUBCATEGORY  	     311

          SUBPART I.  ALTERNATE PSNS FOR THE ZINC
          FORMING SUBCATEGORY  	     311

          SUBPAPv.T J.  ALTERNATE PSNS FOR THE ZIRCONIUM/
          HAFNIUM FORMING SUBCATEGORY  	     311

          SUBPART K.  ALTERNATE PSNS FOR THE IRON AND
          STEEL/COPPER/ALUMINUM METAL  POWDER PRODUCTION
          AND POWDER METALLURGY SUBCATEGORY 	     311

III       INTRODUCTION	     313

          LEGAL AUTHORITY	     313

          GUIDELINES DEVELOPMENT SUMMARY	     315

          Sources of Industry Data	     316
          Utilization of Industry Data	     320
                              IX

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                  TABLE OF CONTENTS (Continued)


Section                                                     Page

III       DESCRIPTION OF THE NONFERROUS METALS FORMING
          CATEGORY	    320

          Historical	    322
          Product Description 	    323
          Wastewater Generation and Treatment  ......    325

          DESCRIPTION OF NONFERROUS METALS FORMING
          PROCESSES	    326

          Nonferrous Metals Forming Operations	    328
          Operations Associated With Nonferrous Metals
          Forming	    337

IV        INDUSTRY SUBCATEGORIZATION	    379

          EVALUATION AND SELECTION OF SUBCATEGORIZATION
          FACTORS	    379

          Factors Considered	    379
          Summary of Subcategorization	    385

          PRODUCTION NORMALIZING PARAMETER SELECTION. ,.   .    386

          Selection of the Production Normalizing
          Parameter	    387

          DESCRIPTION OF SUBCATEGORIES	    387

V         WATER USE AND WASTEWATER CHARACTERISTICS.  . .   .    393

          DATA SOURCES	    393

          Telephone Survey	    393
          Data Collection Portfolios	    393
          Sampling and Analysis Program 	    394
          Historical Data	    400

          WATER USE AND WASTEWATER CHARACTERISTICS.  ...    401

          Lead/Tin/Bismuth Forming Subcategory	    402
          Nickel/Cobalt Forming Subcategory 	    407
          Zinc Forming Subcategory	    415
          Beryllium Forming Subcategory 	    419
          Precious Metals Forming Subcategory  	    422

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                  TABLE OF CONTENTS (Continued)


Section                                                     Page

V         Iron and Steel/Copper/Aluminum Metal Powder
          Production and Powder Metallurgy Subcategory .      429
          Titanium Forming Subcategory 	      433
          Refractory Metals Forming Subcategory	      438
          Zirconium/Hafnium Forming Subcategory	      447
          Magnesium Forming Subcategory	      452
          Uranium Forming Subcategory	      455

VI        SELECTION OF POLLUTANT PARAMETERS	      479

          RATIONALE FOR SELECTION OF POLLUTANT
          PARAMETERS	      480

          DESCRIPTION OF POLLUTANT PARAMETERS	      483

          POLLUTANT SELECTION BY SUBCATEGORY 	      483

          Pollutant Selection for Lead/Tin/Bismuth
          Forming	      483
          Pollutant Selection for Nickel/Cobalt Forming.      486
          Pollutant Selection for Zinc Forming 	      490
          Pollutant Selection for Beryllium Forming.  .  .      491
          Pollutant Selection for Precious Metals
          Forming	      493
          Pollutant Selection for Iron and Steel/Copper/
          Aluminum Metal Powder Production and Powder
          Metallurgy	      497
          Pollutant Selection for Titanium Forming .  .  .      500
          Pollutant Selection for Refractory Metals
          Forming	      503
          Pollutant Selection for Zirconium/Hafnium
          Forming	      507
          Pollutant Selection for Magnesium Forming.  .  .      510
          Pollutant Selection for Uranium Forming. .  .  .      513

VII       CONTROL AND TREATMENT TECHNOLOGY 	      561

          END-OF-PIPE TREATMENT TECHNOLOGIES 	      561

          MAJOR TECHNOLOGIES	      562

          Chemical Emulsion Breaking 	      562
          Skimming	      564
          Ammonia Stripping	      566
          Cyanide Precipitation	      569
                              XI

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                  TABLE OF CONTENTS (Continued)
Section
VII       Chemical Reduction of Chromium 	      571
          Chemical Precipitation 	      573
          Sedimentation	      580
          Granular Bed Filtration	      583
          Vacuum Filtration	      587

          MAJOR TECHNOLOGY EFFECTIVENESS 	      588

          L&S Performance - Combined Metals  Data Base
          (CMDB)	      588
          One-Day Effluent Values	      593
          Average Effluent Values	      596
          Application.  .  .	      598
          Additional Pollutants	      599
          Ammonia Steam Stripping Performance	      600
          LS&F Performance	      601
          Analysis of Treatment System Effectiveness  .  .      602

          MINOR TECHNOLOGIES	      605

          Flotation	      605
          Centrifugation 	      605
          Coalescing	      606
          Cyanide Oxidation by Chlorine	      607
          Cyanide Oxidation by Ozone 	      607
          Cyanide Oxidation by Ozone with UV Radiation  .      608
          Evaporation	      608
          Gravity Sludge Thickening	      609
          Ion Exchange	      609
          Membrane Filtration	      610
          Reverse Osmosis	      610
          Sludge Bed Drying	      611
          Thermal Emulsion Breaking	      612
          Ultrafiltration	      612

          IN-PLANT TECHNOLOGIES	      613

          Process Water Recycle	      613
          Process Water Reuse	      616
          Countercurrent Cascade Rinsing 	      616
          Spray Rinsing	      620
          Regeneration of Chemical Baths 	      620
          Contract Hauling	•      622
          Process Water Use Reduction	      622
          Wastewater Segregation 	  .      624
                              Xll

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                  TABLE OF CONTENTS (Continued)
Section
VII
VIII
IX
Lubricating Oil and Deoiling Solvent Recovery .     625
Dry Air Pollution Control Devices 	     626
Good Housekeeping	     628

COST OF WASTEWATER TREATMENT AND CONTROL.  ...     651

GENERAL APPROACH	     651

Selection of Representative Plants	     652
Costing the Representative Plants 	     655
Estimation of Subcategory and Total Category
Costs	     656
Drawbacks of This Cost Estimation Methodology .     658

COST ESTIMATION METHODOLOGY 	     661

Sources of Cost Data	     661
Components of Costs	     661
Cost Update Factors 	 .....     662
Cost Estimation Model 	     663
Cost Estimates for Individual Treatment
Technologies	     666

NONWATER QUALITY ASPECTS	     678

Air Pollution	     678
Solid Waste	     678
Consumptive Water Loss	     680
Energy Requirements 	     680

BEST PRACTICABLE CONTROL TECHNOLOGY CURRENTLY
AVAILABLE	     695

TECHNICAL APPROACH TO BPT	     695

Effluent Limitations	     696
Treatment Train 	     696
Effluent Concentrations 	     697
Discharge Flows 	     697
Regulated Pollutant Parameters	     698

LEAD/TIN/BISMUTH FORMING SUBCATEGORY	     699

Production Operations and Discharge Flows  .  . .     699
                             Xlll

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                  TABLE OF CONTENTS (Continued)
Section                                                     Page

IX        Calculation of BPT Effluent Mass  Limitations  .      704
          Costs and Benefits	      704

          NICKEL/COBALT FORMING SUBCATEGORY	      704

          Production Operations and Discharge Flows.  .  .      704
          Calculation of BPT Effluent Mass  Limitations  .      711
          Costs and Benefits	      711

          ZINC FORMING SUBCATEGORY 	      712

          Production Operations and Discharge Flows.  .  .      712
          Calculation of BPT Effluent Mass  Limitations  .      715
          Costs and Benefits	      715

          BERYLLIUM FORMING SUBCATEGORY	      715

          Production Operations and Discharge Flows.  .  .      715
          Calculation of BPT Effluent Mass  Limitations  .      716
          Costs and Benefits	      716

          PRECIOUS METALS FORMING SUBCATEGORY	      717

          Production Operations and Discharge Flows.  .  .      717
          Calculation of BPT Effluent Mass  Limitations  .      722
          Costs and Benefits	      722

          IRON AND STEEL/COPPER/ALUMINUM METAL POWDER
          PRODUCTION AND POWDER METALLURGY  SUBCATEGORY  .      722

          Production Operations and Discharge Flows.  .  .      722
          Calculation of BPT Effluent Mass  Limitations  .      724
          Costs and Benefits	      724

          TITANIUM FORMING SUBCATEGORY 	      725

          Production Operations and Discharge Flows.  .  .      725
          Calculation of BPT Effluent Mass  Limitations  .      728
          Costs and Benefits	      728

          REFRACTORY METALS FORMING SUBCATEGORY	      729

          Production Operations and Discharge Flows.  .  .      729
          Calculation of BPT Effluent Mass  Limitations  .      735
          Costs and Benefits	      735
                             XIV

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                  TABLE OF CONTENTS (Continued)


Section

IX        ZIRCONIUM/HAFNIUM FORMING SUBCATEGORY	      735

          Production Operations and Discharge Flows.  .  .      735
          Calculation of BPT Effluent Mass Limitations  .      738
          Costs and Benefits	      738

          MAGNESIUM FORMING SUBCATEGORY	      739

          Production Operations and Discharge Flows.  .  .      739
          Calculation of BPT Effluent Mass Limitations  .      741
          Costs and Benefits	      741

          URANIUM FORMING SUBCATEGORY	      741

          Production Operations and Discharge Flows.  .  .      741
          Calculation of BPT Effluent Mass Limitations  .      743
          Costs and Benefits	      744

          APPLICATION OF REGULATIONS IN PERMITS	      744

          Example 1	      744
          Example 2	      745
          Example 3	      745

X         BEST AVAILABLE TECHNOLOGY ECONOMICALLY
          ACHIEVABLE	      785

          TECHNICAL APPROACH TO BAT	      785

          Option 1	      787
          Option 2	      787
          Option 3	      788
          Estimation of BAT Options Costs and Benefits  .      788

          BAT OPTION SELECTION 	      795

          REGULATED POLLUTANT PARAMETERS 	      797

          APPLICATION OF FLOW REDUCTION TECHNOLOGY ...      797

          Production Operations and Discharge Flows
          for Which Applicable Flow Reduction Technol-
          ogy Could Not Be Identified	      797
          Lead/Tin/Bismuth Forming Subcategory	      798
          Nickel/Cobalt Forming Subcategory	      798
                              XV

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                  TABLE OF CONTENTS (Continued)
Section
X         Zinc Forming Subcategory 	      798
          Beryllium Forming Subcategory	      798
          Precious Metals Forming Subcategory	      798
          Iron and Steel/Copper/Aluminum Metal Powder
          Production and Powder Metallurgy Subcategory  .      799
          Titanium Forming Subcategory 	      799
          Refractory Metals Forming Subcategory	      799
          Zirconium/Hafnium Forming Subcategory	      799
          Magnesium Forming Subcategory	      799
          Uranium Forming Subcategory	      799
          Waste Stream Flow Reduced at BPT	      800
          Lead/Tin/Bismuth Forming Subcategory	      800
          Nickel/Cobalt Forming Subcategory	      800
          Zinc Forming Subcategory 	      800
          Beryllium Forming Subcategory	      801
          Precious Metals Forming Subcategory	      801
          Iron and Steel/Copper/Aluminum Metal Powder
          Production and Powder Metallurgy Subcategory  .      801
          Titanium Forming Subcategory 	      801
          Refractory Metals Forming Subcategory	      802
          Zirconium/Hafnium Forming Subcategory	      802
          Magnesium Forming Subcategory	      802
          Uranium Forming Subcategory	      803
          Flow Reduced Contact Cooling Water - BAT
          Discharge Allowances 	      803
          Lead/Tin/Bismuth Forming Subcategory	      803
          Nickel/Cobalt Forming Subcategory	      803
          Zinc Forming Subcategory 	      804
          Precious Metals Forming Subcategory	      804
          Titanium Forming Subcategory 	      804
          Refractory Metals Forming Subcategory	      804
          Zirconium/Hafnium Forming Subcategory	      805
          Magnesium Forming Subcategory	      805
          Uranium Forming Subcategory	      805
          Flow-Reduced Rinsewater - BAT Discharge
          Allowances	      805
          Lead/Tin/Bismuth Forming Subcategory 	      805
          Nickel/Cobalt Forming Subcategory	      805
          Zinc Forming Subcategory 	      805
          Beryllium Forming Subcategory	      806
          Precious Metals Forming Subcategory	      806
          Titanium Forming Subcategory 	      806
          Refractory Metals Forming Subcategory	      806
          Zirconium/Hafnium Forming Subcategory	      806
          Magnesium Forming Subcategory	      806
          Uranium Forming Subcategory	      806
                              XVI

-------
                  TABLE OF CONTENTS (Continued)
Section
X         Flow-Reduced Emulsions - BAT Discharge
          Allowances	     807
          Precious Metals Forming Subcategory	     807
          Titanium Forming Subcategory 	     807
          Flow-Reduced Wet Air Pollution Control
          Slowdown - BAT Discharge Allowances	     807
          Lead/Tin/Bismuth Forming Subcategory 	     807
          Precious Metals Forming Subcategory	     807
          Iron and Steel/Copper/Aluminum Metal Powder
          Production and Powder Metallurgy Subcategory .     808
          Titanium Forming Subcategory 	     808
          Refractory Metals Forming Subcategory	     808
          Uranium Forming Subcategory	     808
          Miscellaneous Flow-Reduced Waste Streams -
          BAT Discharge Flow Allowances	     808
          Nickel/Cobalt Forming Subcategory	     808
          Precious Metals Forming Subcategory	     809
          Iron and Steel/Copper/Aluminum Metal Powder
          Production and Powder Metallurgy Subcategory .     809
          Titanium Forming Subcategory 	     809
          Refractory Metals Forming Subcategory	     809
          Magnesium Forming Subcategory	     809
          Spent Baths	     809
          Beryllium Forming Subcategory	     810
          Titanium Forming Subcategory 	     810

          CALCULATION OF BAT EFFLUENT MASS LIMITATIONS .     810

          COSTS AND BENEFITS	     810

XI        NEW SOURCE PERFORMANCE STANDARDS 	     845

          TECHNICAL APPROACH TO NSPS	     845

          NSPS OPTION SELECTION	     846

          Costs and Environmental Benefits of Treatment
          Options	     847

          REGULATED POLLUTANT PARAMETERS 	     847

          CALCULATION OF NEW SOURCE PERFORMANCE
          STANDARDS	     847
                             XVll

-------
                  TABLE OF CONTENTS  (Continued)


Section                                                     Page

XII       PRETREATMENT STANDARDS	     849

          DISCHARGE OF NONFERROUS METALS FORMING
          WASTEWATERS TO A POTW	     849

          TECHNICAL APPROACH TO PRETREATMENT  	     852

          PSES AND PSNS OPTION SELECTION	     853

          Costs and Environmental Benefits of Treatment
          Options	     856

          REGULATED POLLUTANT PARAMETERS 	     857

          CALCULATION OF PRETREATMENT STANDARDS	     857

XIII      BEST CONVENTIONAL POLLUTANT CONTROL
          TECHNOLOGY	     877

          TECHNICAL APPROACH TO BCT	     878

          BCT OPTION SELECTION  	     879

          COSTS AND ENVIRONMENTAL BENEFITS OF TREATMENT
          OPTIONS	     880

          REGULATED POLLUTANT PARAMETERS 	     880

          BEST CONVENTIONAL TECHNOLOGY MASS LIMITATIONS.     880

          ALTERNATIVE BCT COST TEST CALCULATIONS ....     881

XIV       REFERENCES	     891

XV        GLOSSARY	     899
                             XVlll

-------
LIST OF FIGURES
Figure
III-l

III-2

III-3
III-4
III-5
III-6
III-7
III-8
III-9
111-10
III-ll
111-12
111-13
111-14
111-15
111-16
111-17
111-18
111-19
111-20
111-21
111-22

GEOGRAPHICAL DISTRIBUTION OF NONFERROUS
FORMING PLANTS 	
SEQUENCE OF NONFERROUS METALS FORMING
OPERATIONS 	
COMMON ROLLING MILL CONFIGURATIONS 	
REVERSING HOT STRIP MILL 	
4-HIGH COLD ROLLING MILL 	
TUBE DRAWING 	
HYDRAULIC DRAW BENCH 	
DIRECT EXTRUSION 	
EXTRUSION PRESS 	
EXTRUSION TOOLING AND SETUP 	
FORGING 	
RING ROLLING 	
IMPACTING 	
SOME CLAD CONFIGURATIONS 	
ATOMIZATION 	
POWDER METALLURGY DIE COMPACTION 	
DIRECT CHILL CASTING 	
DIRECT CHILL (D.C.) CASTING UNIT 	
CONTINUOUS SHEET CASTING 	
CONTINUOUS STRIP CASTING 	
SHOT CASTING 	
ROLLER HEARTH ANNEALING FURNACE 	
Page

350

351
352
353
354
355
356
357
358
359
360
361
362
363
364
365
366
367
368
369
370
371
     XIX

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


Figure                                                       Page

111-23    BULK PICKLING TANK	      372

111-24    CONTINUOUS PICKLING LINE  	      373

111-25    VAPOR DECREASING 	      374

VII-1     FLOW DIAGRAM FOR EMULSION BREAKING WITH
          CHEMICALS	      631

VII-2     GRAVITY OIL/WATER SEPARATOR	      632

VII-3     HEXAVALENT CHROMIUM REDUCTION WITH SULFUR
          DIOXIDE	      633

VII-4     THEORETICAL SOLUBILITIES OF TOXIC METAL
          HYDROXIDES/OXIDES AS A FUNCTION OF pH	      634

VII-5     TYPICAL DRY FEED SYSTEM	      635

VII-6     FILTER CONFIGURATIONS	      636

VII-7     GRANULAR BED FILTRATION	      637

VII-8     VACUUM FILTRATION	      638

VII-9     FLOW DIAGRAM FOR RECYCLING WITH A COOLING
          TOWER	      639

VII-10    COUNTERCURRENT RINSING (TANKS) 	      640

VIII-1    GENERAL LOGIC DIAGRAM OF COMPUTER COST
          MODEL	      682

VIII-2    LOGIC DIAGRAM OF MODULE DESIGN PROCEDURE  .  .  .      683

VIII-3    LOGIC DIAGRAM OF THE COSTING ROUTINE  	      684

IX-1      BPT TREATMENT TRAIN FOR THE NONFERROUS
          METALS FORMING CATEGORY	      747

X-l       BAT OPTION 1 AND 2 TREATMENT TRAIN FOR THE
          NONFERROUS METALS FORMING CATEGORY 	      811
                               XX

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


Figure                                                      Page

X-2       BAT OPTION 3 TREATMENT TRAIN FOR THE NONFER-
          ROUS METALS FORMING CATEGORY 	     812
                              xxi

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                          LIST OF TABLES
Table                                                        Page
III-l     METAL TYPES EXCLUDED FROM REGULATION UNDER
          PARAGRAPH 8 OF THE SETTLEMENT AGREEMENT  ....     375

III-2     METAL TYPES COVERED UNDER THE NONFERROUS
          METALS FORMING CATEGORY  	     376

III-3     YEARS SINCE NONFERROUS FORMING OPERATIONS
          BEGAN AT PLANT	     377

III-4     NONFERROUS METAL PRODUCTION BY PRODUCT
          FORMED (POUNDS) 	     378

IV-1      NUMBER OF PLANTS DISCHARGING NONFERROUS METALS
          FORMING WASTEWATER, BY SUBCATEGORY	     391

V-l       NUMBER OF SAMPLES PER WASTE STREAM, BY
          SUBCATEGORY	     460

V-2       SAMPLE ANALYSIS LABORATORIES	     463

V-3       NONTOXIC POLLUTANTS 	     464

V-4       CONCENTRATION RANGE OF REGULATED POLLUTANTS IN
          SAMPLED WASTE STREAMS LEAD/TIN/BISMUTH FORMING
          SUBCATEGORY	     465

V-5       CONCENTRATION RANGE OF REGULATED POLLUTANTS IN
          SAMPLED WASTE STREAMS NICKEL/COBALT FORMING
          SUBCATEGORY	     466

V-6       CONCENTRATION RANGE OF REGULATED POLLUTANTS IN
          SAMPLED WASTE STREAMS ZINC FORMING SUBCATEGORY.     468

V-7       CONCENTRATION RANGE OF REGULATED POLLUTANTS IN
          SAMPLED WASTE STREAMS BERYLLIUM FORMING
          SUBCATEGORY	     469

V-8       CONCENTRATION RANGE OF REGULATED POLLUTANTS IN
          SAMPLED WASTE STREAMS PRECIOUS METALS FORMING
          SUBCATEGORY	     470

V-9       CONCENTRATION RANGE OF REGULATED POLLUTANTS IN
          SAMPLED WASTE STREAMS IRON AND STEEL/COPPER/
          ALUMINUM METAL POWDER PRODUCTION AND POWDER
          METALLURGY SUBCATEGORY	     471
                              XXll

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


Table                                                        Page

V-10      CONCENTRATION RANGE OF REGULATED  POLLUTANTS  IN
          SAMPLED WASTE STREAMS TITANIUM  FORMING
          SUBCATEGORY	     472

V-ll      CONCENTRATION RANGE OF REGULATED  POLLUTANTS  IN
          SAMPLED WASTE STREAMS REFRACTORY  METALS  FORMING
          SUBCATEGORY	     473

V-12      CONCENTRATION RANGE OF REGULATED  POLLUTANTS  IN
          SAMPLED WASTE STREAMS ZIRCONIUM/HAFNIUM  FORMING
          SUBCATEGORY	     474

V-13      CONCENTRATION RANGE OF REGULATED  POLLUTANTS  IN
          SAMPLED WASTE STREAMS MAGNESIUM FORMING
          SUBCATEGORY	     475

V-14      CONCENTRATION RANGE OF REGULATED  POLLUTANTS  IN
          SAMPLED WASTE STREAMS URANIUM FORMING
          SUBCATEGORY	     476

V-15      RESULTS OF CHEMICAL ANALYSES OF SAMPLED
          LEAD AND NICKEL EXTRUSION PRESS AND SOLUTION
          HEAT TREATMENT CONTACT COOLING WATER	     477

V-16      RESULTS OF CHEMICAL ANALYSES OF SAMPLED
          LEAD, NICKEL, AND PRECIOUS METALS ROLLING
          SPENT EMULSIONS	     478

VI-1      LIST OF 129 TOXIC POLLUTANTS	     515

VI-2      FREQUENCY OF OCCURRENCE OF TOXIC  POLLUTANTS
          LEAD/TIN/BISMUTH FORMING SUBCATEGORY RAW
          WASTEWATER	     520

VI-3      FREQUENCY OF OCCURRENCE OF TOXIC  POLLUTANTS
          NICKEL/COBALT FORMING SUBCATEGORY RAW
          WASTEWATER	     524

VI-4      FREQUENCY OF OCCURRENCE OF TOXIC  POLLUTANTS
          ZINC FORMING SUBCATEGORY RAW WASTEWATER  ....     528

VI-5      FREQUENCY OF OCCURRENCE OF TOXIC  POLLUTANTS
          BERYLLIUM FORMING SUBCATEGORY RAW WASTEWATER.  .     532
                             XX 111

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


Table                                                        Page

VI-6      FREQUENCY OF OCCURRENCE OF TOXIC POLLUTANTS
          PRECIOUS METALS FORMING SUBCATEGORY RAW
          WASTEWATER	     536

VI-7      FREQUENCY OF OCCURRENCE OF TOXIC POLLUTANTS
          IRON AND STEEL/COPPER/ALUMINUM METAL  POWDER
          PRODUCTION AND POWDER METALLURGY SUBCATEGORY
          RAW WASTEWATER	     540

VI-8      FREQUENCY OF OCCURRENCE OF TOXIC POLLUTANTS
          TITANIUM FORMING SUBCATEGORY RAW WASTEWATER  .  .     544

VI-9      FREQUENCY OF OCCURRENCE OF TOXIC POLLUTANTS
          REFRACTORY METALS FORMING SUBCATEGORY RAW
          WASTEWATER	     548

VI-10     FREQUENCY OF OCCURRENCE OF TOXIC POLLUTANTS
          ZIRCONIUM/HAFNIUM FORMING SUBCATEGORY RAW
          WASTEWATER	     552

VI-11     FREQUENCY OF OCCURRENCE OF TOXIC POLLUTANTS
          MAGNESIUM FORMING SUBCATEGORY RAW WASTEWATER.  .     556

VII-1     SOLUBILITY PRODUCTS OF TOXIC METALS  	     641

VII-2     COMBINED METALS DATA EFFLUENT VALUES  (mg/1)  .  .     642

VII-3     LScS PERFORMANCE ADDITIONAL POLLUTANTS	     643

VII-4     COMBINED METALS DATA SET - UNTREATED
          WASTEWATER	     644

VII-5     MAXIMUM POLLUTANT LEVEL IN UNTREATED  WASTEWATER
          ADDITIONAL POLLUTANTS (mg/1)	     645

VII-6     PRECIPITATION-SETTLING-FILTRATION (LS&F)
          PERFORMANCE PLANT A 	     646

VII-7     PRECIPITATION-SETTLING-FILTRATION (LS&F)
          PERFORMANCE PLANT B 	     647

VII-8     PRECIPITATION-SETTLING-FILTRATION (LS&F)
          PERFORMANCE PLANT C 	     648
                              XXIV

-------
LIST OF TABLES (Continued)
Table
VII-9
VII-10
VIII-1
VIII-2
VIII-3

VIII-4
VIII-5
VIII-6
IX-1

IX- 2

IX-3

IX-4

IX-5

IX-6


IX- 7

IX-8

IX- 9


SUMMARY OF TREATMENT EFFECTIVENESS (mg/1) . . .
MULTIMEDIA FILTER PERFORMANCE 	
COSTING GROUPS 	
COST PROGRAM POLLUTANT PARAMETERS 	
COST EQUATIONS FOR RECOMMENDED TREATMENT AND
CONTROL TECHNOLOGIES 	
COMPONENTS OF TOTAL CAPITAL INVESTMENT 	
COMPONENTS OF TOTAL ANNUALIZED COSTS 	
WASTEWATER SAMPLING FREQUENCY 	 \ . . .
POTENTIAL PRELIMINARY TREATMENT REQUIREMENTS
LEAD /TIN /BISMUTH FORMING SUBCATEGORY 	
POTENTIAL PRELIMINARY TREATMENT REQUIREMENTS
NICKEL/COBALT FORMING SUBCATEGORY 	
POTENTIAL PRELIMINARY TREATMENT REQUIREMENTS
ZINC FORMING SUBCATEGORY 	
POTENTIAL PRELIMINARY TREATMENT REQUIREMENTS
BERYLLIUM FORMING SUBCATEGORY 	
POTENTIAL PRELIMINARY TREATMENT REQUIREMENTS
PRECIOUS METALS FORMING SUBCATEGORY 	
POTENTIAL PRELIMINARY TREATMENT REQUIREMENTS
IRON AND STEEL/COPPER/ALUMINUM METAL POWDER
PRODUCTION AND POWDER METALLURGY SUBCATEGORY. .
POTENTIAL PRELIMINARY TREATMENT REQUIREMENTS
TITANIUM FORMING SUBCATEGORY 	
POTENTIAL PRELIMINARY TREATMENT REQUIREMENTS
REFRACTORY METALS FORMING SUBCATEGORY 	
POTENTIAL PRELIMINARY TREATMENT REQUIREMENTS
ZIRCONIUM/HAFNIUM FORMING SUBCATEGORY 	
Page
649
650
685
687

688
692
693
694

748

749

751

752

753


755

756

757

759
          XXV

-------
LIST OF TABLES (Continued)
Table
IX- 10

IX-11

IX-12

IX-13

IX-14

IX-15

IX-16

IX-17


IX-18

IX-19

IX-20

IX-21

IX-22

IX-23

IX-24


POTENTIAL PRELIMINARY TREATMENT REQUIREMENTS
MAGNESIUM FORMING SUB CATEGORY 	
POTENTIAL PRELIMINARY TREATMENT REQUIREMENTS
URANIUM FORMING SUB CATEGORY 	
PRODUCTION OPERATIONS - LEAD /TIN /BISMUTH
FORMING SUB CATEGORY 	
PRODUCTION OPERATIONS - NICKEL /COB ALT FORMING
SUBCATEGORY 	
PRODUCTION OPERATIONS - ZINC FORMING
SUBCATEGORY 	
PRODUCTION OPERATIONS - BERYLLIUM FORMING
SUBCATEGORY 	
PRODUCTION OPERATIONS - PRECIOUS METALS
FORMING SUBCATEGORY 	 . .
PRODUCTION OPERATIONS - IRON AND STEEL /COPPER/
ALUMINUM METAL POWDER PRODUCTION AND POWDER
METALLURGY SUBCATEGORY 	 	
PRODUCTION OPERATIONS - TITANIUM FORMING
SUBCATEGORY 	
PRODUCTION OPERATIONS - REFRACTORY METALS
FORMING SUBCATEGORY 	
PRODUCTION OPERATIONS - ZIRCONIUM/HAFNIUM
FORMING SUBCATEGORY 	
PRODUCTION OPERATIONS - MAGNESIUM FORMING
SUBCATEGORY 	
PRODUCTION OPERATIONS - URANIUM FORMING
SUBCATEGORY 	
ALLOWABLE DISCHARGE CALCULATIONS FOR REFRAC-
TORY METALS FORMING PLANT X IN EXAMPLE 1. ...
ALLOWABLE DISCHARGE CALCULATIONS FOR LEAD/
TIN/BISMUTH FORMING PLANT Y IN EXAMPLE 2. ...
Page

760

761

762

764

767

768

769


771

772

773

776

777

778

779

780
          XXVI

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


Table                                                        Page

IX-25     ALLOWABLE  DISCHARGE  CALCULATIONS  FOR  NICKEL/
          COBALT AND TITANIUM  FORMING  PLANT Z IN
          EXAMPLE  3  (NICKEL)	      781

IX-26     ALLOWABLE  DISCHARGE  CALCULATIONS  FOR  NICKEL/
          COBALT AND TITANIUM  FORMMING PLANT Z  IN
          EXAMPLE  3  (TSS)	      783

X-l       CAPITAL  AND ANNUAL COST ESTIMATES FOR BAT
          OPTIONS  DIRECT  DISCHARGERS  ($1982) 	      813

X-2       SYMBOLS  USED ON TABLES X-4 THROUGH X-14.  .  .  .      815

X-3       NONFERROUS METALS FORMING POLLUTANT BENEFIT
          REDUCTION  ESTIMATES  (kg/yr)  TOTAL CATEGORY
          DIRECT DISCHARGERS  	      816

X-4       NONFERROUS METALS FORMING POLLUTANT BENEFIT
          REDUCTION  ESTIMATES  (kg/yr)  LEAD/TIN/BISMUTH
          FORMING  SUBCATEGORY  DIRECT DISCHARGERS  ....      817

X-5       NONFERROUS METALS FORMING POLLUTANT BENEFIT
          REDUCTION  ESTIMATES  (kg/yr)  NICKEL/COBALT
          FORMING  SUBCATEGORY  DIRECT DISCHARGERS  ....      818

X-6       NONFERROUS METALS FORMING POLLUTANT BENEFIT
          REDUCTION  ESTIMATES  (kg/yr)  ZINC  FORMING
          SUBCATEGORY DIRECT DISCHARGERS  	      819

X-7       NONFERROUS METALS FORMING POLLUTANT BENEFIT
          REDUCTION  ESTIMATES  (kg/yr)  BERYLLIUM FORMING
          SUBCATEGORY DIRECT DISCHARGERS  	      820

X-8       NONFERROUS METALS FORMING POLLUTANT BENEFIT
          REDUCTION ESTIMATES  (kg/yr)  PRECIOUS  METALS
          FORMING  SUBCATEGORY  DIRECT DISCHARGERS  ....      821

X-9       NONFERROUS METALS FORMING POLLUTANT BENEFIT
          REDUCTION ESTIMATES  (kg/yr)  IRON  AND  STEEL/
          COPPER/ALUMINUM METAL POWDER PRODUCTION AND
          POWDER METALLURGY SUBCATEGORY DIRECT
          DISCHARGERS	      '422
                             XXVll

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


                                                            Page

          NONFERROUS METALS FORMING POLLUTANT BENEFIT
          REDUCTION ESTIMATES (kg/yr) TITANIUM FORMING
          SUBCATEGORY DIRECT DISCHARGERS 	     823

X-ll      NONFERROUS METALS FORMING POLLUTANT BENEFIT
          REDUCTION ESTIMATES (kg/yr) REFRACTORY METALS
          FORMING SUBCATEGORY DIRECT DISCHARGERS ....     824

X-12      NONFERROUS METALS FORMING POLLUTANT BENEFIT
          REDUCTION ESTIMATES (kg/yr) ZIRCONIUM/HAFNIUM
          FORMING SUBCATEGORY DIRECT DISCHARGERS ....     825

X-13      NONFERROUS METALS FORMING POLLUTANT BENEFIT
          REDUCTION ESTIMATES (kg/yr) MAGNESIUM FORMING
          SUBCATEGORY DIRECT DISCHARGERS 	     826

X-14      NONFERROUS METALS FORMING POLLUTANT BENEFIT
          REDUCTION ESTIMATES (kg/yr) URANIUM FORMING
          SUBCAEGORY DIRECT DISCHARGERS	     827

X-15      PRODUCTION OPERATIONS - LEAD/TIN/BISMUTH
          FORMING SUBCATEGORY	  .    828

X-16      PRODUCTION OPERATIONS - NICKEL/COBALT FORMING
          SUBCATEGORY	    830

X-17      PRODUCTION OPERATIONS - ZINC FORMING
          SUBCATEGORY	    833

X-18      PRODUCTION OPERATIONS - BERYLLIUM FORMING
          SUBCATEGORY	    834

X-19      PRODUCTION OPERATIONS - PRECIOUS METALS
          FORMING SUBCATEGORY 	    835

X-20      PRODUCTION OPERATIONS - IRON AND STEEL/COPPER/
          ALUMINUM METAL POWDER PRODUCTION AND POWDER
          METALLURGY SUBCATEGORY	    837

X-21      PRODUCTION OPERATIONS - TITANIUM FORMING
          SUBCATEGORY	    838

X-22      PRODUCTION OPERATIONS - REFRACTORY METALS
          FORMING SUBCATEGORY 	    839
                             XXVlll

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


Table                                                        Page

X-23      PRODUCTION OPERATIONS - ZIRCONIUM/HAFNIUM
          FORMING SUBCATEGORY  	     842

X-24      PRODUCTION OPERATIONS - MAGNESIUM FORMING
          SUBCATEGORY	     843

X-25      PRODUCTION OPERATIONS - URANIUM FORMING
          SUBCATEGORY	     844

XII-1     POTW REMOVALS OF TOXIC POLLUTANTS IN THE
          "40 CITIES STUDY"	     859

XII-2     PERCENTAGE REMOVAL BY BAT TECHNOLOGY OPTIONS.  .     860

XII-3     PERCENTAGE REMOVAL - PRETREATMENT OPTION 1
          TO SELECTED  PSES OPTIONS	     863

XII-4     CAPITAL AND  ANNUAL COST ESTIMATES FOR PSES
          OPTIONS INDIRECT DISCHARGERS  ($1982)	     866

XII-5     NONFERROUS METALS FORMING POLLUTANT BENEFIT
          REDUCTION ESTIMATES  (kg/yr) LEAD/TIN/BISMUTH
          FORMING SUBCATEGORY  INDIRECT DISCHARGERS ...      868

XI1-6     NONFERROUS METALS FORMING POLLUTANT BENEFIT
          REDUCTION ESTIMATES  (kg/yr) NICKEL/COBALT
          FORMING SUBCATEGORY  INDIRECT DISCHARGERS ...      869

XII-7     NONFERROUS METALS FORMING POLLUTANT BENEFIT
          REDUCTION ESTIMATES  (kg/yr) ZINC FORMING
          SUBCATEGORY  INDIRECT DISCHARGERS 	      870

XII-8     NONFERROUS METALS FORMING POLLUTANT BENEFIT
          REDUCTION ESTIMATES  (kg/yr) BERYLLIUM FORMING
          SUBCATEGORY  INDIRECT DISCHARGERS 	      871

XII-9     NONFERROUS METALS FORMING POLLUTANT BENEFIT
          REDUCTION ESTIMATES  (kg/yr) PRECIOUS METALS
          FORMING SUBCATEGORY  INDIRECT DISCHARGERS ...      872

XII-10    NONFERROUS METALS FORMING POLLUTANT BENEFIT
          REDUCTION ESTIMATES  (kg/yr) IRON AND STEEL/
          COPPER/ALUMINUM METAL POWDER PRODUCTION AND
          POWDER METALLURGY SUBCATEGORY INDIRECT
          DISCHARGERS	      873
                             XXIX

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

XII-10    NONFERROUS METALS FORMING POLLUTANT BENEFIT
          REDUCTION ESTIMATES (kg/yr) TITANIUM FORMING
          SUBCATEGORY INDIRECT DISCHARGERS 	

XII-11    NONFERROUS METALS FORMING POLLUTANT BENEFIT
          REDUCTION ESTIMATES (kg/yr) REFRACTORY METALS
          FORMING SUBCATEGORY INDIRECT DISCHARGERS . .  .

XII-12    NONFERROUS METALS FORMING POLLUTANT BENEFIT
          REDUCTION ESTIMATES (kg/yr) ZIRCONIUM/HAFNIUM
          FORMING SUBCATEGORY INDIRECT DISCHARGERS . .  .

XII-13    NONFERROUS METALS FORMING POLLUTANT BENEFIT
          REDUCTION ESTIMATES (kg/yr) MAGNESIUM FORMING
          SUBCATEGORY INDIRECT DISCHARGERS 	

XIII-1    ANNUALIZED BCT COST ESTIMATES FOR THE
          NONFERROUS METALS FORMING CATEGORY  	

XIII-2    BCT COST TEST (PART 1) RESULTS FOR  THE
          NONFERROUS METALS FORMING CATEGORY  	

XIII-3    BCT COST TEST (PART 2) RESULTS FOR THE
          NONFERROUS METALS FORMING CATEGORY  	

XIII-4    BCT PRODUCTION NORMALIZED FLOWS AND SELECTED
          TREATMENT OPTIONS	

XIII-5    ALTERNATIVE ANNUALIZED BCT COST ESTIMATES
          FOR THE NONFERROUS METALS FORMING CATEGORY .  ,

XIII-6    ALTERNATE BCT COST TEST (PART 1) RESULTS FOR
          THE NONFERROUS METALS FORMING CATEGORY . .  .  .

XIII-7    ALTERNATE BCT COST TEST (PART 2) RESULTS FOR
          THE NONFERROUS METALS FORMING CATEGORY . . .  .
Page



 873



 874



 875



 876


 883


 884


 885


 886


 887


 888


 889
                              XXX

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                         ACKNOWLEDGEMENTS


The technical study supporting this proposed regulation was con-
ducted by Radian Corporation, of McLean, Virginia, under the
direction of Mr. James S. Sherman, Program Manager, Mr. Mark L.
Hereth, Project Director, and Mr. Michael A. Zapkin, Task Leader.
Major contributors were Ms. Betsy Bicknell, Ms. Jeanne Holmes,
Ms. Jill Myerson, and Mr. John Kovacic.  Engineering cost
estimates were prepared by Mr. Marc Papai, Mr. Robert Eng,
Mr. Matthew Phillips, Ms. Lori Stoll, and Mr. Patrick Murphy.
Additional people who contributed in specific assignments
throughout the project include Mr. Tom Emmel, Ms. Barbara Lee,
Mr. Tom Grome, Ms. Gwen DuPoix, Ms. Carol Jamgochian, Ms. Carol
Thompson, and Ms. Gwen Ecklund.  The work was performed by Radian
Corporation under Contract No. 68-01-6529.  Some field samples
were collected by Sverdrup & Parcel and Associates, of St. Louis,
Missouri, under the direction of Mr. Garry Aronberg under Con-
tract No. 68-01-4408.

The project was conducted by the Environmental Protection Agency,
G. Edward Stigall, Chief, Inorganic Chemicals Branch.  The tech-
nical project officer is Dr. Thomas E. Fielding, previous techni-
cal project officer was Ms. Janet K. Goodwin.

Ms. Susan Lepow and Ms. Meg Silver of the Office of General Coun-
sel are especially acknowledged for their extensive contribution
to the drafting of the regulations and this development document.

Mr. Russ Roegner of the Office of Analysis and Evaluation, and
Mr. Rod Frederick, Monitoring and Data Support Division, and Mr.
Mahesh Podar, Office of Planning and Evaluation are acknowledged
for their assistance.

The cooperation and assistance of numerous individual corpora-
tions was provided during the course of this study.  The numerous
company and plant personnel who submitted information, cooperated
with plant visits, and otherwise provided information and data
are acknowledged and thanked for their patience and help.

Acknowledgement and appreciation is also given to the secretarial
staff of Radian Corporation, in particular Ms. Nancy Reid, Pro-
ject Secretary, and Ms. Daphne Phillips, for their efforts in the
typing of drafts, necessary revisions, and preparation of this
effluent guidelines document.
                              XXXI

-------
       of precious metals surface treated

118  CADMIUM                    970                           43O
120  COPPER                   5,400                         2,80O
121  CYANIDE                    820                           340
126  SILVER                   1,200                           480
     OIL & GREASE            57,000                        34,000
     TOTAL SUSPENDED        120,000                        55,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.


        Alkaline Cleaning Spent Baths
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of precious metals alkaline cleaned

118  CADMIUM                   1.20                           .60
120  COPPER                    7.00                          3.70
121  CYANIDE                   1.10                           .40
126  SILVER                    1.50                           .60
     OIL & GREASE             73.00                         44.00
     TOTAL SUSPENDED         15O.OO                         72.00
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
                               33

-------
      (s)  Alkaline Cleaning Rinsewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of precious metals alkaline cleaned

118  CADMIUM                  2,400                         1,000
12O  COPPER                  13,OOO                         6,90O
121  CYANIDE                  2,000                           830
126  SILVER                   2,800                         1,200
     OIL & GREASE           140,000                        83,000
     TOTAL SUSPENDED        280,OOO                       130,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.


      
-------
        Tumbling Wastewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of precious metals tumbled

118  CADMIUM                    390                           17O
120  COPPER                   2,200                         1,200
121  CYANIDE                    330                           140
126  SILVER                     470                           200
     OIL S, GREASE            23,OOO                        14,OOO
     TOTAL SUSPENDED         47,000                        22,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.


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


    mg/kkg Clb/billion Ibs) of precious metals burnished

118  CADMIUM                  8,700                         3,900
12O  COPPER                  49,OOO                        26,000
121  CYANIDE                  7,5OO                         3,1OO
126  SILVER                  11,OOO                         4,40O
     OIL & GREASE           510,000                       310,000
     TOTAL SUSPENDED      1,100,OOO                       500,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
                                 35

-------
      (w)  Sawing/Grinding Spent Emulsions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of precious metals sawed or ground

118  CADMIUM                   2.10                           .90
120  COPPER                   11.00                          6.10
121  CYANIDE                   1.8O                           .70
126  SILVER                    2.50                          l.OO
     OIL & GREASE            12O.OO                         73.00
     TOTAL SUSPENDED         25O.OO                        120.OO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.


      (x>  Degreaaing Spent Solvents

There shall be no discharge of process wastewater pollutants.
SUBPART F.    BPT MASS LIMITATIONS FOR THE REFRACTORY METALS
              FORMING SUBCATEGORY

      (a)  Rolling Spent Neat Oils

There shall be no discharge of process wastewater pollutants,


      (b)  Rolling Spent Emulsions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg  (Ib/billion Iba) of refractory metals rolled with
       emulsions

120  COPPER                   2,300                         1,200
124  NICKEL                   2,300                         1,5OO
     COLUMBIUM                2,50O                         1,10O
     FLUORIDE                71,OOO                        32,OOO
     MOLYBDENUM               2,500                         1,1OO
     TANTALUM                 2,500                         1,10O
     TUNGSTEN                 2,500                         1,100
     VANADIUM                 2,5OO                         1,1OO
     OIL & GREASE            24,OOO                        14,OOO
     TOTAL SUSPENDED         49,OOO                        23,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
                                  36

-------
        Drawing Spent Lubricants

There shall be no discharge of process wastewater pollutants.
        Extrusion Press And Solution Heat Treatment Contact
             Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day             * Monthly Averag*
    mg/kkg (Ib/billion Iba) of extruded refractory metals heat
       treated
120
124










COPPER
NICKEL
COLUMBIUM
FLUORIDE
MOLYBDENUM
TANTALUM
TUNGSTEN
VANADIUM
OIL & GREASE
TOTAL SUSPENDED
SOLIDS
pH Within
6,600
6,6OO
7,100
210,000
7,100
7,100
7,10O
7,100
69,000
140, OOO

the range of 7.5
3,500
4,4OO
3,100
91,OOO
3,100
3,1OO
3,100
3,100
42,OOO
67,000

to 10.0 at all times.
        Extrusion Press Hydraulic Fluid Leakage
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
mg/kkg (Ib/billion Ibs) of refractory metals extruded
120
124









COPPER
NICKEL
COLUMBIUM
FLUORIDE
MOLYBDENUM
TANTALUM
TUNGSTEN
VANADIUM
OIL & GREASE
TOTAL SUSPENDED
SOLIDS
2,300
2,3OO
2,400
71,000
2,4OO
2,4OO
2,400
2,400
24, OOO
49,OOO

1,200
1,50O
1,1OO
31, OOO
1,100
1,1OO
1,1OO
1,1OO
14, OOO
23, OOO

     pH             Within the range of 7.5 to 10.O at all times.
                                  37

-------
        Forging Spent Lubricants

There shall be no discharge of process wastewater pollutants.


      (g)  Forging Solution Heat Treatment Contact Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg  of forged refractory metals heat
       treated
12O
124










COPPER
NICKEL
COLUMBIUM
FLUORIDE
MOLYBDENUM
TANTALUM
TUNGSTEN
VANADIUM
OIL & GREASE
TOTAL SUSPENDED
SOLIDS
pH Within
11,000
11,000
12,OOO
340,000
12,OOO
12,000
12,000
12,000
120,000
240,000

the range
5,800
7,40O
5,300
150,000
5,3OO
5,30O
5,300
5,3OO
69,OOO
110,OOO

of 7.5 to 10. O at all times.
        Extrusion And Forging Equipment Cleaning Wastewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


  mg/kkg (Ib/bllllon Ibs) of refractory metals extruded or forged

120  COPPER                     79O                           42O
124  NICKEL                     8OO                           53O
     COLUMBIUM                  850                           38O
     FLUORIDE                25,000                        11,OOO
     MOLYBDENUM                 850                           38O
     TANTALUM                   850                           38O
     TUNGSTEN                   850                           380
     VANADIUM                   85O                           33O
     OIL & GREASE             8,300                         5,000
     TOTAL SUSPENDED         17,OOO                         8,1OO
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all times.
                               38

-------
        Metal Powder Production Uaatewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Iba). of refractory metala powder produced

120  COPPER                   3,10O                         1,600
124  NICKEL                   3,100                         2,1OO
     COLUMBIUM                3,400                         1,500
     FLUORIDE                98,000                        43,000
     MOLYBDENUM               3,400                         1,500
     TANTALUM                 3,400                         1,5OO
     TUNGSTEN                 3,400                         1,500
     VANADIUM                 3,400                         1,5OO
     OIL & GREASE            33,OOO                        2O,OOO
     TOTAL SUSPENDED         67,000                        32,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all timea.
                                  39

-------
        Metal Powder Production Wet APC Slowdown

There shall be no discharge of process wastewater pollutants.


      (k>  Metal Powder Pressing Spent Lubricants

There shall be no discharge of process wastewater pollutants.


      (!)  Casting Contact Cooling Water

There shall be no discharge of process wastewater pollutants.


      Cm)  Post-Casting Billet Washwater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


  mg/kkg (Ib/bllllon Ibs) of cast refractory metals billet washed

12O  COPPER                      57                            3O
124  NICKEL                      57                            38
     COLUMBIUM                   61                            27
     FLUORIDE                 1,800                           79O
     MOLYBDENUM                  61                            27
     TANTALUM                    61                            27
     TUNGSTEN                    61                            27
     VANADIUM                    61                            27
     OIL S. GREASE               60O                           36O
     TOTAL SUSPENDED          1,2OO                           58O
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all times.
                              40

-------
      (n)  Surface Treatment Spent Batha
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion lba> of refractory metala aurface treated

120  COPPER                      24                            13
124  NICKEL                      24                            16
     COLUMBIUM                   26                            12
     FLUORIDE                   760                           340
     MOLYBDENUM                  26                            12
     TANTALUM                    26                            12
     TUNGSTEN                    26                            12
     VANADIUM                    26                            12
     OIL & GREASE               250                           15O
     TOTAL SUSPENDED            520                           25O
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all timea.


      (o)  Surface Treatment Rinaewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Iba) of refractory metala aurface treated

120  COPPER                 230,000                       120,000
124  NICKEL                 230,000                       150,OOO
     COLUMBIUM              250,000                       11O,OOO
     FLUORIDE             7,200,000                     3,20O,OOO
     MOLYBDENUM             25O,OOO                       110,000
     TANTALUM               250,000                       110,OOO
     TUNGSTEN               25O,OOO                       110,OOO
     VANADIUM               250,000                       110,OOO
     OIL & GREASE         2,400,000                     1,500,000
     TOTAL SUSPENDED      5,OOO,OOO                     2,4OO,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.O at all timea.
                            41

-------
      

Surface Treatment Wet APC Slowdown Pollutant or Maximum for Maximum for Pollutant Property Any One Day Monthly Average mg/kkg (Ib/billion lbs> of refractory metals surface treated 120 COPPER 22,000 12,000 124 NICKEL 23,000 15,OOO COLUMBIUM 24,000 11,OOO FLUORIDE 70O,OOO 310,000 MOLYBDENUM 24,000 11,000 TANTALUM 24,000 11,OOO TUNGSTEN 24,000 11,OOO VANADIUM 24,OOO 11,OOO OIL & GREASE 240,000 140,000 TOTAL SUSPENDED 480,000 230,000 SOLIDS pH Within the range of 7.5 to 10.0 at all times. Surface Coating Wet APC Slowdown Pollutant or Maximum for Maximum for Pollutant Property Any One Day Monthly Average mg/kkg (Ib/billion Iba) of refractory metals surface coated 120 COPPER 2,100 1,1OO 124 NICKEL 2,1OO 1,400 COLUMBIUM 2,200 980 FLUORIDE 64,000 29,OOO MOLYBDENUM 2,2OO 980 TANTALUM 2,20O 98O TUNGSTEN 2,2OO 98O VANADIUM 2,200 98O OIL ft GREASE 22,000 13,OOO TOTAL SUSPENDED 44,OOO 21,OOO SOLIDS pH Within the range of 7.5 to 10.0 at all times. 42


-------
        Alkaline Cleaning Spent Baths
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/bllllon Iba) of refractory metala alkaline cleaned

120  COPPER                      58                            31
124  NICKEL                      59                            39
     COLUMBIUM                   63                            28
     FLUORIDE                 1,800                           810
     MOLYBDENUM                  63                            28
     TANTALUM                    63                            28
     TUNGSTEN                    63                            28
     VANADIUM                    63                            28
     OIL & GREASE               610                           37O
     TOTAL SUSPENDED          1,30O                           6OO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.


      (a)  Alkaline Cleaning Rlnaewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg 
-------
        Mo1tan Salt Cleaning Rinaewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


  mg/kkg (Ib/billion Iba) of refractory metala cleaned with molten
     aalt

120  COPPER                 170,OOO                        90,OOO
124  NICKEL                 170,OOO                       110,OOO
     COLUMBIUM              18O,OOO                        82,000
     FLUORIDE             5,400,000                     2,400,OOO
     MOLYBDENUM             180,000                        82,OOO
     TANTALUM               180,OOO                        82,OOO
     TUNGSTEN               180,000                        82,000
     VANADIUM               180,000                        82,OOO
     OIL & GREASE         1,8OO,OOO                     1,1OO,OOO
     TOTAL SUSPENDED      3,700,000                     1,800,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all tlmea.


      (u)  Tumbling/Burniahlng Waatewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of refractory metala tumbled or
       burniahed

120  COPPER                  42,000                        22,OOO
124  NICKEL                  42,000                        28,OOO
     COLUMBIUM               45,OOO                        20,000
     FLUOR I DE             1 , 300 , OOO                       580 , OOO
     MOLYBDENUM              45 , OOO                        20 , OOO
     TANTALUM                45,000                        2O,OOO
     TUNGSTEN                45, OOO                        20, OOO
     VANADIUM                45,OOO                        20,OOO
     OIL & GREASE           440,000                       270, OOO
     TOTAL SUSPENDED        910,000                       43O,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10. O at all tlmea.
        Sawing/Grinding Spent Neat Oila

There shall be no diacharge of proceaa waatewater pollutants.
                              44

-------
      Cw>  Sawing/Grinding Spent Emulaiona
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion lba> of refractory metala aawed or ground
       with emulsiona

12O  COPPER                     410                           22O
124  NICKEL                     420                           28O
     COLUMBIUM                  440                           2OO
     FLUORIDE                13,OOO                         5,7OO
     MOLYBDENUM                 440                           20O
     TANTALUM                   44O                           2OO
     TUNGSTEN                   44O                           20O
     VANADIUM                   440                           2OO
     OIL & GREASE             4,30O                         2,600
     TOTAL SUSPENDED          S,9OO                         4,2OO
       SOLIDS
     pH             Within the range of 7.9 to 10.0 at all times.


        Sawing/Grinding Contact Lubricant-Coolant Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion lba> of refractory metala aawed or ground
       with lubricant-coolant water

12O  COPPER                   1,5OO                           81O
124  NICKEL                   1,6OO                         1,000
     COLUMBIUM                1,700                           74O
     FLUORIDE                48,OOO                        21,OOO
     MOLYBDENUM               1,7OO                           74O
     TANTALUM                 1,700                           740
     TUNGSTEN                 1,7OO                           74O
     VANADIUM                 1,7OO                           74O
     OIL & GREASE            16,OOO                         9,7OO
     TOTAL SUSPENDED         33,OOO                        16,OOO
       SOLIDS
     pH             Within the range of 7.9 to 1O.O at all time*.
                                 45

-------
        Sawing/Grinding Wet APC Slowdown
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One'Day              Monthly Average


    mg/kkg (Ib/blllion lba> of refractory metals sawed or ground

120  COPPER                   2,100                         1,100
124  NICKEL                   2,100                         1,40O
     COLUMBIUM                2,200                           98O
     FLUORIDE                64,000                        29,OOO
     MOLYBDENUM               2,200                           98O
     TANTALUM                 2,200                           980
     TUNGSTEN                 2,2OO                           98O
     VANADIUM                 2,2OO                           98O
     OIL & GREASE            22,000                        13,OOO
     TOTAL SUSPENDED         44,OOO                        21,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.O at all times.


      (z)  Post Sawing/Grinding Rinsewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of sawed or ground refractory metals
       rinsed

12O  COPPER                     970                           51O
124  NICKEL                     9SO                           65O
     COLUMBIUM                1,1OO                           47O
     FLUORIDE                31,OOO                        14,OOO
     MOLYBDENUM               1,1OO                           47O
     TANTALUM                 1,1OO                           47O
     TUNGSTEN                 1,10O                           47O
     VANADIUM                 1,100                           47O
     OIL & GREASE            10,000                         6,200
     TOTAL SUSPENDED         21,OOO                        10,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
                                46

-------
      (««>  Product Teating Waatewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Iba) of refractory metala product teated

120  COPPER                     150                            78
124  NICKEL                     150                            99
     COLUMBIUH                  160                            71
     FLUORIDE                 4,60O                         2,OOO
     MOLYBDENUM                 160                            71
     TANTALUM                   160                            71
     TUNGSTEN                   160                            71
     VANADIUM                   160                            71
     OIL & GREASE             1,600                           930
     TOTAL SUSPENDED          3,20O                         1,5OO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all tinea.


      (ab>  Degreaaing Spent Solvent*

There shall be no diacharge of proceaa waatewater pollutants.
SUBPART G.    BPT MASS LIMITATIONS FOR THE TITANIUM FORMING
              SUBCATEGORY

      (a>  Cold Rolling Spent Lubricanta
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
mg/kkg 
-------
        Hot Rolling Contact Lubricant-Coolant Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of titanium hot rolled with contact
       lubricant-coolant water
121
122
128







CYANIDE
LEAD
ZINC
AMMONIA
FLUORIDE
TITANIUM
OIL & GREASE
TOTAL SUSPENDED
SOLIDS
pH Within
1,200
1,800
6,300
570,000
260, OOO
8,800
86,OOO
180,000

the range of 7.5 to
52O
860
2,600
250,000
11O,OOO
3,900
52,000
84, OOO

10.0 at all timea.
        Extruaion Spent Lubricanta
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg   Forging Spent Lubricanta

There ahall be no diacharge of proceaa waatewater pollutanta.
                               48

-------
        Forging Die Contact Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/blllion lba> of titanium forged

121  CYANIDE                    870                           36O
122  LEAD                     1,3OO                           600
128  ZINC                     4,4OO                         1,80O
     AMMONIA                400,000                       180,000
     FLUORIDE               18O,OOO                        79,000
     TITANIUM                 6,200                         2,700
     OIL & GREASE            60,000                        36,OOO
     TOTAL SUSPENDED        120,000                        59,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.


      (f)  Forging Wet APC Slowdown
   Pollutant or         Maximum for                .Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Iba) of titanium forged

121  CYANIDE                    590                           240
122  LEAD                       850                           4OO
128  ZINC                     2,900                         1,20O
     AMMONIA                270,OOO                       120,OOO
     FLUORIDE               12O,OOO                        53,OOO
     TITANIUM                 4,100                         1,80O
     OIL & GREASE            40,000                        24,OOO
     TOTAL SUSPENDED         83,OOO                        39,OOO
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all times.
                                49

-------
        Heat Treatment Contact Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of titanium heat treated

121  CYANIDE                  1,300                           540
122  LEAD                     1,900                           900
128  ZINC                     6,600                         2,8OO
     AMMONIA                600,000                       260,000
     FLUORIDE               27O,OOO                       12O,OOO
     TITANIUM                 9,200                         4,1OO
     OIL & GREASE            90,000                        54,OOO
     TOTAL SUSPENDED        180,000                        88,OOO
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all times.


      (h)  Surface Treatment Spent Baths
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of titanium surface treated

121  CYANIDE                     46                            19
122  LEAD                        67                            32
128  ZINC                       23O                            98
     AMMONIA                 21,000                         9,4OO
     FLUORIDE                 9,500                         4,2OO
     TITANIUM                   330                           ISO
     OIL & GREASE             3,2OO                         1,9OO
     TOTAL SUSPENDED          6,6OO                         3,1OO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
                                50

-------
      (i>  Surface Treatment Rinaewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of titanium surface treated
121
122
128







CYANIDE
LEAD
ZINC
AMMONIA
FLUORIDE
TITANIUM
OIL S, GREASE
TOTAL SUSPENDED
SOLIDS
pH Within
6,100
8,900
31,000
2,800,000
1,30O,OOO
43,OOO
42O,OOO
870,000

the range of 7.5 to
2,500
4,200
13,OOO
1,2OO,OOO
560, OOO
19,OOO
250,000
410,OOO

10.0 at all times.
           Surface Treatment Wet APC Slowdown
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg 
-------
        Alkaline Cleaning Spent Batha
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Iba) of titanium alkaline cleaned

121  CYANIDE                    740                           310
122  LEAD                     1,100                           51O
128  ZINC                     3,700                         1,600
     AMMONIA                340,OOO                       150,OOO
     FLUORIDE               150,000                        67,OOO
     TITANIUM                 5,200                         2,3OO
     OIL & GREASE            51,OOO                        31,OOO
     TOTAL SUSPENDED        100,000                        5O,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.


      <1>  Alkaline Cleaning Rinaewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg 
-------
      <»>  Tumbling Waatewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg   Sawing/Grinding Spent Lubrlcanta
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of titanium aawed or ground
121
122
128







CYANIDE
LEAD
ZINC
AMMONIA
FLUORIDE
TITANIUM
OIL & GREASE
TOTAL SUSPENDED
SOLIDS
pH Within
14.0
21. 0
73.0
6,6OO.O
3,OOO.O
100.0
99O.O
2,OOO.O

the range of 7.5
6.O
1O.O
30. 0
2,9OO.O
1,300.0
45. 0
60O.O
97O.O

to 10. O at all times.
        Degreaaing Spent Solvents

There shall be no discharge of procesa wastewater pollutants.
                              53

-------
SUBPART H.    BPT MASS LIMITATIONS FOR THE URANIUM FORMING
              SUBCATEGORY

      (a)  Extrusion Spent Lubricants

There ahall be no discharge of process wastewater pollutants.


      (b)  Extrusion Tool Contact Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of uranium extruded

118  CADMIUM                    180                            78
120  COPPER                     98O                           52O
124  NICKEL                     990                           660
     FLUORIDE                31,OOO                        14,OOO
     RADIUM                     (1)                           (1)
     URANIUM                  1,100                           470
     OIL & GREASE            1O,OOO                         6,2OO
     TOTAL SUSPENDED         21,OOO                        10,OOO
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all times.

     <1> Concentration Value Is 5 Picocuries Per Liter

      Cc)  Extrusion Press And Solution Heat Treatment Contact
             Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg 
5,600
54,OOO
11O,OOO

the range of 7.5 to
410
2,700
3,5OO
72,000
(1)
2,500
33,OOO
53,000

10.0 at all times.
     <1) Concentration Value Is 5 Picocuries Per Liter
                               54

-------
      (d)  Forging Spent Lubricants

There shall be no discharge of process wastewater pollutants.


        Forging Solution Heat Treatment Contact Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average

118
120
124







mg/kkg Ub/billion Ibs)
CADMIUM
COPPER
NICKEL
FLUORIDE
RADIUM
URANIUM
OIL & GREASE
TOTAL SUSPENDED
SOLIDS
pH Within
> of forged uranium I
970
5,400
5,500
17O,OOO
(1)
5,800
57,000
12O,OOO

the range of 7.5 to
isat treated
43O
2,8OO
3,600
75,OOO
(1)
2,600
34,OOO
55,OOO

10. O at all times.
     <1> Concentration Value Is 5 Picocuriea Per Liter

      (f)  Surface Treatment Spent Baths
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average

118
12O
124







mg/kkg (Ib/billion Ibs:
CADMIUM
COPPER
NICKEL
FLUORIDE
RADIUM
URANIUM
OIL & GREASE
TOTAL SUSPENDED
SOLIDS
pH Within
> of uranium surface treated
12. 0
68.0
68. 0
2,100.0
(1)
73. 0
71O.O
1,500.O

the range of 7.5 to 10.0 at all

5.3
36.0
45. 0
940.0
(1)
32.0
43O.O
690.0

times .
     (1) Concentration Value Is 5 Picocuries Per Liter
                              55

-------
        Surface Treatment Rinsewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average

118
120
124







mg/kkg (Ib/billion Iba:
CADMIUM
COPPER
NICKEL
FLUORIDE
RADIUM
URANIUM
OIL & GREASE
TOTAL SUSPENDED
SOLIDS
pH Within
» of uranium surface
500
2,8OO
2,800
88,000
(1)
3,OOO
30,OOO
61,000

the range of 7.5 to
treated
220
1,500
1,900
39,000
(1)
1,300
18,OOO
29,000

1O.O at all times.
     (1) Concentration Value la 5 Picocuries Per Liter

      (h)  Surface Treatment Wet APC Blowdown
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of uranium surface treated

118  CADMIUM                     25                            11
12O  COPPER                     14O                            74
124  NICKEL                     140                            94
     FLUORIDE                 4,400                         2,OOO
     RADIUM                     (!)                           (1>
     URANIUM                    ISO                            68
     OIL & GREASE             1,5OO                           89O
     TOTAL SUSPENDED          3,OOO                         1,4OO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.

     (!) Concentration Value Is 5 Picocuries Per Liter
                               56

-------
      (i)  Sawing/Grinding Spent Emulsiona
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Iba) of uranium aawed or ground

118  CADMIUM                   1.1O                           .50
120  COPPER                    5.90                          3.10
124  NICKEL                    6.OO                          3.90
     FLUORIDE                180.00                         82.00
     RADIUM                     (1)                           <1)
     URANIUM                   6.40                          2.80
     OIL & GREASE             62.00                         37.OO
     TOTAL SUSPENDED         130.00                         60.OO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all timea.

      (1) Concentration Value la 5 Picocuriea Per Liter

      (3)  Post-Sawing/Grinding Rinaewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of aawed or ground uranium rlnaed
118
12O
124







CADMIUM
COPPER
NICKEL
FLUORIDE
RADIUM
URANIUM
OIL & GREASE
TOTAL SUSPENDED
SOLIDS
pH Within
13.0
72.0
73.0
2,300.0
<1>
78. 0
760. 0
1,6OO.O

the range of 7.5 to
5.7
38. 0
48.0
1 , OOO . O
(1)
35. O
460. 0
74O.O

10.0 at all timea.
      <1> Concentration Value la 5 Picocuriea Per Liter

        Degreasing Spent Solvents

There shall be no diacharge of proceaa wastewater pollutanta,
                              57

-------
SUBPART I.    BPT MASS LIMITATIONS FOR THE ZINC FORMING
              SUBCATEGORY

      (a)  Rolling Spent Neat Oils

There shall be no discharge of process wastewater pollutants.


      (b)  Rolling Spent Emulsions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
  mg/kkg (Ib/billion Iba) of zinc rolled with emulsions.

119  CHROMIUM                   .60                           .30
121  CYANIDE                    .40                           .20
128  ZINC                      2.00                           .80
     OIL & GREASE             28.00                         17.00
     TOTAL SUSPENDED          57.00                         27.OO
       SOLIDS
     pH *           Within the range of 7.5 to 10.0 at all times.
        Rolling Contact Lubricant-Coolant Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg  
-------
        Drawing Spent Emulsions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of zinc drawn with emulsiona

119  CHROMIUM                   3.5                           1.4
121  CYANIDE                    2.3                           l.O
128  ZINC                      12.0                           4.9
     OIL S, GREASE             160.0                          96.0
     TOTAL SUSPENDED          33O.O                         160.0
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.


        Direct Chill Casting Contact Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


  mg/kkg (Ib/billion Ibs) of zinc cast by the direct chill method

119  CHROMIUM                   220                            91
121  CYANIDE                    ISO                            6O
128  ZINC                       730                           310
     OIL & GREASE            10,OOO                         6,OOO
     TOTAL SUSPENDED         21,OOO                         9,8OO
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all times.
      (f)  Stationary Casting Contact Cooling Water

There shall be no discharge of process wastewater pollutants,
                              59

-------
        Heat Treatment Contact Colling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of zinc heat treated
119
121
128




CHROMIUM
CYANIDE
ZINC
OIL K, GREASE
TOTAL SUSPENDED
SOLIDS
pH Within
330
220
1,100
15,000
31,000

the range of 7.5 to 10. O at all
140
91
460
9,100
15,000

times.
        Surface Treatment Rinsewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of zinc surface treated

119  CHROMIUM                 2,100                           870
121  CYANIDE                  1,4OO                           58O
128  ZINC                     7,10O                         3,OOO
     OIL S, GREASE            97,OOO                        58,OOO
     TOTAL SUSPENDED        200,000                        95,000
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
                              60

-------
           Alkaline Cleaning Spent Baths
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of zinc alkaline cleaned

119  CHROMIUM                   .30                           .10
121  CYANIDE                    .20                           .10
128  ZINC                      l.OO                           .40
     OIL & GREASE             14.OO                          8.SO
     TOTAL SUSPENDED          29.00                         14.00
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
      (k)  Alkaline Cleaning Rlnsewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of zinc alkaline cleaned

119  CHROMIUM                 2,5OO                         1,000
121  CYANIDE                  1,7OO                           69O
128  ZINC                     8,4OO                         3,5OO
     OIL & GREASE           110,OOO                        69,OOO
     TOTAL SUSPENDED        230,000                       110,000
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all times.


      (1)  Sawing/Grinding Spent Lubricants
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


  mg/kkg (Ib/billion Ibs) of zinc sawed or ground

119  CHROMIUM                  24.O                          10.O
121  CYANIDE                   16.0                           6.6
128  ZINC                      80.0                          33.O
     OIL 6. GREASE           1,100.0                         66O.O
     TOTAL SUSPENDED        2,3OO.O                       1,100.O
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
                               61

-------
        Extrusion Spent Emulsions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
mg/kkg (Ib/billion Ibs) of zirconium/hafnium extruded with

119
121
124








emulsions
CHROMIUM
CYANIDE
NICKEL
AMMONIA
FLUORIDE
HAFNIUM
ZIRCONIUM
OIL & GREASE
TOTAL SUSPENDED
SOLIDS
pH Within

33.0
21.0
14O.O
9,9OO.O
4,4OO.O
15O.O
15O.O
1,5OO.O
3,OOO.O

the range of

13.0
8.9
94.0
4,3OO.O
2,OOO.O
67.0
67. 0
89O.O
1,4OO.O

7.5 to 10. O at all times.
                               62

-------
        Extrusion Press Hydraulic Fluid Leakage

— — — — — — — — — — — — — — — — — —————___ __ __ ____ .^ — — — — — — — — — — — — — — — — — — _. — _ — —________
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
mg/kkg (Ib/billion Ibs) of zirconium/hafnium extruded
119
121
124








CHROMIUM
CYANIDE
NICKEL
AMMONIA
FLUORIDE
HAFNIUM
ZIRCONIUM
OIL 6. GREASE
TOTAL SUSPENDED
SOLIDS
pH Within
160
110
710
49,OOO
22,OOO
760
760
7,4OO
15,OOO

the range of
67
44
47O
22,OOO
9,800
34O
340
4,4OO
7,2OO

7.5 to 1O.O at all times.
       t'd)  Extrusion Press And Solution  Heat  Treatment  Contact
             Cooling Water


   Pollutant or          Maximum  for                 Maximum for
Pollutant Property       Any  One  Day               Monthly  Average
    mg/kkg  (Ib/billion  Ibs)  of  extruded  zirconium/hafnium heat
       treated

119  CHROMIUM                    13O                             51
121  CYANIDE                      S3                             34
124  NICKEL                      550                            360
     AMMONIA                  38,OOO                         17,OOO
     FLUORIDE                 17,OOO                          7,500
     HAFNIUM                     58O                            26O
     ZIRCONIUM                   58O                            260
     OIL 6.  GREASE             5,7OO                          3,40O
     TOTAL  SUSPENDED          12,OOO                          5,6OO
       SOLIDS
     pH             Within  the  range of  7.5 to 1O.O at all times.
       
-------
      <£>  Forging Solution Heat Treatment Contact Cooling Water


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


  mg/kkg (Ib/billion Iba) of forged zirconium/hafnium heat treated

119  CHROMIUM                  15.0                           6.3
121  CYANIDE                   10.0                           4.2
124  NICKEL                    67.0                          44.O
     AMMONIA                4,70O.O                       2,000.0
     FLUORIDE               2,100.0                         92O.O
     HAFNIUM                   72.0                          32.0
     ZIRCONIUM                 72.0                          32.O
     OIL & GREASE             70O.O                         420.0
     TOTAL SUSPENDED        1,400.O                         68O.O
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all timea.


      (g>  Surface Treatment Spent Baths
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    rag/kkg (Ib/billion Iba) of zirconium/hafnium rolled with
      emulsions

119  CHROMIUM                   180                            72
121  CYANIDE                    120                            48
124  NICKEL                     770                           51O
     AMMONIA                 53,000                        23,OOO
     FLUORIDE                24,OOO                        11,OOO
     HAFNIUM                    82O                           36O
     ZIRCONIUM                  82O                           36O
     OIL & GREASE             8,OOO                         4,8OO
     TOTAL SUSPENDED         16,OOO                         7,80O
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all times.
                              64

-------
        Surface Treatment Rinsewater


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


    mg/kkg   Alkaline Cleaning Spent Baths
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Averagt
    mg/kkg 
-------
        Alkaline Cleaning Rinsewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of precious metals alkaline cleaned

118  CADMIUM                  2,400                         1,000
120  COPPER                  13,OOO                         6,9OO
121  CYANIDE                  2,OOO                           830
126  SILVER                   2,800                         1,200
     OIL & GREASE           140,000                        83,OOO
     TOTAL SUSPENDED        280,000                       130,000
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
      
-------
        Tumbling Waatewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg   Burnishing Waatewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of precious metals burnished

118  CADMIUM                  8,7OO                         3,90O
120  COPPER                  49,OOO                        26,OOO
121  CYANIDE                  7,500                         3,100
126  SILVER                  11,OOO                         4,4OO
     OIL & GREASE           51O,OOO                       310,000
     TOTAL SUSPENDED      1,10O,OOO                       500,OOO
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all times.
                                 35

-------
        Sawing/Grinding Spent Emulsions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Iba) of precious metals sawed or ground

118  CADMIUM                   2.10                           .90
120  COPPER                   11.OO                          6.1O
121  CYANIDE                   1.80                           .70
126  SILVER                    2.50                          l.OO
     OIL & GREASE            120.00                         73.00
     TOTAL SUSPENDED         25O.OO                        120.OO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
      (x)  Degreaaing Spent Solvents

There shall be no discharge of process wastewater pollutants.
•^ —»^—"•.•— — •» _ ____ •«••_ __ «• « •_ ^ ^ _• •« _ _«^_..___ _,» — ^ « _ « _ ^ •»••• —_ ^ .««_^__ -•_ ^ .•_ — — — •_- — — —. _ ~~~—^^ ,


SUBPART F.    BPT MASS LIMITATIONS FOR THE REFRACTORY METALS
              FORMING SUBCATEGORY

      (a)  Rolling Spent Neat Oils

There shall be no discharge of process wastewater pollutants.


      (b)  Rolling Spent Emulsions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of refractory metals rolled with
       emulsions

120  COPPER                   2,3OO                         1, 2OO
124  NICKEL                   2,3OO                         1,5OO
     COLUMBIUM                2,500                         1,100
     FLUORIDE                71,000                        32,OOO
     MOLYBDENUM               2,500                         1,100
     TANTALUM                 2,500                         1,1OO
     TUNGSTEN                 2,5OO                         1,100
     VANADIUM                 2,500                         1,1OO
     OIL & GREASE            24,000                        14,000
     TOTAL SUSPENDED         49,OOO                        23,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
                                  36

-------
        Drawing Spent Lubricanta

There ahall be no diacharge of proceaa waat.ewat.er pollutanta.
      (d)  Extruaion Preaa And Solution Heat Treatment Contact
             Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day             'Monthly Average
    mg/kkg (Ib/blllion Iba) of extruded refractory metal a heat
       treated
120
124










COPPER
NICKEL
COLUMBIUN
FLUORIDE
MOLYBDENUM
TANTALUM
TUNGSTEN
VANADIUM
OIL & GREASE
TOTAL SUSPENDED
SOLIDS
pH Within
6,600
6,600
7,1OO
210,000
7,10O
7,100
7,1OO
7,10O
69, OOO
140, OOO

the range of 7.5 to
3,5OO
4,4OO
3,100
91, OOO
3,100
3,100
3,100
3,1OO
42, OOO
67, OOO

1O.O at all timea.
        Extruaion Preaa Hydraulic Fluid Leakage
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
mg/kkg (Ib/billion Iba) of refractory metala extruded
120
124









COPPER
NICKEL
COLUMBIUM
FLUORIDE
MOLYBDENUM
TANTALUM
TUNGSTEN
VANADIUM
OIL & GREASE
TOTAL SUSPENDED
SOLIDS
2,300
2,30O
2,400
71,000
2,4OO
2,4OO
2,400
2,400
24, OOO
49,OOO

1,200
1,500
1,100
31, OOO
1,100
1,1OO
1,100
1,100
14, OOO
23, OOO

     pH             Within the range of 7.5 to 1O.O at all timea.
                                  37

-------
        Forging Spent Lubricants

There ahall be no diacharge of proceaa waatewater pollutants.


        Forging Solution Heat Treatment Contact Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Iba) of forged refractory metala heat
       treated
120
124










COPPER
NICKEL.
COLUMBIUM
FLUORIDE
MOLYBDENUM
TANTALUM
TUNGSTEN
VANADIUM
OIL & GREASE
TOTAL SUSPENDED
SOLIDS
pH Within
11,OOO
11,OOO
12,000
340,000
12,OOO
12,OOO
12,000
12,OOO
120,000
240,000

the range of 7.5
5,800
7,400
5,3OO
150, OOO
5,300
5,30O
5,300
5,30O
69, OOO
110,OOO

to 10. O at all times.
        Extruaion And Forging Equipment Cleaning Waatewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


  mg/kkg (Ib/billlon Iba) of refractory metala extruded or forged

12O  COPPER                     790                           42O
124  NICKEL                     8OO                           53O
     COLUMBIUM                  850                           38O
     FLUORIDE                25,000                        11,OOO
     MOLYBDENUM                 850                           3SO
     TANTALUM                   850                           38O
     TUNGSTEN                   850                           380
     VANADIUM                   850                           38O
     OIL & GREASE             8,300                         5,000
     TOTAL SUSPENDED         17,000                         8,1OO
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all timea.
                               38

-------
      (!)  Metal Powder Production Waatewater
   Pollutant or          Maximum for                Maximum for
Pollutant Property       Any One Day              Monthly Average
^n	u	||	ru 	 ±J^ iiff 	 mm 	r _,_ _-rr _,_,_ „, _r ^ —p- u- -„ 1Tr- „_ j,^ ^	„	, ^_ j^	 jm	m	 „„ ^j llm_ _^ ,__, ^ _, ,^ -^ „_-, ^ mr um -,„ ^p M -^ ^- -„, _-r- ^- -^ un- ^ -„- ^ -mr mr ^ ^n TT 11

    mg/kkg (Ib/billion Iba). of refractory metala powder produced

12O  COPPER                    3,10O                         1,600
124  NICKEL                    3,100                         2,1OO
     COLUMBIUM                 3,400                         1,5OO
     FLUORIDE                 98,000                        43,OOO
     MOLYBDENUM                3,400                         1,5OO
     TANTALUM                  3,400                         1,50O
     TUNGSTEN                  3,400                         1,500
     VANADIUM                  3,400                         1,5OO
     OIL & GREASE             33,OOO                        20,OOO
     TOTAL SUSPENDED          67,OOO                        32,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
                                   39

-------
      <3>  Metal Powder Production Wet APC Slowdown

There shall be no discharge of process wastewater pollutants.


      (k)  Metal Powder Pressing Spent Lubricants

There shall be no discharge of process wastewater pollutants.


      (1)  Casting Contact Cooling Water

There shall be no discharge of process wastewater pollutants.


      (m)  Post-Casting Billet Washwater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


  mg/kkg (Ib/blllion Iba) of cast refractory metals billet washed

12O  COPPER                      57                            3O
124  NICKEL                      57                            38
     COLUMBIUM                   61                            27
     FLUORIDE                 1,800                           790
     MOLYBDENUM                  61                            27
     TANTALUM                    61                            27
     TUNGSTEN                    61                            27
     VANADIUM                    61                            27
     OIL & GREASE               60O                           36O
     TOTAL SUSPENDED          1,2OO                           58O
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all times.
                              40

-------
        Surface Treatment Spent Batha
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billlon lba> of refractory metals surface treated

120  COPPER                      24                            13
124  NICKEL                      24                            16
     COLUMBIUM                   26                            12
     FLUORIDE                   760                           340
     MOLYBDENUM                  26                            12
     TANTALUM                    26                            12
     TUNGSTEN                    26                            12
     VANADIUM                    26                            12
     OIL & GREASE               250                           150
     TOTAL SUSPENDED            520                           25O
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.


        Surface Treatment Rinaewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of refractory metals surface treated

120  COPPER                 230,OOO                       120,000
124  NICKEL                 23O,OOO                       150,000
     COLUMBIUM              250,000                       110,000
     FLUORIDE             7,200,000                     3,200,OOO
     MOLYBDENUM             250,000                       110,OOO
     TANTALUM               250,000                       110,OOO
     TUNGSTEN               250,OOO                       110,OOO
     VANADIUM               250,000                       110,OOO
     OIL & GREASE         2,400,000                     1,5OO,OOO
     TOTAL SUSPENDED      5,OOO,OOO                     2,4OO,OOO
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all times.
                             41

-------
      

Surface Treatment Wet APC Slowdown Pollutant or Maximum for Maximum for Pollutant Property Any One Day Monthly Average mg/kkg (Ib/billlon Ibe) of refractory metala surface treated 120 COPPER 22,000 12,OOO 124 NICKEL 23,000 15,OOO COLUMBIUM 24,OOO 11,OOO FLUORIDE 700,000 310,000 MOLYBDENUM 24,000 11,OOO TANTALUM 24,000 11,OOO TUNGSTEN 24,000 11,OOO VANADIUM 24,000 11,OOO OIL & GREASE 240,000 140,000 TOTAL SUSPENDED 480,000 230,OOO SOLIDS pH Within the range of 7.5 to 1O.O at all timea. Surface Coating Wet APC Blowdown Pollutant or Maximum for Maximum for Pollutant Property Any One Day Monthly Average mg/kkg (Ib/blllion Iba) of refractory metala surface coated 120 COPPER 2,100 1,100 124 NICKEL 2,100 1,4OO COLUMBIUM 2,200 960 FLUORIDE 64,OOO 29,OOO MOLYBDENUM 2,200 98O TANTALUM 2,2OO 98O TUNGSTEN 2,200 98O VANADIUM 2,20O 98O OIL & GREASE 22,000 13,OOO TOTAL SUSPENDED 44,OOO 21,OOO SOLIDS pH Within the range of 7.5 to 10.0 at all times. 42


-------
        Alkaline Cleaning Spent Batha
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    rag/kkg (Ib/billion Ibs) of refractory metala alkaline cleaned

120  COPPER                      58                            31
124  NICKEL                      59                            39
     COLUMBIUM                   63                            28
     FLUORIDE                 1,800                           810
     MOLYBDENUM                  63                            28
     TANTALUM                    63                            28
     TUNGSTEN                    63                            28
     VANADIUM                    63                            28
     OIL & GREASE               610                           370
     TOTAL SUSPENDED          1,3OO                           6OO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
      (a>  Alkaline Cleaning Rinaewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Iba) of refractory metala alkaline cleaned

12O  COPPER                 270,000                       140,000
124  NICKEL                 270,000                       180,OOO
     COLUMBIUM              290,OOO                       130,000
     FLUORIDE             8,300,000                     3,700,OOO
     MOLYBDENUM             29O,OOO                       13O,OOO
     TANTALUM               29O,OOO                       13O,OOO
     TUNGSTEN               29O,OOO                       13O,OOO
     VANADIUM               290,OOO                       130,OOO
     OIL & GREASE         2,8OO,OOO                     1,7OO,OOO
     TOTAL SUSPENDED      5,7OO,OOO                     2,7OO,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.O at all times.
                               43

-------
        Molten Salt Cleaning Rinsewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


  mg/kkg (Ib/blllion lba> of refractory metals cleaned with molten
     •alt

120  COPPER                 170,000                        90,OOO
124  NICKEL                 17O,OOO                       110,000
     COLUMBIUM              180,000                        82,000
     FLUORIDE             5,400,000                     2,400,000
     MOLYBDENUM             18O,OOO                        82,OOO
     TANTALUM               180,OOO                        82,OOO
     TUNGSTEN               1SO,OOO                        82,000
     VANADIUM               180,OOO                        82,OOO
     OIL & GREASE         1,800,000                     1,1OO,OOO
     TOTAL SUSPENDED      3,700,000                     1,8OO,OOO
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all timea.


        Tumbling/Burnishing Wastewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of refractory metals tumbled or
       burniahed
12O
124










COPPER
NICKEL
COLUMBIUM
FLUORIDE
MOLYBDENUM
TANTALUM
TUNGSTEN
VANADIUM
OIL & GREASE
TOTAL SUSPENDED
SOLIDS
pH Within
42,OOO
42,000
45,OOO
1,300,000
45,OOO
4S,OOO
45,OOO
45,000
440,OOO
910,000

the range of 7.5 to
22,000
28, OOO
2O,OOO
580,000
2O,000
20,000
20,OOO
20,OOO
27O,OOO
43O,OOO

10.0 at all timea.
      (v>  Sawing/Grinding Spent Neat 01la

There ahall be no discharge of process wastewater pollutants.
                              44

-------
      Cw)  Sawing/Grinding Spent Emulalorui
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/blllion lba> of refractory Metal* flawed or ground
       with emulaiona

12O  COPPER                     410                           22O
124  NICKEL                     420                           28O
     COLUMBIUM                  44O                           20O
     FLUORIDE                13,000                         5,70O
     MOLYBDENUM                 440                           20O
     TANTALUM                   44O                           2OO
     TUNGSTEN                   44O                           2OO
     VANADIUM                   440                           2OO
     OIL & GREASE             4,3OO                         2,600
     TOTAL SUSPENDED          8,900                         4,2OO
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all timea.


        Sawing/Grinding Contact Lubricant-Coolant Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg Clb/billion Iba) of refractory metala aawed or ground
       with lubricant-coolant water

12O  COPPER                   1,5OO                           81O
124  NICKEL                   1,600                         1,OOO
     COLUMBIUM                1,700                           74O
     FLUORIDE                46,OOO                        21,OOO
     MOLYBDENUM               1,7OO                           74O
     TANTALUM                 1,7OO                           74O
     TUNGSTEN                 1,7OO                           74O
     VANADIUM                 1,7OO                           740
     OIL & GREASE            16,OOO                         9,7OO
     TOTAL SUSPENDED         33,OOO                        16,OOO
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all timea.
                                 45

-------
        Sawing/Grinding Wet APC Slowdown
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One*Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of refractory metala sawed or ground

120  COPPER                   2,100                         1,1OO
124  NICKEL                   2,100                         1,40O
     COLUMBIUM                2,200                           980
     FLUORIDE                64,000                        29,OOO
     MOLYBDENUM               2,200                           98O
     TANTALUM                 2,200                           980
     TUNGSTEN                 2,2OO                           98O
     VANADIUM                 2,200                           98O
     OIL & GREASE            22,000                        13,000
     TOTAL SUSPENDED         44,OOO                        21,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.


        Post Sawing/Grinding Rinsewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billlon Ibs) of aawed or ground refractory metala
       rinsed

120  COPPER                     970                           51O
124  NICKEL                     980                           65O
     COLUMBIUM                1,10O                           470
     FLUORIDE                31,000                        14,OOO
     MOLYBDENUM               1,100                           47O
     TANTALUM                 1,1OO                           47O
     TUNGSTEN                 1,1OO                           47O
     VANADIUM                 1,10O                           47O
     OIL & GREASE            10,000                         6,200
     TOTAL SUSPENDED         21,OOO                        10,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
                                46

-------
        Product Taating Waatewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion lba> of refractory metala product teated

120  COPPER                     150                            78
124  NICKEL                     150                            99
     COLUMBIUM                  160                            71
     FLUORIDE                 4,6OO                         2,OOO
     MOLYBDENUM                 160                            71
     TANTALUM                   16O                            71
     TUNGSTEN                   160                            71
     VANADIUM                   160                            71
     OIL & GREASE             1,600                           930
     TOTAL SUSPENDED          3,20O                         1,5OO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all tinea.


      tab)  Degreaaing Spent Solventa

There ahall be no diacharge of proceaa waatewater pollutants.
SUBPART G.    BPT MASS LIMITATIONS FOR THE TITANIUM FORMING
              SUBCATEGORY

      (a)  Cold Rolling Spent Lubricanta
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average

121
122
128






mg/kkg (Ib/billion lba>
CYANIDE
LEAD
ZINC
AMMONIA
FLUORIDE
TITANIUM
OIL & GREASE
TOTAL SUSPENDED
SOLIDS
of titanium cold rolled
97O
1,400
4,900
450,000
20O,OOO
6,800
67,OOO
140,000


4OO
670
2,OOO
20O,OOO
88,OOO
3,OOO
4O,OOO
65,OOO

     pH             Within the range of 7.5 to 1O.O at all timea.
                               47

-------
        Hot Rolling Contact Lubricant-Coolant Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of titanium hot rolled with contact
       lubricant-coolant water
121
122
128







CYANIDE
LEAD
ZINC
AMMONIA
FLUORIDE
TITANIUM
OIL & GREASE
TOTAL SUSPENDED
SOLIDS
pH Within
1,200
1,800
6,300
570,000
260,000
8,800
86,OOO
180,000

the range of 7.5 to
52O
.860
2,6OO
250,000
110,OOO
3,9OO
52,OOO
84,OOO

1O.O at all times.
        Extruaion Spent Lubricants
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg   Forging Spent Lubricants

There shall be no discharge of process wastewater pollutants.
                               48

-------
      (e>  Forging Die Contact Cooling Water
   Pollutant or
Pollutant Property
                   Maximum for
                   Any One Day
                       Maximum for
                     Monthly Average
    *g/kkg (Ib/billion Iba) of titanium forged
121
122
128
CYANIDE
LEAD
ZINC
AMMONIA
FLUORIDE
TITANIUM
OIL & GREASE
TOTAL SUSPENDED
  SOLIDS
pH
    87O
  1,300
  4,400
400,000
180,000
  6,200
 60,000
120,000
    360
    600
  i,aoo
180,000
 79,OOO
  2,700
 36,OOO
 59,000
                    Within the range of 7.5 to 1O.O at all times.
        Forging Wet APC Slowdown
   Pollutant or
Pollutant Property
                   Maximum for
                   Any One Day
                       .Maximum for
                     Monthly Average
    mg/kkg (Ib/billion Ibs) of titanium forged
121
122
128
CYANIDE
LEAD
ZINC
AMMONIA
FLUORIDE
TITANIUM
OIL E, GREASE
TOTAL SUSPENDED
  SOLIDS
    590
    &5O
  2,90O
270,000
12O,OOO
  4,100
 40,OOO
 83,OOO
    240
    4OO
  1,200
12O,OOO
 53,OOO
  1,800
 24,000
 39,OOO
     PH
               Within the range of 7.5 to 1O.O at all times,
                                49

-------
        Heat Treatment Contact Cooling Water
   Pollutant or
Pollutant Property
    Maximum for
    Any One Day
  Maximum for
Monthly Average
    mg/kkg (Ib/billion Iba) of titanium heat treated
121  CYANIDE
122  LEAD
128  ZINC
     AMMONIA
     FLUORIDE
     TITANIUM
     OIL 6, GREASE
     TOTAL SUSPENDED
       SOLIDS
     pH
          1,30O
          1,900
          6,600
        600,000
        270,000
          9,20O
         90,000
        180,000
             540
             900
           2,800
         260,000
         12O,OOO
           4,100
          54,000
          88,OOO
Within the range of 7.5 to 10.0 at all times.
      (h)  Surface Treatment Spent Baths
   Pollutant or
Pollutant Property
    Maximum for
    Any One Day
  Maximum for
Monthly Average
    mg/kkg 
-------
        Surface Treatment Rinaewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg 
-------
        Alkaline Cleaning Spent Baths
   Pollutant or
Pollutant Property
    Maximum for
    Any One Day
  Maximum for
Monthly Average
    mg/kkg (Ib/billion Iba) of titanium alkaline cleaned
121  CYANIDE
122  LEAD
128  ZINC
     AMMONIA
     FLUORIDE
     TITANIUM
     OIL & GREASE
     TOTAL SUSPENDED
       SOLIDS
     PH
            740
          1,100
          3,700
        340,000
        150,000
          5,200
         51,OOO
        10O,OOO
             310
             510
           1,60O
         150,OOO
          67,OOO
           2,300
          31,OOO
          50,OOO
Within the range of 7.5 to 10.0 at all times.
      (1)  Alkaline Cleaning Rinsewater
   Pollutant or
Pollutant Property
    Maximum for
    Any One Day
  Maximum for
Monthly Average
    mg/kkg (Ib/billion Iba) of titanium alkaline cleaned
121  CYANIDE
122  LEAD
128  ZINC
     AMMONIA
     FLUORIDE
     TITANIUM
     OIL & GREASE
     TOTAL SUSPENDED
       SOLIDS
     PH
            800
          1,2OO
          4,OOO
        37O,OOO
        16O,OOO
          5,7OO
         55,OOO
        11O,OOO
             330
             550
           1,700
         160,OOO
          73,OOO
           2,5OO
          33,OOO
          54,OOO
Within the range of 7.5 to 1O.O at. all timea.
                               52

-------
      <»)  Tumbling Wastewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg   Sawing/Grinding Spent Lubricants
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg  of titanium sawed or ground
121
122
128







CYANIDE
LEAD
ZINC
AMMONIA
FLUORIDE
TITANIUM
OIL & GREASE
TOTAL SUSPENDED
SOLIDS
pH Within
14.0
21.0
73. 0
6,6OO.O
3,OOO.O
1OO.O
99O.O
2,OOO.O

the range of 7.5
6.0
10.0
30. 0
2,9OO.O
1 , 3OO . O
45. 0
600.0
97O.O

to 1O.O at all times.
      (o)  Degreasing Spent Solvents

There shall be no discharge of process wastewater pollutants.
                              53

-------
SUBPART H.    BPT MASS LIMITATIONS FOR THE URANIUM FORMING
              SUBCATEGORY

      (a)  Extrusion Spent Lubricants

There shall be no discharge of process wastewater pollutants.


        Extrusion Tool Contact Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of uranium extruded

118  CADMIUM                    180                            78
120  COPPER                     980                           52O
124  NICKEL                     990                           660
     FLUORIDE                31,000                        14,OOO
     RADIUM                     (1)                           (1)
     URANIUM                  1,1OO                           47O
     OIL & GREASE            1O,OOO                         6,200
     TOTAL SUSPENDED         21,OOO                        10,OOO
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all times.

     (1) Concentration Value Is 5 Picocuries Per Liter

      (c)  Extrusion Press And Solution Heat Treatment Contact
             Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Iba) of extruded uranium heat treated

118  CADMIUM                    920                           41O
120  COPPER                   5,200                         2,700
124  NICKEL                   5,200                         3,5OO
     FLUORIDE               160,000                        72,000
     RADIUM                     <1>                           (1)
     URANIUM                  5,600                         2,500
     OIL S, GREASE            54,OOO                        33,OOO
     TOTAL SUSPENDED        11O,OOO                        53,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.O at all times.

     (1) Concentration Value Is 5 Picocuries Per Liter
                               54

-------
      (d)  Forging Spent Lubricants

There shall be no discharge of process wastewater pollutants.


        Forging Solution Heat Treatment Contact Cooling Water


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


    mg/kkg (Ib/billion Ibs) of forged uranium heat treated

118  CADMIUM                    970                           43O
120  COPPER                   5,400                         2,8OO
124  NICKEL                   5,500                         3,600
     FLUORIDE               170,000                        75,OOO
     RADIUM                     <1>                           (!)
     URANIUM                  5,8OO                         2,60O
     OIL & GREASE            57,OOO                        34,000
     TOTAL SUSPENDED        120,OOO                        55,OOO
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all times.

     <1> Concentration Value Is 5 Picocuriea Per Liter

      (f)  Surface Treatment Spent Baths
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average

118
120
124







mg/kkg (Ib/billion Iba:
CADMIUM
COPPER
NICKEL
FLUORIDE
RADIUM
URANIUM
OIL & GREASE
TOTAL SUSPENDED
SOLIDS
pH Within
I of uranium surface treated
12.0
68. 0
68. 0
2,100.0
(1)
73.0
71O.O
1 , 500 . 0

the range of 7.5 to 10.0 at all

5.3
36.0
45. 0
94O.O
(1)
32.0
43O.O
69O.O

times.
     (!) Concentration Value Is 5 Picocurles Per Liter
                              55

-------
        Surface Treatment Rinsewater
   Poliutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average

118
120
124







mg/kkg  Concentration Value Is 5 Picocuriea Per Liter

      (h)  Surface Treatment Wet APC Slowdown
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of uranium surface treated

118  CADMIUM                     25                            11
12O  COPPER                     140                            74
124  NICKEL                     14O                            94
     FLUORIDE                 4,4OO                         2,OOO
     RADIUM                     (!)                           <1>
     URANIUM                    150                            68
     OIL & GREASE             1,5OO                           89O
     TOTAL SUSPENDED          3,000                         1,4OO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.

     (!) Concentration Value Is 5 Picocuriea Per Liter
                               56

-------
      (i)  Sawing/Grinding Spent Emulsiona
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Iba) of uranium aawed or ground
118
120
124







CADMIUM
COPPER
NICKEL
FLUORIDE
RADIUM
URANIUM
OIL & GREASE
TOTAL SUSPENDED
SOLIDS
pH Within
1.1O
5.9O
6.OO
18O.OO
(1)
6.40
62.00
130.00

the range of 7.5 to
.50
3.10
3.90
82.00
<1>
2.80
37.OO
60. OO

10.0 at all times.
      (1) Concentration Value Is 5 Picocuriea Per Liter

      (3)  Post-Sawing/Grinding Rinaewater


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


    mg/kkg  Concentration Value la 5 Picocuriea Per Liter

      (k)  Degreaaing Spent Solvents

There ahall be no discharge of proceaa waatewater pollutants,
                              57

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SUBPART I.    BPT MASS LIMITATIONS FOR THE ZINC FORMING
              SUBCATEGORY

      (a)  Rolling Spent Neat Oils

There shall be no discharge of process wastewater pollutants.


      (b)  Rolling Spent Emulsions


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


  mg/kkg  (Ib/billion Ibs) of zinc rolled with emulsions

119  CHROMIUM                   .60                           .30
121  CYANIDE                    .40                           .20
128  ZINC                      2.00                           .80
     OIL & GREASE             28.00                         17.00
     TOTAL SUSPENDED          57.OO                         27.OO
       SOLIDS
     pH "           Within the range of 7.5 to 1O.O at all times.


        Rolling Contact Lubricant-Coolant Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg  
-------
         Drawing Spent Emulsions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of zinc drawn with emulaione

119  CHROMIUM                   3.5                           1.4
121  CYANIDE                    2.3                           l.O
128  ZINC                      12.0                           4.9
     OIL & GREASE             160.0                          96.O
     TOTAL SUSPENDED          330.0                         160.0
       SOLIDS
     pH             Within th<=s range of 7.5 to 10.0 at all times.


        Direct Chill Casting Contact Cooling Water


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


  mg/kkg (Ib/billion Ibs) of zinc cast by the direct chill method

119  CHROMIUM                   220                            91
121  CYANIDE                    150                            6O
128  ZINC                       730                           31O
     OIL & GREASE            1O,OOO                         6,OOO
     TOTAL SUSPENDED         21,OOO                         9,800
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.


        Stationary Casting Contact Cooling Water

There shall be no discharge of process wastewater pollutants.
                              59

-------
      (g)  Heat Treatment Contact Colling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of zinc heat treated

119  CHROMIUM                   330                           14O
121  CYANIDE                    220                            91
128  ZINC                     1,100                           460
     OIL & GREASE            15,000                         9,100
     TOTAL SUSPENDED         31,000                        15,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.


        Surface Treatment Spent Baths
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of zinc surface treated

119  CHROMIUM                   4.2                           1.7
121  CYANIDE                    2.8                           1.1
128  ZINC                      14.0                           5.8
     OIL & GREASE             19O.O                         110.O
     TOTAL SUSPENDED          39O.O                         190.0
       SOLIDS
     pH             Within the range of 7.5 to 10.O at all times.


      
-------
      <3>  Alkaline Cleaning Spent Baths
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of zinc alkaline cleaned

119  CHROMIUM                   .30                           .10
121  CYANIDE                    .20                           .10
128  ZINC                      1.00                           .40
     OIL & GREASE             14.OO                          8.60
     TOTAL SUSPENDED          29.00                         14.OO
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all times.


        Alkaline Cleaning Rlnaewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Iba) of zinc alkaline cleaned

119  CHROMIUM                 2,500                         1,OOO
121  CYANIDE                  1,7OO                           69O
128  ZINC                     8,400                         3,5OO
     OIL & GREASE           110,OOO                        69,OOO
     TOTAL SUSPENDED        23O,OOO                       110,000
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all times.


      <1>  Sawing/Grinding Spent Lubricants
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


  mg/kkg (Ib/billion lbs> of zinc sawed or ground

119  CHROMIUM                  24.0                          1O.O
121  CYANIDE                   16.O                           6.6
128  ZINC                      8O.O                          33.O
     OIL & GREASE           1,1OO.O                         66O.O
     TOTAL SUSPENDED        2,3OO.O                       1,1OO.O
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
                               61

-------
      (m)  Degreasing Spent Solvents

There shall be no discharge of process wastewater pollutants.



SUBPART J.    BPT MASS LIMITATIONS FOR THE ZIRCONIUM/HAFNIUM
              FORMING SUBCATEGORY

      (a)  Drawing Spent Lubricants

There shall be no discharge of process wastewater pollutants.


      (b)  Extrusion Spent Emulsions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of zirconium/hafnium extruded with
       emulsions

119  CHROMIUM                  33.O                          13.O
121  CYANIDE                   21.0                           8.9
124  NICKEL                   140.0                          94.O
     AMMONIA                9,90O.O                       4,300.0
     FLUORIDE               4,40O.O                       2,OOO.O
     HAFNIUM                  150.O                          67.O
     ZIRCONIUM                150.0                          67.0
     OIL & GREASE           1,500.O                         89O.O
     TOTAL SUSPENDED        3,OOO.O                       1,4OO.0
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all times.
                               62

-------
         Extrusion Press Hydraulic Fluid Leakage


   Pollutant or         Maximum for                Maximuni~f or
Pollutant Property      Any One Day              Monthly Average

119
121
124








mg/kkg (Ib/billion Ibs)
CHROMIUM
CYANIDE
NICKEL
AMMONIA
FLUORIDE
HAFNIUM
ZIRCONIUM
OIL & GREASE
TOTAL SUSPENDED
SOLIDS
pH Within
1 o£ zirconium/haf nic
160
110
710
49,OOO
22,OOO
760
760
7,400
15,OOO

the range of 7.5 to
im extruded
67
44
470
22,OOO
9,8OO
34O
340
4,4OO
7,2OO

1O.O at all times.
      (id)  Extrusion Press And Solution Heat Treatment  Contact
             Cooling Water
   Pollutant or         Maximum for                 Maximum  for
Pollutant Property      Any One Day               Monthly  Average
    mg/kkg  (Ib/billion Ibs) of extruded zirconium/hafnium  heat
       treated

119  CHROMIUM                    13O                             51
121  CYANIDE                     83                             34
124  NICKEL                      550                           36O
     AMMONIA                  38,OOO                         17,OOO
     FLUORIDE                 17,OOO                          7,5OO
     HAFNIUM                     580                           26O
     ZIRCONIUM                   58O                           260
     OIL S. GREASE             5,7OO                          3,4OO
     TOTAL SUSPENDED          12,OOO                          5,6OO
       SOLIDS
     pH             Within the range  of 7.5  to  10.0 at  all times.
       (e)  Tube Reducing Spent  Lubricants

There  shall be no discharge  of  process  wastewater pollutants.
                               63

-------
      <£>  Forging Solution Heat Treatment Contact Cooling Water


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


  mg/kkg (Ib/billion lba> of forged zirconium/hafnium heat treated

119  CHROMIUM                  15.0                           6.3
121  CYANIDE                   1O.O                           4.2
124  NICKEL                    67.0                          44.O
     AMMONIA                4,700.0                       2,000.0
     FLUORIDE               2,100.O                         920.O
     HAFNIUM                   72.0                          32.0
     ZIRCONIUM                 72.0                          32.O
     OIL & GREASE             7OO.O                         420.O
     TOTAL SUSPENDED        1,4OO.O                         680.O
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at. all times.


        Surface Treatment Spent Baths
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of zirconium/hafnium rolled with
      emulsions

119  CHROMIUM                   ISO                            72
121  CYANIDE                    120                            48
124  NICKEL                     770                           510
     AMMONIA                 53,OOO                        23,OOO
     FLUORIDE                24,OOO                        11,OOO
     HAFNIUM                    82O                           36O
     ZIRCONIUM                  820                           36O
     OIL & GREASE             8,OOO                         4,8OO
     TOTAL SUSPENDED         16,000                         7,80O
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
                              64

-------
        Surface Treatment Rinsewater
   Pollutant or
Pollutant Property
    Maximum for
    Any One Day
  Maximum for
Monthly Average
    mg/kkg (Ib/billion lba> of zirconium/hafnium surface treated
119  CHROMIUM
121  CYANIDE
124  NICKEL
     AMMONIA
     FLUORIDE
     HAFNIUM
     ZIRCONIUM
     OIL 6, GREASE
     TOTAL SUSPENDED
       SOLIDS
     pH
          6,700
          4,4OO
         29,OOO
      2fOOO,OOO
        910,000
         31,OOO
         31,OOO
        310,000
        63O,OOO
           2,800
           1,8OO
          19,000
         900,000
         400,000
          14,OOO
          14,OOO
         1SO,OOO
         300,000
Within the range of 7.5 to 10.O at all times.
        Alkaline Cleaning Spent Baths
   Pollutant or
Pollutant Property
    Maximum for
    Any One Day
  Maximum for
Monthly Average
    mg/kkg (Ib/billion lbs> of zirconium/hafnium alkaline cleaned
119  CHROMIUM
121  CYANIDE
124  NICKEL
     AMMONIA
     FLUORIDE
     HAFNIUM
     ZIRCONIUM
     OIL 6, GREASE
     TOTAL SUSPENDED
       SOLIDS
     pH
            940
            62O
          4,1OO
        280,OOO
        13O,OOO
          4,40O
          4,4OO
         43,OOO
         87,OOO
             38O
             26O
           2,70O
         120,OOO
          56,000
           1,9OO
           1,900
          26,OOO
          42,OOO
Within the range of 7.5 to 10.O at all times.
                               65

-------
           Alkaline Cleaning Rinsewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    rag/kkg (Ib/billion Iba) of zirconium/hafnium alkaline cleaned

119  CHROMIUM                24,000                        10,000
121  CYANIDE                 16,000                         6,60O
124  NICKEL                 110,000                        70,OOO
     AMMONIA              7,400,000                     3,200,000
     FLUORIDE             3,300,000                     1,50O,OOO
     HAFNIUM                110,OOO                        50,OOO
     ZIRCONIUM              110,000                        50,000
     OIL E, GREASE         1,1OO,OOO                       660,OOO
     TOTAL SUSPENDED      2,300,000                     1,100,000
       SOLIDS
     pH             Within the range of 7.5 to 10.O at all times.
      (k)  Sawing/Grinding Spent Lubricants
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
\

119
121
1.24








mg/kkg (Ib/billion Ibs)
CHROMIUM
CYANIDE
NICKEL
AMMONIA
FLUORIDE
HAFNIUM
ZIRCONIUM
OIL & GREASE
TOTAL SUSPENDED
SOLIDS
pH Within
of zirconium/hafnium sawed
4.0
2.6
17.0
1,2OO.O
54O.O
18. 0
18. 0
180. 0
37O.O

the range of 7.5 to 1O.O at
or ground
1.6
1.1
11.0
530.0
24O.O
8.2
8.2
11O.O
180.0

all times.
                                66

-------
      <1>  Sawing/Grinding Wet APC Slowdown

There ahall be no discharge of process wastewater pollutants,


      (m)  Degreasing Spent Solvents

There shall be no discharge of process wastewater pollutants,


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


  mg/kkg  of zirconium/hafnium degreased

119  CHROMIUM                   890                           370
121  CYANIDE                    590                           24O
124  NICKEL                   3,900                         2,600
     AMMONIA                270,000                       12O,OOO
     FLUORIDE               120,000                        54,000
     HAFNIUM                  4,200                         1,8OO
     ZIRCONIUM                4,200                         1,800
     OIL & GREASE            41,000                        24,OOO
     TOTAL SUSPENDED         83,000                        4O,000
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
                             67

-------
SUBPART K.    BPT MASS LIMITATIONS FOR THE IRON AND STEEL/COPPER/
       ALUMINUM METAL POWDER PRODUCTION AND POWDER METALLURGY
       SUBCATEGORY

      (a)  Metal Powder Production Atomization Waatewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of Iron, copper, and aluminum powder
       wet atomized

120  COPPER                   9,600                         5,OOO
121  CYANIDE                  1,50O                           6OO
122  LEAD                     2,10O                         1,000
     ALUMINUM                32,000                        16,OOO
     IRON                     6,OOO                         3,10O
     OIL & GREASE           100,OOO                        60,OOO
     TOTAL SUSPENDED        210,OOO                        98,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.


        Metal Powder Production Milling Waatewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Iba) of iron, copper, and aluminum powder
       wet milled

12O  COPPER                   3,2OO                         1,7OO
121  CYANIDE                    480                           2OO
122  LEAD                       7OO                           33O
     ALUMINUM                11,OOO                         5,3OO
     IRON                     2,OOO                         1,OOO
     OIL & GREASE            33,000                        20,OOO
     TOTAL SUSPENDED         68,000                        33,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.O at all timea.
                              68

-------
        Metal Powder Production Wet APC Slowdown
   Pollutant or
Pollutant Property
    Maximum for
    Any One Day
  Maximum for
Monthly Average
    mg/kkg (Ib/billion lbs> of iron, copper, and aluminum powder
       produced
12O  COPPER
121  CYANIDE
122  LEAD
     ALUMINUM
     IRON
     OIL & GREASE
     TOTAL SUSPENDED
       SOLIDS
     PH
          5,000
            77O
          1,100
         17,OOO
          3,200
         53,OOO
        110,000
           2,600
             320
             530
           8,400
           1,600
          32,000
          51,000
Within the range of 7.5 to 10.0 at all times.
      (d)  Sizing/Repressing Spent Lubricanta

There shall be no discharge of process wastewater pollutants.


      (e>  Oil-Resin Impregnation Wastewater
   Pollutant or
Pollutant Property
    Maximum for
    Any One Day
  Maximum for
Monthly Average
    mg/kkg (Ib/billion Ibs) of iron, copper, and aluminum powder
       metallurgy parts impregnated with oil-resin
120  COPPER
121  CYANIDE
122  LEAD
     ALUMINUM
     IRON
     OIL fi. GREASE
     TOTAL SUSPENDED
       SOLIDS
     PH
          140.0
           22.0
           31.0
          48O.O
           89.0
        1,5OO.O
        3,1OO.O
            75.0
             8.9
            15.0
           240.0
            45.0
           89O.O
         1,5OO.0
Within the range of 7.5 to 10.0 at all times.
                                 69

-------
        Steam Treatment Wet APC Slowdown
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of iron, copper, and aluminum powder
       powder metallurgy parts steam treated

120  COPPER                   5,400                         2,80O
121  CYANIDE                    820                           340
122  LEAD                     1,200                           57O
     ALUMINUM                18,000                         9,100
     IRON                     3,40O                         1,70O
     OIL & GREASE            57,000                        34,OOO
     TOTAL SUSPENDED        120,OOO                        55,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.O at all times.


        Tumbling, Burnishing And Cleaning Waatewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of iron, copper, and aluminum powder
       metallurgy parts tumbled, burnished, or cleaned

120  COPPER                  14,OOO                         7,20O
121  CYANIDE                  2,100                           860
122  LEAD                     3,000                         1,4OO
     ALUMINUM                46,OOO                        23,OOO
     IRON                     8,60O                         4,4OO
     OIL & GREASE           14O,OOO                        86,OOO
     TOTAL SUSPENDED        29O,OOO                       14O,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
                              70

-------
        Sawing/Grinding Spent Lubricants
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of iron, copper, and aluminum powder
       metallurgy parts sawed or ground

12O  COPPER                   1,9OO                         1,OOO
121  CYANIDE                    290                           12O
122  LEAD                       420                           20O
     ALUMINUM                 6,400                         3,2OO
     IRON                     1,20O                           61O
     OIL & GREASE            20,000                        12,OOO
     TOTAL SUSPENDED         41,000                        20,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
      (i)  Degreaaing Spent Solvents

There shall be no discharge of process wastewater pollutants.
    BAT is proposed based on the treatment effectiveness
    achievable by the application of chemical precipitation and
    sedimentation with the addition of filtration (lime, settle,
    and filter) technology and in-proceas flow reduction control
    methods for nine of the eleven subcategories.  BAT is
    proposed baaed on the treatment effectiveness achievable by
    the application of chemical precipitation and sedimentation
    (lime and settle) technology and in-proceas flow reduction
    control methods for the Lead/Tin/Biamuth Forming and the
    Iron And Steel/Copper/Aluminum Metal Powder Production And
    Powder Metallurgy Subcategories.  The following BAT effluent
    limitations are proposed for existing sources:
                               71

-------
SUBPAF-: A.    BAT MASS LIMITATIONS FOR THE BERYLLIUM FORMING
              SUBCATEGORY

      (a)  Area Cleaning Wastewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of beryllium formed

117  BERYLLIUM             - 17,OOO                         7,20O
120  COPPER                  27,000                        13,000
121  CYANIDE                  4,300                         1,70O
     FLUORIDE             1,300,000                       560,000


      >  Billet Washing Wastewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of beryllium billets washed

117  BERYLLIUM                 31.O                          13.0
12O  COPPER                    49.O                          23.O
121  CYANIDE                    7.6                           3.1
     FLUORIDE               2,300.0                       1,OOO.O
      (c>  Surface Treatment Spent Baths


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


    mg/kkg (Ib/billion Ibs) of beryllium surface treated

117  BERYLLIUM                  25O                           10O
120  COPPER                     39O                           190
121  CYANIDE                     62                            25
     FLUORIDE                18,OOO                         8,100
                              72

-------
        Surface Treatment Rinaewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Iba) of beryllium surface treated

117  BERYLLIUM                  630                           260
120  COPPER                     980                           47O
121  CYANIDE                    150                            61
     FLUORIDE                46,000                        20,000
      (e)  Sawing/Grinding Spent Lubricants


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


    mg/kkg  of beryllium sawed or ground

117  BERYLLIUM                  350                           14O
120  COPPER                     540                           260
121  CYANIDE                     85                            34
     FLUORIDE                25,000                        11,000


      
-------
SUBPART B.     BAT MASS LIMITATIONS FOR THE LEAD/TIN/BISMUTH
              FORMING SUBCATEGORY

      (a)  Rolling Spent Emulsions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of lead/tin/bismuth rolled with
       emulsions

114  ANTIMONY                  67.0                          3O.O
122  LEAD                      1O.O                           4.7
      (b>  Rolling Spent Soap Solutions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


  mg/kkg (Ib/billion Ibs) of lead/tin/bismuth rolled with soap
     solutions

114  ANTIMONY                 120.0                          55.O
122  LEAD                      18.O                           8.6
      (c)  Drawing Spent Neat Oils

There shall be no discharge of process waatewater pollutants,


      (d)  Drawing Spent Emulsions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of lead/tin/bismuth drawn with
       emulsions

114  ANTIMONY                  48.0                          21.0
122  LEAD                       7.0                           3.3
                                74

-------
      (e)  Drawing Spent Soap Solutions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day •             Monthly Average
   mg/kkg (Ib/billion lba> of lead/tin/bismuth drawn with soap
      solutions

114  ANTIMONY                  21.O                          10.0
122  LEAD                       3.1                           1.5
      (f>  Extrusion Press And Solution Heat Treatment Contact
              Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg 
-------
      (i)  Semi-Continuous Ingot Casting Contact Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg  of lead/tin/bismuth cast by the
       continuous strip method

114  ANTIMONY                  8.40                          3.8O
122  LEAD                      1.20                           .SO
        Shot Casting Contact Cooling Water


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


    mg/kkg 
-------
      (*)  Alkaline Cleaning Rinaewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Iba) of lead/tin/bismuth alkaline cleaned

114  ANTIMONY                 1,900                           830
122  LEAD                       270                           13O


      (n)  Swaging Spent Emulsions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg 
-------
      (b)  Forging Spent Lubricants

There shall be no discharge of process wastewater pollutants.


        Forging Wet APC Slowdown


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


    mg/kkg (Ib/billion Ibs) of magnesium forged

119  CHROMIUM                98,000                        40,OOO
128  ZINC                   270,000                       110,000
     AMMONIA             35,OOO,OOO                    16,OOO,OOO
     FLUORIDE            16,000,000                     7,000,000
     MAGNESIUM              180,OOO                        80,000


      (d>  Forging Solution Heat Treatment Contact Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of forged magnesium heat treated

119  CHROMIUM                   230                            95
128  ZINC                       65O                           27O
     AMMONIA                 84,OOO                        37,OOO
     FLUORIDE                38,000                        17,000
     MAGNESIUM                  44O                           19O
      (e)  Forging Equipment Cleaning Waatewater


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


    mg/kkg (Ib/billion Iba) of magnesium forged

119  CHROMIUM                    6O                            24
128  ZINC                       170                            68
     AMMONIA                 22,OOO                         9,50O
     FLUORIDE                 9,600                         4,3OO
     MAGNESIUM                  11O                            49
                              78

-------
        Direct Chill Casting Contact Cooling Water

There shall be no discharge of process wastewater pollutants.


        Surface Treatment Rinsewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of magnesium surface treated

119  CHROMIUM                   650                           27O
128  ZINC                     1,8OO                           74O
     AMMONIA                240,000                       100,000
     FLUORIDE               110,000                        47,OOO
     MAGNESIUM                1,200                           530


      (i)  Sawing/Grinding Spent Lubricants

There shall be no discharge of process wastewater pollutants.
                              79

-------
      <3>  Sanding And Repairing Wet APC Slowdown
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of magnesium aanded and repaired

119  CHROMIUM                   ISO                            64
128  ZINC                       440                           180
     AMMONIA                 57,000                        25,000
     FLUORIDE                25,000                        11,000
     MAGNESIUM                  300                           130
      (k)  Degreasing Spent Solvents

There shall be no discharge of process wastewater pollutants.



SUBPART D.    BAT MASS LIMITATIONS FOR THE NICKEL/COBALT FORMING
              SUBCATEGORY

      (a)  Rolling Spent Neat Oils

There shall be no discharge of process wastewater pollutants.


      (b)  Rolling Spent Emulsions


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


    mg/kkg (Ib/billion Iba) of nickel/cobalt rolled with emulsions

119  CHROMIUM                   550                           22O
124  NICKEL                     820                           550
     FLUORIDE                89,000                        39,OOO
                           80

-------
      (c)  Rolling Contact Lubricant-Coolant Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of nickel/cobalt rolled with contact
       lubricant-coolant water

119  CHROMIUM                   500                           200
124  NICKEL                     740                           50O
     FLUORIDE                80,000                        35,000
      Cd)  Rolling Solution Heat Treatment Contact Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


  mg/kkg (Ib/billion Iba) of rolled nickel/cobalt heat treated

119  CHROMIUM                   .00                           .00
124  NICKEL                     .00                           .00
     FLUORIDE                  1.60                           .70
      (e)  Tube Reducing Spent Lubricants

There shall be no discharge of process wastewater pollutants.


      (f)  Drawing Spent Neat Oils

There ahall be no discharge of process wastewater pollutants.


      (g)  Drawing Spent Emulsions


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


    mg/kkg (Ib/billion Ibs) of nickel/cobalt drawn with emulsions

119  CHROMIUM                    35                            14
124  NICKEL                      52                            35
     FLUORIDE                 5,700                         2,50O
                             81

-------
        Extruaion Spent Lubricants

There shall be no discharge of process wastewater pollutants.
        Extrusion Press And Solution Heat Treatment Contact
             Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg   Forging Equipment Cleaning Wastewater


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


    mg/kkg 
-------
      <1>  Forging Die Contact Cooling Water
   Pollutant or         Maximum for                 Maximum for
Pollutant Property      Any One Day               Monthly Average


    mg/kkg (Ib/billion Iba) of nickel/cobalt forged

119  CHROMIUM                    47                             19
124  NICKEL                      69                             47
     FLUORIDE                 7,500                          3,300
___________.____-___»_.»-___—___.—.—_.— —_ — _.-.______ — _—_ — ______________ — _ — —._— ___—___-_—._ — _*-

      <»)  Forging/Swaging Spent Neat Oils

There shall be no discharge of process wastewater pollutants.
      (n)  Stationary And Direct  Chill  Casting Contact Cooling
             Water
   Pollutant or         Maximum for                 Maximum for
Pollutant Property      Any One Day               Monthly Average
    mg/kkg 
-------
        Annealing Solution Heat Treatment Contact Cooling
           Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of nickel/cobalt annealed

119  CHROMIUM                   17O                            69
124  NICKEL                     250                           170
     FLUORIDE                27,000                        12,000
      (r)  Wet APC Slowdown


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


    mg/kkg (Ib/billion Iba) of nickel/cobalt formed

119  CHROMIUM                    93                            38
124  NICKEL                     14O                            93
     FLUORIDE                15,OOO                         6,6OO
                              84

-------
      (a)  Surface Treatment Spent Baths
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg 
-------
        Molten Salt Rinsewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg   Ammonia Rinse Wastewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
  mg/kkg (Ib/billion Ibs) of nickel/cobalt treated with ammonia
     solution

119  CHROMIUM                   5.8                           2.4
124  NICKEL                     8.6                           5.8
     FLUORIDE                 930.O                         410.0
        Sawing/Grinding Spent Lubricants


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


    mg/kkg 
-------
        Hydrostatic Tube Testing Waatewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of nickel/cobalt tube tested by the
       hydrostatic method

119  CHROMIUM                    50                            20
124  NICKEL                      74                            5O
     FLUORIDE                 8,OOO                         3,60O
      
-------
SUBPART E.    BAT MASS LIMITATIONS FOR THE PRECIOUS METALS FORMING
             SUBCATEGORY

      (a)  Rolling Spent Emulsiona
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


  mg/kkg (Ib/billion Ibs) of precious metala rolled with emulsions

118  CADMIUM                    7.2                           2.9
120  COPPER                    46.0                          22.0
121  CYANIDE                    7.2                           2.9
126  SILVER                    10.0                           4.3
      (b)  Rolling Solution Heat Treatment Contact Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


   mg/kkg (Ib/billion Iba) of rolled precious metals heat treated

118  CADMIUM                    140                            56
12O  COPPER                     9OO                           43O
121  CYANIDE                    140                            56
126  SILVER                     20O                            84
      (c)  Drawing Spent Neat Oils

There shall be no discharge of process wastewater pollutants,


      (d)  Drawing Spent Emulsions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


  mg/kkg (Ib/billion Iba) of precious metala drawn with emulsions

118  CADMIUM                    4.3                           1.7
120  COPPER                    27.0                          13.O
121  CYANIDE                    4.3                           1.7
126  SILVER                     6.2                           2.6
                                38

-------
        Drawing Spent Soap Solutions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
   mg/kkg (Ib/billion lba> of precious metals drawn with soap
      solutions
118
120
121
126
CADMIUM
COPPER
CYANIDE
SILVER
1.40
8.9O
1.40
2.00
.60
4. 2O
.60
.80
      <£>  Extrusion Press And Solution Heat Treatment Contact
             Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


  mg/kkg  of extruded precious metals heat treated

118  CADMIUM                    270                           HO
120  COPPER                   1,800                           840
121  CYANIDE                    27O                           11O
126  SILVER                     400                           160
        Semi-Continuous And Continuous Casting Contact Cooling
              Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg 
-------
      (h>  Stationary Casting Contact Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg Clb/billion Iba) of precioua metals cast by the
       stationary method

US  CADMIUM                    .80                           .30
120  COPPER                ,5.30                          2.5O
121  CYANIDE                    .80                           .30
126  SILVER                    1.20                           .50
        Direct Chill Casting Contact Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg 
-------
        Casting Wet APC Blowdown
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


   mg/kkg  of precious metals cast

118  CADMIUM                   1.20                           .50
120  COPPER                    7.50                          3.60
121  CYANIDE                   1.20                           .50
126  SILVER                    1.7O                           .70
      (!)  Metal Powder Production Atomization Wastewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


   mg/kkg (Ib/billion Ibs) of precious metals powder wet atomized

118  CADMIUM                  1,300                           53O
120  COPPER                   8,500                         4,1OO
121  CYANIDE                  1,300                           530
126  SILVER                   1,900                           800


        Metal Powder Production Ball Milling Wastewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of precious metals powder wet ball
       milled

118  CADMIUM                    43O                           170
12O  COPPER                   2,8OO                         1,3OO
121  CYANIDE                    43O                           17O
126  SILVER                     630                           26O
                               91

-------
      (n)  Preaaure Bonding Contact Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billlon Iba) of precloua metal and baae metal
       preaaure bonded

118  CADMIUM                   17.0                           6.7
120  COPPER                   110.0                          51.O
121  CYANIDE                   17.0                           6.7
126  SILVER                    24.O                          10.O
      (o)  Annealing Solution Heat Treatment Contact Cooling
             Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/bllllon Iba) of precloua metala annealed

118  CADMIUM                    2OO                            8O
120  COPPER                   1,3OO                           61O
121  CYANIDE                    200                            8O
126  SILVER                     29O                           12O


      (p>  Surface Treatment Spent Batha


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


    mg/kkg (Ib/bllllon Iba) of precloua metala aurface treated

118  CADMIUM                     31                            12
12O  COPPER                     200                            95
121  CYANIDE                     31                            12
126  SILVER                      45                            19
                               92

-------
        Surface Treatment Rinaewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg __w ^ w _ — — — M .«•_«

        Alkaline Cleaning Spent Baths


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


    mg/kkg (Ib/billion Ibs) of precious metals alkaline cleaned

118  CADMIUM                    .70                           .30
120  COPPER                    4.70                          2.2O
121  CYANIDE                    .70                           .30
126  SILVER                    1.10                           -4O


      (s)  Alkaline Cleaning Rinaewater

— — — —~ ^«W —*• —~ — ^ — ^- — ^ .^— — _—_.—._ ^^ ~_ ___ ^ ^ ^ ___ ~~—,.~^~ _^ _—«__^_^ ^l^v_^_^__ _„, __ _^_^ .^ __. _ ^^ _v« _««M ^ __ _ —
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg 
-------
      (t)  Pre-Bonding Cleaning Wastewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of precious metal and base metal
       cleaned prior to bonding
118
120
121
126
CADMIUM
COPPER
CYANIDE
SILVER
68
440
68
99
27
210
27
41
      (u)  Tumbling Wastewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg 
-------
      (w)  Sawing/Grinding Spent Emulsions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Iba) of precloua metals sawed or ground

118  CADMIUM                   1.20                           .50
120  COPPER                    7.70                          3.7O
121  CYANIDE                   1.20                           .50
126  SILVER                    1.80                           .70


        Degreasing Spent Solvents

There shall be no discharge of process wastewater pollutants.
SUBPART F.    BAT MASS LIMITATIONS FOR THE REFRACTORY METALS
              FORMING SUBCATEGORY

      (a)  Rolling Spent Neat Oila

There shall be no discharge of process waatewater pollutants.


        Rolling Spent Emulsions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of refractory metals rolled with
       emulsions

120  COPPER                   1,500                           730
124  NICKEL                     660                           44O
     COLUMBIUM                  830                           36O
     FLUORIDE                71,000                        32,OOO
     MOLYBDENUM                 83O                           36O
     TANTALUM                   830                           36O
     TUNGSTEN                   830                           36O
     VANADIUM                   83O                           36O
                               95

-------
        Drawing Spent Lubricants

There shall be no discharge of process wastewater pollutants.


      (d)  Extrusion Press And Solution Heat Treatment Contact
             Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of extruded refractory metals heat
       treated

120  COPPER                     440                           210
124  NICKEL                     190                           130
     COLUMBIUM                  24O                           100
     FLUORIDE                21,OOO                         9,1OO
     MOLYBDENUM                 24O                           100
     TANTALUM                   240                           1OO
     TUNGSTEN                   24O                           100
     VANADIUM                   24O                           1OO
      (e)  Extrusion Press Hydraulic Fluid Leakage
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of refractory metals extruded

120  COPPER                   1,5OO                           73O
124  NICKEL                     650                           44O
     COLUMBIUM                  82O                           36O
     FLUORIDE                71,OOO                        31,OOO
     MOLYBDENUM                 82O                           36O
     TANTALUM                   S2O                           360
     TUNGSTEN                   82O                           36O
     VANADIUM                   82O                           36O
      
-------
        Forging Solution Heat Treatment Contact Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of forged refractory metals heat
       treated
12O
124






COPPER
NICKEL
CQLUMBIUM
FLUORIDE
MOLYBDENUM
TANTALUM
TUNGSTEN
VANADIUM
740
320
40O
34,000
400
400
400
400
350
210
170
15,000
170
17O
170
17O
        Extrusion And Forging Equipment Cleaning Wastewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
  mg/kkg (Ib/billion Ibs) of refractory metals extruded or forged

120  COPPER                      53                            25
124  NICKEL                      23                            15
     COLUMBIUM                   29                            13
     FLUORIDE                 2,500                         1,1OO
     MOLYBDENUM                  29                            13
     TANTALUM                    29                            13
     TUNGSTEN                    29                            13
     VANADIUM                    29                            13
                              97

-------
         Metal Powder Production Wastewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of refractory metals powder produced

120  COPPER                   2,100                         1,OOO
124  NICKEL                     900                           61O
     COLUMBIUM                1,100                           490
     FLUORIDE                98,000                        43,OOO
     MOLYBDENUM               1,100                           490
     TANTALUM                 1,100                           49O
     TUNGSTEN                 1,100                           490
     VANADIUM                 1,100                           490
        Metal Powder Production Wet APC Blowdown

There shall be no discharge of process wastewater pollutants.


        Metal Powder Pressing Spent Lubricants

There shall be no discharge of process wastewater pollutants.


      (1)  Casting Contact Cooling Water

There shall be no discharge of process waatewater pollutants.


      <»>  Poat-Casting Billet Uashwater


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


  mg/kkg (Ib/billion lbs> of cast refractory metals billet washed

12O  COPPER                    38.O                          18.0
124  NICKEL                    16.0                          11.O
     COLUMBIUM                 21.0                           8.9
     FLUORIDE               1,800.O                         79O.O
     MOLYBDENUM                21.0                           8.9
     TANTALUM                  21.0                           8.9
     TUNGSTEN                  21.O                           8.9
     VANADIUM                  21.0                           8.9
                               98

-------
      (n>  Surface Treatment Spent Batha
   Pollutant or
Pollutant Property
Maximum for
Any One Day
  Maximum for
Monthly Average
    mg/kkg (lb/billion Iba) of refractory metala surface treated
120
124






COPPER
NICKEL
COLUMBIUM
FLUORIDE
MOLYBDENUM
TANTALUM
TUNGSTEN
VANADIUM
16.0
7.0
a. 8
76O.O
8.S
8. 8
8.8
8.8
7.7
4.7
3.8
340.0
3.8
3.8
3.8
3.8
        Surface Treatment Rinaewater
   Pollutant or
Pollutant Property
Maximum for
Any One Day
  Maximum for
Monthly Average
    mg/kkg 
-------
      (p)  Surface Treatment Wet APC Slowdown
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg   Surface Coating Wet APC Slowdown
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Iba) of refractory metala surface coated

12O  COPPER                   1,40O                           660
124  NICKEL                     590                           4OO
     COLUMBIUM                  75O                           320
     FLUORIDE                64,OOO                        29,OOO
     MOLYBDENUM                 750                           32O
     TANTALUM                   75O                           32O
     TUNGSTEN                   75O                           32O
     VANADIUM                   75O                           32O
                              100

-------
      (r)  Alkaline Cleaning Spent Baths
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    ng/kkg (Ib/billlon Iba) of refractory metals alkaline cleaned
120
124






COPPER
NICKEL
COLUMBIUM
FLUORIDE
MOLYBDENUM
TANTALUM
TUNGSTEN
VANADIUM
39.0
17.0
21.0
1,800.0
21. 0
21.0
21.0
21.0
19. 0
11.0
9.2
810.0
9.2
9.2
9.2
9.2
      (a)  Alkaline Cleaning Rinsewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg 
-------
       (t)  Molten Salt Cleaning Rinsewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
  mg/kkg   Sawing/Grinding Spent Neat Oils

There shall be no discharge of process wastewater pollutants.
                             102

-------
      (w)  Sawing/Grinding Spent Emulaiona
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg 
-------
       (y>  Sawing/Grinding Wet APC Slowdown
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Iba) of refractory metals aawed or ground

120  COPPER                     140                            66
124  NICKEL                      59                            40
     COLUMBIUM                   75                            32
     FLUORIDE                 6,400                         2,900
     MOLYBDENUM                  75                            32
     TANTALUM                    75                            32
     TUNGSTEN                    75                            32
     VANADIUM                    75                            32
        Post Sawing/Grinding Rinaewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Iba) of aawed or ground refractory metals
       rinsed

120  COPPER                      66                            31
124  NICKEL                      28                            19
     COLUMBIUM                   35                            15
     FLUORIDE                 3,10O                         1,4OO
     MOLYBDENUM                  35                            15
     TANTALUM                    35                            15
     TUNGSTEN                    35                            15
     VANADIUM                    35                            15
                             104

-------
      Caa)  Product Testing Wastewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of refractory metala product tested
120
124






COPPER
NICKEL
COLUMBIUM
FLUORIDE
MOLYBDENUM
TANTALUM
TUNGSTEN
VANADIUM
10.0
4.3
5.4
460.0
5.4
5.4
5.4
5.4
4.7
2.9
2.3
200.0
2.3
2.3
2.3
2.3
      (ab)  Degreasing Spent Solvents

There shall be no discharge of process wastewater pollutants,
SUBPART G.    BAT MASS LIMITATIONS FOR THE TITANIUM FORMING
              SUBCATEGORY

      (a)  Cold Rolling Spent Lubricants
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg 
-------
        Hot Rolling Contact Lubricant-Coolant Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg  of titanium hot rolled with contact
       lubricant-coolant water
121
122
128



CYANIDE
LEAD
ZINC
AMMONIA
FLUORIDE
TITANIUM
86
12O
440
57,OOO
26,OOO
3OO
34
56
180
25,000
11,OOO
130
      
-------
   Forging Die Contact Cooling Water
Pollutant or
Pollutant Property
mg/kkg (Ib/billion
121 CYANIDE
122 LEAD
128 ZINC
AMMONIA
FLUORIDE
TITANIUM
(£> Forging Wet
Pollutant or
Pollutant Property
mg/kkg  Heat Treatme
Pollutant or
Pollutant Property
mg/kkg 
-------
Ch)   Surface Treatment Spent Baths
Pollutant or
Pollutant Property
mg/kkg  Surface Treatment Rlnaewater
Pollutant or
Pollutant Property
mg/kkg (Ib/billion
121 CYANIDE
122 LEAD
128 ZINC
AMMONIA
FLUORIDE
TITANIUM
Maximum for
Any One Day
Ibs) of titanium surface
42O
59O
2,2OO
280, OOO
13O,OOO
1,5OO
Maximum for
Monthly Average
treated
170
27O
890
12O,OOO
56, OOO
63O
<3> Surface Treatment Wet APC Slowdown
Pollutant or
Pollutant Property
mg/kkg 
-------
   Alkaline Cleaning Spent Baths
Pollutant or
Pollutant Property
mg/kkg (Ib/billion
121 CYANIDE
122 LEAD
128 ZINC
AMMONIA
FLUORIDE
TITANIUM
(1) Alkaline Cl«
Pollutant or
Pollutant Property
mg/kkg (Ib/billion
121 CYANIDE
122 LEAD
128 ZINC
AMMONIA
FLUORIDE
TITANIUM
<») Tumbling Wae
Pollutant or
Pollutant Property
mg/kkg (Ib/billion
121 CYANIDE
122 LEAD
128 ZINC
AMMONIA
FLUORIDE
TITANIUM
Maximum for
Any One Day
Ibs) of titanium alkaline
130
180
650
85,000
38,000
440
janing Rinsewater
Maximum for
Any One Day
Iba) of titanium alkaline
55
77
28O
37,OOO
16,OOO
19O
ttewater
Maximum for
Any One Day
Ibs) of titanium tumbled
16.0
22.0
81.0
11,OOO.O
4,7OO.O
55.0
Maximum for
Monthly Average
cleaned
51
83
27O
37,000
17,000
190

Maximum for
Monthly Average
cleaned
22
36
12O
16,OOO
7,300
83

Maximum for
Monthly Average

6.3
10.0
33.0
4,60O.O
2,100.0
24.0
                       109

-------
        Sawing/Grinding Spent Lubricants
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of titanium sawed or ground

121  CYANIDE                   10.0                           4.0
122  LEAD                      14.0                           6.5
128  ZINC                      51.0                          21.0
     AMMONIA                6,600.0                       2,90O.O
     FLUORIDE               3,000.0                       1,3OO.O
     TITANIUM                  34.0                          15.O
      (o)  Degreasing Spent Solvents

There shall be no discharge of process wastewater pollutants.



SUBPART H.    BAT MASS LIMITATIONS FOR THE URANIUM FORMING
              SUBCATEGORY

      (a)  Extrusion Spent Lubricants

There shall be no discharge of process wastewater pollutants.


      (b)  Extrusion Tool Contact Cooling Water


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


    mg/kkg 
     URANIUM                   36.0                          16.0

     <1> Concentration Value Is 5 Picocuries Per Liter
                              110

-------
      (c)  Extrusion Press And Solution Heat Treatment Contact
             Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of extruded uranium heat treated

118  CADMIUM                     54                            22
120  COPPER                     35O                           17O
124  NICKEL                     150                           100
     FLUORIDE                16,000                         7,200
     RADIUM                     (1)                           (1>
     URANIUM                    190                            82

     (1) Concentration Value Is 5 Picocuries Per Liter

      (d>  Forging Spent Lubricants

There ahall be no discharge of process wastewater pollutants.


      (e)  Forging Solution Heat Treatment Contact Cooling Water


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


    mg/kkg (Ib/billion Ibs) of forged uranium heat treated

118  CADMIUM                     57                            23
120  COPPER                     36O                           17O
124  NICKEL                     160                           HO
     FLUORIDE                17,OOO                         7,5OO
     RADIUM                     (!)                           (1)
     URANIUM                    200                            85

     (1) Concentration Value Is 5 Picocuries Per Liter
                            111

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       Concentration Value Is 5 Picocuries Per Liter

        Surface Treatment Wet APC Slowdown
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of uranium surface treated

118  CADMIUM                   15.0                           5.9
120  COPPER                    95.0                          45.0
124  NICKEL                    41.O                          27.0
     FLUORIDE               4,40O.O                       2,OOO.O
     RADIUM                     <1)                           (1)
     URANIUM                   51.O                          22.O

     (1) Concentration Value Is 5 Picocuries Per Liter
                             112

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      (i)  Sawing/Grinding Spent Emulsions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion lbs> of uranium sawed or ground

118  CADMIUM                    .60                           .20
120  COPPER                    4.00                          1.9O
124  NICKEL                    1.70                          1.1O
     FLUORIDE                180.00                         82.00
     RADIUM                     (1)                           (1)
     URANIUM                   2.1O                           .90

      (1) Concentration Value la 5 Picocuries Per Liter

      (3)  Post-Sawing/Grinding Rinaewater


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


    mg/kkg (Ib/billion Ibs) of sawed or ground uranium rinaed

118  CADMIUM                    7.6                           3.0
120  COPPER                    49.O                          23.0
124  NICKEL                    21.0                          14.O
     FLUORIDE               2,300.0                       1,OOO.O
     RADIUM                     (1)                           (!)
     URANIUM                   26.O                          11.0

      (!) Concentration Value Is 5 Picocuriea Per Liter

      (k)  Degreaaing Spent Solvents

There shall be no discharge of process wastewater pollutants.
SUBPART I.    BAT MASS LIMITATIONS FOR THE ZINC FORMING
              SUBCATEGORY

      (a)  Rolling Spent Neat Oils

There shall be no discharge of process wastewater pollutants.
                           113

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      (b)  Rolling Spent Emulsions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


  mg/kkg (Ib/billion Ibs) of zinc rolled with emulsions

119  CHROMIUM                   .50                           .20
121  CYANIDE                    .30                           .10
128  ZINC                      1.4O                           .60
      (c)  Rolling Contact Lubricant-Coolant Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of zinc rolled with contact
       lubricant-coolant water

119  CHROMIUM                  13.0                           5.2
121  CYANIDE                    6.9                           2.8
128  ZINC                      35.0                          15.0
      (d)  Drawing Spent Emulsions


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


    mg/kkg 
-------
      (e>  Direct Chill Casting Contact Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


  mg/kkg (Ib/billion Iba) of zinc cast by the direct chill method

119  CHROMIUM                  19.0                           7.5
121  CYANIDE                   10.0                           4.0
128  ZINC                      51.O                          21.O
      (f)  Stationary Casting Contact Cooling Water

There ahall be no discharge of process waatewater pollutants.


        Surface Treatment Spent Baths


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


    mg/kkg (Ib/billion lbs> of zinc surface treated

119  CHROMIUM                  3.50                          1.4O
121  CYANIDE                   1.9O                           .SO
128  ZINC                     1O.OO                          4.OO
                          115

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      (i)  Surface Treatment Rinsewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of zinc surface treated

119  CHROMIUM                   180                            73
121  CYANIDE                     97                            39
128  ZINC                       500                           200
        Alkaline Cleaning Spent Baths


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


    mg/kkg (Ib/billion Ibs) of zinc alkaline cleaned

119  CHROMIUM                   .30                           .10
121  CYANIDE                    .10                           .1O
128  ZINC                       .70                           .30


      (k)  Alkaline Cleaning Rinsewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of zinc alkaline cleaned

119  CHROMIUM                 2,100                           860
121  CYANIDE                  1,10O                           46O
128  ZINC                     5,8OO                         2,4OO


      (1)  Sawing/Grinding Spent Lubricants
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
  mg/kkg (Ib/billion Ibs) of zinc sawed or ground

119  CHROMIUM                  20.0                           8.2
121  CYANIDE                   11.O                           4.4
128  ZINC                      56.O                          23.0
                                116

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      (»)  Degreaslng Spent Solvents

There shall be no discharge of process wastewater pollutants.



SUBPART J.    BAT MASS LIMITATIONS FOR THE ZIRCONIUM/HAFNIUM
              FORMING SUBCATEGORY

      (a)  Drawing Spent Lubricants

There ahall be no discharge of process wastewater pollutants.


        Extrusion Spent Emulsions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
mg/kkg (Ib/billion lbs> of zirconium/hafnium extruded with

119
121
124




emulsions
CHROMIUM
CYANIDE
NICKEL
AMMONIA
FLUORIDE
HAFNIUM
ZIRCONIUM

27.0
15.0
41.0
9,90O.O
4 , 400 . 0
51. 0
51. 0

11.0
5.9
27.0
4,30O.O
2,000.0
22.0
22. 0
        Extrusion Press Hydraulic Fluid Leakage
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
mg/kkg (Ib/billion Ibs) of zirconium/hafnium extruded
119
121
124




CHROMIUM
CYANIDE
NICKEL
AMMONIA
FLUORIDE
HAFNIUM
ZIRCONIUM
140
74
200
49,OOO
22,000
260
260
56
3O
140
22,OOO
9,800
110
110
                             117

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        Extrusion Press And Solution Heat Treatment Contact
             Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of extruded zirconium/hafnium heat
       treated

119  CHROMIUM                  11.0                           4.3
121  CYANIDE                    5.7                           2.3
124  NICKEL                    16.0                          11.0
     AMMONIA                3,800.0                       1,70O.O
     FLUORIDE               1,7OO.O                         750.0
     HAFNIUM                   2O.0                           8.6
     ZIRCONIUM                 20.0                           8.6
        Tube Reducing Spent Lubricants

There shell be no discharge of process wastewater pollutants.


      (f)  Forging Solution Heat Treatment Contact Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


  mg/kkg (Ib/billion Ibs) of forged zirconium/hafnium heat treated

119  CHROMIUM                  13.O                           5.2
121  CYANIDE                    7.0                           2.8
124  NICKEL                    19.O                          13.O
     AMMONIA                4,7OO.O                       2,OOO.O
     FLUORIDE               2,1OO.O                         92O.O
     HAFNIUM                   24.O                          10.0
     ZIRCONIUM                 24.0                          10.O
                            118

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(g)   Surface Treatment Spent Baths
Pollutant or Maximum for
Pollutant Property Any One Day
mg/kkg 
-------
      <3>  Alkaline Cleaning Rinsewater



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

—•""•—••"— —•""™ — — —-~     ~~     ~~              "~"             ~      "~    • ~~

    mg/kkg (Ib/billion lbs> of zirconium/hafnium  alkaline cleaned
119
121
124




CHROMIUM
CYANIDE
NICKEL
AMMONIA
FLUORIDE
HAFNIUM
ZIRCONIUM
2,000
1,100
3,OOO
740,000
330,000
3,8OO
3,800
830
44O
2,000
320,000
150,000
1,7OO
1,700
      (k>  Sawing/Grinding Spent Lubricants
   Pollutant or         Maximum for                 Maximum for
Pollutant Property      Any One Day               Monthly Average


    mg/kkg  of zirconium/hafnium  sawed or ground
119
121
124




CHROMIUM
CYANIDE
NICKEL
AMMONIA
FLUORIDE
HAFNIUM
ZIRCONIUM
3.30
1.8O
5.OO
1,20O.OO
54O.OO
6. 2O
6.20
1.40
.70
3.3O
53O.OO
24O.OO
2.70
2.7O
      (1)  Sawing/Grinding Wet APC Slowdown

There shall be no discharge of process wastewater  pollutants,


      (m)  Degreasing Spent Solvents

There shall be no discharge of process wastewater  pollutants.
                               120

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        Degreasing Rinaewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
  mg/kkg (Ib/billion Ibs) of zirconium/hafnium degreaaed
119
121
124




CHROMIUM
CYANIDE
NICKEL
AMMONIA
FLUORIDE
HAFNIUM
ZIRCONIUM
75
41
110
27,000
12,OOO
140
140
30
16
75
12,OOO
5,400
61
61
SUBPART K.    BAT MASS LIMITATIONS FOR THE IRON AND STEEL/COPPER/
       ALUMINUM METAL POWDER PRODUCTION AND POWDER METALLURGY
       SUBCATEGORY

      (a)  Metal Powder Production Atoraization Waatewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of iron, copper, and aluminum powder
       wet atomized

120  COPPER                   9,6OO                         5,000
121  CYANIDE                  1,500                           6OO
122  LEAD                     2,1OO                         1,000
     ALUMINUM                32,OOO                        16,OOO
     IRON                     6,OOO                         3,100
                                 121

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      (b)  Metal Powder Production Milling Wastewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of iron, copper, and aluminum powder
       wet milled

120  COPPER                   3,200                         1,700
121  CYANIDE                    480                           20O
122  LEAD                       700                           330
     ALUMINUM                11,000                         5,30O
     IRON                     2,000                         1,000
        Metal Powder Production Wet APC Blowdown
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of iron, copper, and aluminum powder
       produced

120  COPPER                   5,000                         2,600
121  CYANIDE                    770                           320
122  LEAD                     1,100                           53O
     ALUMINUM                17,OOO                         8,4OO
     IRON                     3,2OO                         1,6OO


      
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      (f)  Steam Treatment Wet APC Slowdown
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg 
      (i)  Degreasing Spent Solvents

There shall be no discharge of process wastewater pollutants.
                              123

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4.  NSPS is proposed baaed on the treatment effectiveness
    achievable by the application of chemical precipitation and
    sedimentation with the addition of filtration (lime, settle,
    and filter) technology and in-process flow reduction control
    methods for nine of the eleven subcategories.  NSPS is
    proposed based on the treatment effectiveness achievable by
    the application of chemical precipitation and sedimentation
    (lime and settle) technology and in-process flow reduction
    control methods for the Lead/Tin/Bismuth Forming and the
    Iron And Steel/Copper/Aluminum Metal Powder Production
    And Powder Metallurgy Subcategories.  The following effluent
    standards are proposed for new sources:
SUBPART A.    NSPS FOR THE BERYLLIUM FORMING SUBCATEGORY

      (a)  Area Cleaning Wastewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of beryllium formed

117  BERYLLIUM               17,OOO                         7,20O
120  COPPER                  27,000                        13,OOO
121  CYANIDE                  4,300                         1,700
     FLUORIDE             1,3OO,000                       560,000
     OIL S, GREASE           21O,OOO                       21O,OOO
     TOTAL SUSPENDED        32O,OOO                       26O,OOO
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all times.


      (b)  Billet Washing Wastewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of beryllium billets washed

117  BERYLLIUM                 31.0                          13.0
12O  COPPER                    49.0                          23.O
121  CYANIDE                    7.6                           3.1
     FLUORIDE               2,3OO.O                       1,OOO.O
     OIL & GREASE             380.0                         38O.O
     TOTAL SUSPENDED          57O.O                         46O.O
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
                              124

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        Surface Treatment Spent Baths
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg   Surface Treatment Rinaewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of beryllium aurface treated

117  BERYLLIUM                  630                           260
120  COPPER                     980                           47O
121  CYANIDE                    150                            61
     FLUORIDE                46,OOO                        20,OOO
     OIL & GREASE             7,7OO                         7,70O
     TOTAL SUSPENDED         12,000                         9,20O
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all timea.
                               125

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        Sawing/Grinding Spent Lubricants
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg 
-------
SUBPART D.    NSPS FOR THE NICKEL/COBALT FORMING SUBCATEGORY

The standards for chromium, nickel, and fluoride are the same as
specified in Section II, Part 3, Subpart D.  The standards for TSS,
oil and grease, and pH are the same as specified in Section II,
Part 7, Subpart D.
SUBPART E.    NSPS FOR THE PRECIOUS METALS FORMING SUBCATEGORY

      (a)  Rolling Spent Emulsions


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


  mg/kkg (Ib/billion Ibs) of precious metala rolled with emulsions

118  CADMIUM                    7.2                           2.9
120  COPPER                    46.0                          22.O
121  CYANIDE                    7.2                           2.9
126  SILVER                    10.0                           4.3
     OIL 6, GREASE             360.0                         360.0
     TOTAL SUSPENDED          54O.O                         430.0
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all times.


        Rolling Solution Heat Treatment Contact Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
   mg/kkg (Ib/billion Ibs) of rolled precious metals heat treated

118  CADMIUM                    14O                            56
120  COPPER                     9OO                           43O
121  CYANIDE                    14O                            56
126  SILVER                     20O                            84
     OIL & GREASE             7,OOO                         7,OOO
     TOTAL SUSPENDED         11,OOO                         8,4OO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
      
-------
      (d)  Drawing Spent Emulsions
   Pollutant, or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


  mg/kkg (Ib/billion Iba) of precious metals drawn with emulsions

118  CADMIUM                    4.3                           1.7
120  COPPER                    27.0                          13.0
121  CYANIDE                    4.3                           1.7
126  SILVER                     6.2                           2.6
     OIL & GREASE             210.O                         21O.O
     TOTAL SUSPENDED          320.O                         260.0
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.


        Drawing Spent Soap Solutions


   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
   mg/kkg (Ib/billion Ibs) of precious metals drawn with soap
      solutions

118  CADMIUM                   1.40                           .60
120  COPPER                    8.9O                          4.20
121  CYANIDE                   1.40                           .60
126  SILVER                    2.OO                           .SO
     OIL & GREASE             69.00                         69.OO
     TOTAL SUSPENDED         1OO.OO                         83.OO
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all times.
                            128

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      (.£)  Extrusion Press And Solution Heat Treatment Contact
             Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
  mg/kkg (Ifa/billion Iba) of extruded precious metals heat treated

118  CADMIUM                    270                           HO
120  COPPER                   1,800                           840
121  CYANIDE                    270                           110
126  SILVER                     400                           16O
     OIL 6, GREASE            14,.OOO                        14,OOO
     TOTAL SUSPENDED         21,000                        16,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.


        Semi-Continuous And Continuous Casting Contact Cooling
              Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of precious metals cast by the
       semi-continuous or continuous method

118  CADMIUM                    22O                            90
120  COPPER                   1,4OO                           68O
121  CYANIDE                    220                            9O
126  SILVER                     320                           13O
     OIL & GREASE            11,OOO                        11,OOO
     TOTAL SUSPENDED         17,OOO                        13,OOO
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all times.
                              129

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        Stationary Casting Contact Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of precious metals cast by the
       stationary method

118  CADMIUM                    .80                           .30
120  COPPER                    5.3O                          2.5O
121  CYANIDE                    .80                           .30
126  SILVER                    1.20                           .50
     OIL & GREASE             42.00                         42.00
     TOTAL SUSPENDED          63.00                         50.OO
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all times.
        Direct Chill Casting Contact Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of precious metals cast by the direct
       chill method

118  CADMIUM                    160                            65
12O  COPPER                   1,OOO                           5OO
121  CYANIDE                    16O                            65
126  SILVER                     240                            98
     OIL & GREASE             8,2OO                         8,2OO
     TOTAL SUSPENDED         12,OOO                         9,8OO
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all times.
                             130

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        Shot Casting Contact Cooling Water
   Pollutant or
Pollutant Property
    Maximum for
    Any One Day
                     Maximum for
                   Monthly Average
    mg/kkg (Ib/billion Ibs) of precious metals shot cast
US  CADMIUM
120  COPPER
121  CYANIDE
126  SILVER
     OIL & GREASE
     TOTAL SUSPENDED
       SOLIDS
     PH
           18.0
          110.0
           ia.o
           26.0
          890.0
        1,3OO.0
                                7.1
                               54.0
                                7.1
                               11.0
                              89O.O
                            1,100.0
Within the range of 7.5 to 10.0 at all times.
        Casting Wet APC Slowdown
   Pollutant or
Pollutant Property
    Maximum for
    Any One Day
                     Maximum for
                   Monthly Average
   mg/kkg (Ib/billion Ibs) of precious metals cast
118  CADMIUM
120  COPPER
121  CYANIDE
126  SILVER
     OIL E. GREASE
     TOTAL SUSPENDED
       SOLIDS
     PH
           1,
           7,
           1,
           1,
  .20
  .50
  ,20
  .70
59.00
88.OO
  .50
 3.6O
  .50
  .70
59.00
7O.OO
Within the range of 7.5 to 10.0 at all times.
                               131

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      (1)  Metal Powder Production Atomization Wastewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


   mg/kkg (Ib/billion Iba) of precious metals powder wet atomized

118  CADMIUM                  1,3OO                           530
120  COPPER                   8,500                         4,1OO
121  CYANIDE                  1,300                           530
126  SILVER                   1,90O                           8OO
     OIL & GREASE            67,OOO                        67,OOO
     TOTAL SUSPENDED        1OO,OOO                        80,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
        Metal Powder Production Ball Milling Wastewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


118
120
121
126



mg/kkg (Ib/billion 11
milled
CADMIUM
COPPER
CYANIDE
SILVER
OIL & GREASE
TOTAL SUSPENDED
SOLIDS
DS> of precious metals

430
2,8OO
430
630
22,000
33,OOO

powder wet ball

170
1,3OO
17O
26O
22,000
26,OOO

     pH             Within the range of 7.5 to 1O.O at all times.
                               132

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        Pressure Bonding Contact Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg 
-------
      (p)  Surface Treatment Spent Baths
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Iba) of precious metals surface treated

118  CADMIUM                     31                            12
12O  COPPER                     200                            95
121  CYANIDE                     31                            12
126  SILVER                      45                            19
     OIL & GREASE             1,600                         1,600
     TOTAL SUSPENDED          2,3OO                         1,9OO
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all times.


      
-------
      
-------
      (t)  Pre-Bonding Cleaning Waatewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of precious metal and base metal
       cleaned prior to bonding

118  CADMIUM                     68                            27
120  COPPER                     44O                           210
121  CYANIDE                     68                            27
126  SILVER                      99                            41
     OIL E, GREASE             3,400                         3,4OO
     TOTAL SUSPENDED          5,100                         4,100
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
      (u)  Tumbling Wastewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg 
-------
        Burnishing Waatewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Iba) of precious metals burnished

116  CADMIUM                    510                           210
120  COPPER                   3,300                         1,60O
121  CYANIDE                    510                           21O
126  SILVER                     750                           31O
     OIL & GREASE            26,000                        26,000
     TOTAL SUSPENDED        110,000                        50,000
       SOLIDS
     pH             Within the range of 7.5. to 10.0 at all times.


        Sawing/Grinding Spent Emulsions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Iba) of precious metals sawed or ground

US  CADMIUM                   1.20                           .50
120  COPPER                    7.70                          3.7O
121  CYANIDE                   1.20                           .50
126  SILVER                    1.80                           .70
     OIL & GREASE             61.OO                         61.OO
     TOTAL SUSPENDED         250.OO                        120.OO
       SOLIDS
     pH             Within the range of 7.5 to 10.O at all times.


      (x)  Degreasing Spent Solvents

There shall be no discharge of process wastewater pollutants.
SUBPART F.    NSPS FOR THE REFRACTORY METALS FORMING SUBCATEGORY

      (a)  Rolling Spent Neat Oils

There shall be no discharge of process wastewater pollutants.
                              137

-------
       (b)  Rolling Spent Emulsions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
mg/kkg   Extrusion Press And Solution Heat Treatment Contact
             Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


120
124









mg/kkg (Ib/billion It
treated
COPPER
NICKEL
COLUMBIUM
FLUORIDE
MOLYBDENUM
TANTALUM
TUNGSTEN
VANADIUM
OIL & GREASE
TOTAL SUSPENDED
SOLIDS
33) of extruded refractc

440
190
24O
21,OOO
240
240
240
240
3,50O
5,200

jry metala heat

21O
13O
1OO
9,100
100
10O
1OO
1OO
3,5OO
4,200

     pH             Within the range of 7.5 to 10.O at all times.
                               138

-------
      (e)  Extrusion Press Hydraulic Fluid Leakage
   Pollutant, or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg   Forging Spent Lubricants

There shall be no discharge of process wastewater pollutants.


      (g)  Forging Solution Heat Treatment Contact Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg 
-------
      (h)  Extrusion And Forging Equipment Cleaning Wastewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


  mg/kkg (Ib/billion Iba) of refractory metals extruded or forged

120  COPPER                      53                            25
124  NICKEL                      23                            15
     COLUMBIUM                   29                            13
     FLUORIDE                 2,500                         1,1OO
     MOLYBDENUM                  29                            13
     TANTALUM                    29                            13
     TUNGSTEN                    29                            13
     VANADIUM                    29                            13
     OIL 6. GREASE               420                           420
     TOTAL SUSPENDED            630                           50O
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
      (i)  Metal Powder Production Wastewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg 
-------
      £ 3 >  Metal Powder Production Wet APC Slowdown

There shall be no discharge of process wastewater pollutants.


      (k)  Metal Powder Pressing Spent Lubricants

There shall be no discharge of process wastewater pollutants,


      (1)  Casting Contact Cooling Water

There shall be no discharge of process wastewater pollutants,


      (m)  Post-Casting Billet Washwater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


  mg/kkg (lb/billion Ibs) of cast refractory metals billet washed

120  COPPER                    38.0                          18.O
124  NICKEL                    16.0                          11.0
     COLUMBIUM                 21.0                           8.9
     FLUORIDE               1,800.O                         790.O
     MOLYBDENUM                21.0                           8.9
     TANTALUM                  21.0                           8.9
     TUNGSTEN                  21.O                           8.9
     VANADIUM                  21.0                           8.9
     OIL & GREASE             300.O                         3OO.O
     TOTAL SUSPENDED          450.0                         36O.O
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
                                 141

-------
      (n)  Surface Treatment Spent Baths
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion lbs> of refractory metala surface treated

120  COPPER                    16.0                           7.7
124  NICKEL                     7.0                           4.7
     COLUMBIUM                  8.8                           3.8
     FLUORIDE                 760.0                         340.0
     MOLYBDENUM                 8.8                           3.8
     TANTALUM                   8.8                           3.8
     TUNGSTEN                   8.8                           3.8
     VANADIUM                   8.8                           3.8
     OIL & GREASE             130.0                         130.0
     TOTAL SUSPENDED          190.0                         15O.O
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all times.


        Surface Treatment Rinsewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of refractory metals surface treated

120  COPPER                  15,000                         7,4OO
124  NICKEL                   6,7OO                         4,5OO
     COLUMBIUM                8,300                         3,600
     FLUORIDE               720,OOO                       320,000
     MOLYBDENUM               8,3OO                         3,6OO
     TANTALUM                 8,300                         3,6OO
     TUNGSTEN                 8,3OO                         3,6OO
     VANADIUM                 8,30O                         3,6OO
     OIL & GREASE           120,000                       120,000
     TOTAL SUSPENDED        180,OOO                       15O,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
                                  142

-------
      (p)  Surface Treatment Wet APC Slowdown
   Pollutant or         Maximum for .               Maximum for
Pollutant Property      Any One Day              Monthly Average

120
124










mg/kkg (Ib/billion Ibs)
COPPER
NICKEL
COLUMBIUM
FLUORIDE
MOLYBDENUM
TANTALUM
TUNGSTEN
VANADIUM
OIL & GREASE
TOTAL SUSPENDED
SOLIDS
pH Within
of refractory
15,000
6,500
8,100
700,000
8,100
8,1OO
8,100
8,10O
12O,OOO
180,000

the range of 7
metals surface treated
7,200
4,400
3,5OO
310,OOO
3,500
3,500
3,500
3,500
120,000
140,000

.5 to 10. O at all times.
      (q)  Surface Coating Wet APC Slowdown
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of refractory metals surface coated

120  COPPER                   1,4OO                           660
124  NICKEL                     59O                           4OO
     COLUMBIUM                  750                           320
     FLUORIDE                64,000                        29,OOO
     MOLYBDENUM                 75O                           32O
     TANTALUM                   75O                           32O
     TUNGSTEN                   75O                           320
     VANADIUM                   750                           32O
     OIL & GREASE            11,OOO                        11,OOO
     TOTAL SUSPENDED         16,OOO                        13,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.O at all times.
                                143

-------
        Alkaline Cleaning Spent Baths
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of refractory metals alkaline cleaned

120  COPPER                    39.O                          19.0
124  NICKEL                    17.0                          11.0
     COLUMBIUM                 21.0                           9.2
     FLUORIDE               1,800.0                         810.O
     MOLYBDENUM                21.0                           9.2
     TANTALUM                  21.O                           9.2
     TUNGSTEN                  21.0                           9.2
     VANADIUM                  21.0                           9.2
     OIL & GREASE             310.O                         31O.O
     TOTAL SUSPENDED          460.0                         370.0
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.


      (s>  Alkaline Cleaning Rinsewater
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average

120
124









mg/kkg (Ib/billion lbs>
COPPER
NICKEL
COLUMBIUM
FLUORIDE
MOLYBDENUM
TANTALUM
TUNGSTEN
VANADIUM
OIL & GREASE
TOTAL SUSPENDED
SOLIDS
of refractory metals alkaline
1,800
770
97O
83,OOO
97O
970
970
970
14,OOO
21,OOO

cleaned
850
520
420
37,OOO
42O
42O
42O
42O
14,OOO
17,OOO

     pH             Within the range of 7.5 to 1O.O at all times.
                            144

-------
      (t)  Molten Salt Cleaning Rinaewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
  mg/kkg (Ib/billion Ibs) of refractory metals cleaned with molten
     salt
12O
124










COPPER
NICKEL
COLUMBIUM
FLUORIDE
MOLYBDENUM
TANTALUM
TUNGSTEN
VANADIUM
OIL €, GREASE
TOTAL SUSPENDED
SOLIDS
pH Within
120,OOO
50, OOO
62, OOO
5,400,000
62,000
62, OOO
62,000
62,000
900,000
1,400,000

the range of
55,000
33,OOO
27,000
2,400,OOO
27,000
27,OOO
27,000
27,OOO
9OO,OOO
1,100,OOO

7.5 to 10.0 at all times.
      (u)  Tumbling/Burnishing Waatewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of refractory metals tumbled or
       burnished
120
124










COPPER
NICKEL
COLUMBIUM
FLUORIDE
MOLYBDENUM
TANTALUM
TUNGSTEN
VANADIUM
OIL & GREASE
TOTAL SUSPENDED
SOLIDS
pH Within
2,800
1,2OO
1,500
130, OOO
1,500
1,50O
1,500
1,5OO
22,OOO
33,OOO

the range of
1,300
82O
660
58,000
660
66O
660
66O
22,000
27, OOO

7.5 to 10. O at all times.
      (v>  Sawing/Grinding Spent Neat Oils

There shall be no discharge of process wastewater pollutants.
                             145

-------
      (w)  Sawing/Grinding Spent Emulsions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg   Sawing/Grinding Contact Lubricant-Coolant Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billlon Ibs) of refractory metals sawed or ground
       with lubricant-coolant water

120  COPPER                   1,OOO                           50O
124  NICKEL                     450                           3OO
     COLUMBIUM                  560                           24O
     FLUORIDE                48,000                        21,OOO
     MOLYBDENUM                 56O                           24O
     TANTALUM                   56O                           240
     TUNGSTEN                   560                           24O
     VANADIUM                   560                           24O
     OIL & GREASE             8,1OO                         8,1OO
     TOTAL SUSPENDED         12,OOO                         9,700
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
                               146

-------
        Sawing/Grinding Wet APC Slowdown
   Pollutant or
Pollutant Property
    Maximum for
    Any One Day
  Maximum for
Monthly Average
    mg/kkg (Ib/billion lbs> of refractory metals sawed or ground
120  COPPER
124  NICKEL
     COLUMBIUM
     FLUORIDE
     MOLYBDENUM
     TANTALUM
     TUNGSTEN
     VANADIUM
     OIL & GREASE
     TOTAL SUSPENDED
       SOLIDS
     pH
            140
             59
             75
          6,40O
             75
             75
             75
             75
          1,100
          1,600
              66
              40
              32
           2,900
              32
              32
              32
              32
           1,100
           1,30O
Within the range of 7.5 to 10.0 at all times,
      (z>  Post Sawing/Grinding Rinsewater
   Pollutant or
Pollutant Property
    Maximum for
    Any One Day
  Maximum for
Monthly Average
    mg/kkg (Ib/billion Ibs) of sawed or ground refractory metals
       rinsed
12O  COPPER
124  NICKEL
     COLUMBIUM
     FLUORIDE
     MOLYBDENUM
     TANTALUM
     TUNGSTEN
     VANADIUM
     OIL & GREASE
     TOTAL SUSPENDED
       SOLIDS
     PH
             66
             28
             35
           ,10O
             35
             35
             35
             35
            510
            77O
              31
              19
              15
           1,400
              15
              15
              15
              15
             510
             620
Within the range of 7.5 to 10.0 at all times.
                                 147

-------
            Product Testing Waatewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average

120
124










mg/kkg (Ib/billion lbs>
COPPER
NICKEL
COLUMBIUM
FLUORIDE
MOLYBDENUM
TANTALUM
TUNGSTEN
VANADIUM
OIL & GREASE
TOTAL SUSPENDED
SOLIDS
pH Within
of refractory
10.0
4.3
5.4
460.0
5.4
5.4
5.4
5.4
78.0
120.0

the range of 7.
metala product tested
4.7
2.9
2.3
200.0
2.3
2.3
2.3
2.3
78.0
93.0

5 to 10.0 at all timea.
      Cab)  Degreaaing Spent Solventa

There shall be no discharge of process waatewater pollutants.



SUBPART G.    NSPS FOR THE TITANIUM FORMING SUBCATEGORV

The standards for cyanide, lead, zinc, ammonia, fluoride, and
titanium are the same as specified in Section II, Part 3, Subpart
G.  The standards for TSS, oil and grease, and pH are the same as
specified in Section II, Part 7, Subpart G.


SUBPART H.    NSPS FOR THE URANIUM FORMING SUBCATEGORY

The standards for cadmium, copper, nickel, fluoride, radium, and
uranium are the same as specified in Section II, Part 3, Subpart H,
The standards for TSS, oil and grease, and pH are the same as
specified in Section II, Part 7, Subpart H.


SUBPART I.    NSPS FOR THE ZINC FORMING SUBCATEGORY

        Rolling Spent Neat Oils

There shall be no discharge of process wastewater pollutants.
                               148

-------
      (b)  Rolling Spent Emulsiona
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
  mg/kkg (Ib/billion lba> of zinc rolled with emulsions

119  CHROMIUM                   .50                           .20
121  CYANIDE                    .30                           .10
128  ZINC                      1.4O                           .60
     OIL S, GREASE             14.00                         14.00
     TOTAL SUSPENDED          21.00                         17.00
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.


        Rolling Contact Lubricant-Coolant Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of zinc rolled with contact
       lubricant-coolant water

119  CHROMIUM                  13.0                           5.2
121  CYANIDE                    6.9                           2.8
128  ZINC                      35.0                          15.0
     OIL & GREASE             350.0                         35O.O
     TOTAL SUSPENDED          52O.O                         42O.O
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.


        Drawing Spent Emulsions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day  '            Monthly Average
    mg/kkg (Ib/billion Ibs) of zinc drawn with emulsions

119  CHROMIUM                  3.00                          1.20
121  CYANIDE                   1.60                           .60
128  ZINC                      8.20                          3.40
     OIL & GREASE             80.OO                         80.00
     TOTAL SUSPENDED         120.OO                         96.OO
       SOLIDS
     pH             Within the range of 7.5 to 10.O at all times.
                                149

-------
           Direct Chill Casting Contact Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


  mg/kkg (Ib/billion Ibs) of zinc cast by the direct chill method

119  CHROMIUM                  19.0                           7.5
121  CYANIDE                   10.0                           4.0
128  2INC                    '-  51.0                          21.0
     OIL 6. GREASE             500.0                         500.0
     TOTAL SUSPENDED          750.0                         600.0
       SOLIDS
     pH


        Stationary Casting Contact Cooling Water

There ahall be no discharge of process wastewater pollutants.


        Heat Treatment Contact Colling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg 
-------
        Surface Treatment Spent Baths
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of zinc surface treated

119  CHROMIUM                  3.50                          1.40
121  CYANIDE                   1.90                           .80
128  ZINC                     10.00                          4.00
     OIL & GREASE             95.00                         95.OO
     TOTAL SUSPENDED         14O.OO                        11O.OO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
        Surface Treatment Rinaewater


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


    mg/kkg (Ib/billion Ibs) of zinc surface treated

119  CHROMIUM                   180                            73
121  CYANIDE                     97                            39
128  ZINC                       500                           200
     OIL & GREASE             4,900                         4,9OO
     TOTAL SUSPENDED          7,3OO                         5,800
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.


      (j >  Alkaline Cleaning Spent Batha
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion lbs> of zinc alkaline cleaned

119  CHROMIUM                   .30                           .10
121  CYANIDE                    .10                           .10
128  ZINC                       .70                           .30
     OIL & GREASE              7.2O                          7.2O
     TOTAL SUSPENDED          11.00                          8.60
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
                               151

-------
        Alkaline Cleaning Rinaewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of zinc alkaline cleaned

119  CHROMIUM                 2,100                           860
121  CYANIDE                  1,10O                           46O
123  ZINC                     5,800                         2,40O
     OIL 6, GREASE            57,000                        57,OOO
     TOTAL SUSPENDED         86,000                        69,000
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.


      (1)  Sawing/Grinding Spent Lubricants
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


  mg/kkg (Ib/billion Ibs) of zinc sawed or ground

119  CHROMIUM                  20.0                           8.2
121  CYANIDE                   11.0                           4.4
128  ZINC                      56.0                          23.0
     OIL 6. GREASE             55O.O                         55O.O
     TOTAL SUSPENDED          820.0                         660.0
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all times.
      (m)  Degreaaing Spent Solvents

There shall be no discharge of process wastewater pollutants.



SUBPART J.    NSPS FOR THE ZIRCONIUM/HAFNIUM FORMING SUBCATEGORY

      (a)  Drawing Spent Lubricants

There shall be no discharge of process wastewater pollutants.
                               152

-------
      (b)  Extrusion Spent Emulsions
   Pollutant or
Pollutant Property
    Maximum for
    Any One Day
  Maximum for
Monthly Average
    mg/kkg (Ib/billion Ibs) of zirconium/hafnium extruded with
       emulsions
119  CHROMIUM
121  CYANIDE
124  NICKEL
     AMMONIA
     FLUORIDE
     HAFNIUM
     ZIRCONIUM
     OIL S. GREASE
     TOTAL SUSPENDED
       SOLIDS
     pH
           27.0
           15.0
           41.0
        9,900.0
        4,4OO.O
           51.0
           51.0
          740.0
        1,100.0
            11.0
             5.9
            27 .0
         4,300.O
         2,OOO.O
            22.0
            22.0
           740.0
           89O.O
Within the range of 7.5 to 10.0 at all times.
      (c)  Extrusion Press Hydraulic Fluid Leakage
   Pollutant or
Pollutant Property
    Maximum for
    Any One Day
  Maximum for
Monthly Average
    mg/kkg 
-------
        Extrusion Preaa And Solution Heat Treatment Contact
             Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    nig/kkg (Ib/billion Iba) of extruded zirconium/hafnium heat
       treated

119  CHROMIUM                  11.0                           4.3
121  CYANIDE                    5.7                           2.3
124  NICKEL                    16.0                          11.0
     AMMONIA                3,800.O                       1,70O.O
     FLUORIDE               1,700.0                         750.0
     HAFNIUM                   20.0                           8.6
     ZIRCONIUM                 20.0                           8.6
     OIL S. GREASE             290.0                         290.0
     TOTAL SUSPENDED          43O.O                         340.O
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
       of forged zirconium/hafnium heat treated

119  CHROMIUM                  13.O                           5.2
121  CYANIDE                    7.0                           2.8
124  NICKEL                    19.0                          13.O
     AMMONIA                4,700.0                       2,000.0
     FLUORIDE               2,100.O                         920.O
     HAFNIUM                   24.0                          10.O
     ZIRCONIUM                 24.0                          10.O
     OIL & GREASE             350.0                         350.0
     TOTAL SUSPENDED          520.0                         420.O
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all times.
                               154

-------
        Surface Treatment Spent Baths
   Pollutant or
Pollutant Property
    Maximum for
    Any One Day
  Maximum for
Monthly Average
    mg/kkg (Ib/billion Iba) of zirconium/hafnium rolled with
      emulsions
119  CHROMIUM
121  CYANIDE
124  NICKEL
     AMMONIA
     FLUORIDE
     HAFNIUM
     ZIRCONIUM
     OIL S, GREASE
     TOTAL SUSPENDED
       SOLIDS
     pH
            150
             SO
            220
         53,OOO
         24,OOO
            280
            280
          4,OOO
          6,OOO
              60
              32
             150
          23,OOO
          11,OOO
             120
             120
           4,OOO
           4,800
Within the range of 7.5 to 10.0 at all times.
        Surface Treatment Rinsewater
   Pollutant or
Pollutant Property
    Maximum for
    Any One Day
  Maximum for
Monthly Average
    mg/kkg (Ib/billion Ibs) of zirconium/hafnium surface treated
119  CHROMIUM
121  CYANIDE
124  NICKEL
     AMMONIA
     FLUORIDE
     HAFNIUM
     ZIRCONIUM
     OIL & GREASE
     TOTAL SUSPENDED
       SOLIDS
     PH
            570
            310
            S4O
        200,000
         91,OOO
          1,10O
          1,100
         15,OOO
         23,000
             230
             12O
             570
          90,OOO
          40,000
             46O
             460
          15,OOO
          18,000
Within the range of 7.5 to 10.0 at all times.
                              155

-------
      (i)  Alkaline Cleaning Spent Batha
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of zirconium/hafnium alkaline cleaned

119  CHROMIUM                   790                           32O
121  CYANIDE                    430                           17O
124  NICKEL                   1,200                           79O
     AMMONIA                280,000                       120,000
     FLUORIDE               13O,OOO                        56,OOO
     HAFNIUM                  1,500                           64O
     ZIRCONIUM                1,50O                           640
     OIL 6, GREASE            21,000                        21,OOO
     TOTAL SUSPENDED         32,000                        26,000
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all times.


      (j>  Alkaline Cleaning Rlnaewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of zirconium/hafnium alkaline cleaned

119  CHROMIUM                 2,000                           S3O
121  CYANIDE                  1,1OO                           44O
124  NICKEL                   3,000                         2,OOO
     AMMONIA                74O,OOO                       32O,OOO
     FLUORIDE               33O,OOO                       15O,OOO
     HAFNIUM                  3,8OO                         1,7OO
     ZIRCONIUM                3,8OO                         1, 7OO
     OIL fi, GREASE            55,OOO                        55,OOO
     TOTAL SUSPENDED         83,OOO                        66,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
                            156

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      (k)  Sawing/Grinding Spent. Lubricants
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg   Sawing/Grinding Wet APC Slowdown

There shall be no discharge of process waatewater pollutants.


      (m)  Degreasing Spent Solvents

There shall be no discharge of process wastewater pollutants.


      (n)  Degreasing Rinsewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
mg/kkg (Ib/billion Ibs) of zirconium/hafnium
119
121
124







CHROMIUM
CYANIDE
NICKEL
AMMONIA
FLUORIDE
HAFNIUM
ZIRCONIUM
OIL & GREASE
TOTAL SUSPENDED
SOLIDS
75
41
110
27,OOO
12,OOO
14O
14O
2,000
3,000

degreased
3O
16
75
12,OOO
5,4OO
61
61
2,OOO
2,4OO

     pH             Within the range of 7.5 to 10.0 at all times.
                                 157

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SUBPART K.    NSPS FOR THE IRON AND STEEL/COPPER/ALUMINUM METAL
       POWDER PRODUCTION AND POWDER METALLURGY SUBCATEGORY

The standards for copper, cyanide, lead, aluminum, and iron are
the same as specified in Section II, Part 3, Subpart K.  The
standards for TSS, oil and grease, and pH are the same as specified
in Section II, Part 7, Subpart K.
5.  PSES is proposed based on the treatment effectiveness
    achievable by the application of chemical precipitation and
    sedimentation with the addition of filtration (lime, settle,
    and filter) technology and in-process flow reduction control
    methods for seven of the eleven subcategories.  PSE'S is
    proposed based on the treatment effectiveness achievable by
    the application of chemical precipitation and sedimentation
    (lime and settle) technology and in-process flow reduction
    control methods for the Lead/Tin/Bismuth Forming and the
    Iron And Steel/Copper/Aluminum Metal Powder Production And
    Powder Metallurgy Subcategories.  The Agency proposes to
    exclude the Beryllium Forming and Zinc Forming Subcategories.
    The following pretreatment standards are proposed for existing
    sources:
SUBPART A.    PSES FOR THE BERYLLIUM FORMING SUBCATEGORY

[Reserved]


SUBPART B.    PSES FOR THE LEAD/TIN/BISMUTH FORMING SUBCATEGORY

The standards for antimony and lead are the same as specified in
Section II, Part 3, Subpart B.


SUBPART C.    PSES FOR THE MAGNESIUM FORMING SUBCATEGORY

The standards for chromium, zinc, ammonia, fluoride, and magnesium
are the same as specified in Section II, Part 3, Subpart C.


SUBPART D.    PSES FOR THE NICKEL/COBALT FORMING SUBCATEGORY

The standards for chromium, nickel, and fluoride are the same as
specified in Section II, Part 3, Subpart D.
                              158

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SUBPART E.    PSES FOR THE PRECIOUS METALS FORMING SUBCATEGORY

The standards for cadmium, copper, silver, and cyanide are the
same as specified in Section II, Part 3, Subpart E.


SUBPART F.    PSES FOR THE REFRACTORY METALS FORMING SUBCATEGORY

The standards for copper, nickel, columbium, fluoride, molybdenum,
tantalum, tungsten, and vanadium are the same as specified in
Section II, Part 3, Subpart F.
SUBPART G.    PSES FOR THE TITANIUM FORMING SUBCATEGORY

The standards for cyanide, lead, zinc, ammonia, fluoride, and
titanium are the same as specified in Section II, Part 3, Subpart
G.
SUBPART H.    PSES FOR THE URANIUM FORMING SUBCATEGORY

The standards for cadmium, copper, nickel, fluoride, radium, and
uranium are the same as specified in Section II, Part 3, Subpart H,


SUBPART I.    PSES FOR THE ZINC FORMING SUBCATEGORY

[Reserved]


SUBPART J.    PSES FOR THE ZIRCONIUM/HAFNIUM FORMING SUBCATEGORY

The standards for chromium, cyanide, nickel, ammonia, fluoride,
hafnium, and zirconium are the same as specified in Section II,
Part 3, Subpart J.


SUBPART K.    PSES FOR THE IRON AND STEEL/COPPER/ALUMINUM METAL
       POWDER PRODUCTION AND POWDER METALLURGY SUBCATEGORY

The standards for copper, cyanide, lead, aluminum, and iron are
the same as specified in Section II, Part 3, Subpart K.
                              159

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6.  PSNS is proposed baaed on the treatment effectiveness
    achievable by the application o£ chemical precipitation and
    sedimentation with the addition of filtration (lime, settle,
    and filter) technology and in-process flow reduction control
    methods for nine of the eleven subcategories.  PSNS is
    proposed based on the treatment effectiveness achievable by
    the application of chemical precipitation and sedimentation
    (lime and settle) technology and in-process flow reduction
    control methods for the Lead/Tin/Bismuth Forming and the
    Iron And Steel/Copper/Aluminum Metal Powder Production And
    Powder Metallurgy Subcategories.  The following pretreatment
    standards are being proposed for new sources:
SUBPART A.    PSNS FOR THE BERYLLIUM FORMING SUBCATEGORY

The standards for beryllium, copper, cyanide, and fluoride are the
same as specified in Section II, Part 3, Subpart A.


SUBPART. B.    PSNS FOR THE LEAD/TIN/BISMUTH FORMING SUBCATEGORY

The standards for antimony and lead are the same as specified in
Section II, Part 3, Subpart B.


SUBPART C.    PSNS FOR THE MAGNESIUM FORMING SUBCATEGORY

The standards for chromium, zinc, ammonia, fluoride, and magnesium
are the same as specified in Section II, Part 3, Subpart C.


SUBPART D.    PSNS FOR THE NICKEL/COBALT FORMING SUBCATEGORY

The standards for chromium, nickel, and fluoride are the same as
specified in Section II, Part 3, Subpart D.


SUBPART E.    PSNS FOR THE PRECIOUS METALS FORMING SUBCATEGORY

The standards for cadmium, copper, silver, and cyanide are the
same as specified in Section II, Part 3, Subpart E.


SUBPART F.    PSNS FOR THE REFRACTORY METALS FORMING SUBCATEGORY

The standards for copper, nickel, columbium, fluoride, molybdenum,
tantalum, tungsten, and vanadium are the same as specified in
Section II, Part 3, Subpart F.
                              160

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SUBPART G.    PSNS FOR THE TITANIUM FORMING SUBCATEGORY

The standards for cyanide, lead, zinc, ammonia, fluoride, and
titanium are the same as specified in Section II, Part 3, Subpart
G.
SUBPART H.    PSNS FOR THE URANIUM FORMING SUBCATEGORY

The standards for cadmium, copper, nickel, fluoride, radium, and
uranium are the same as specified in Section II, Part 3, Subpart H,


SUBPART I.    PSNS FOR THE ZINC FORMING SUBCATEGORY

The standards for chromium, cyanide, and zinc are the same as
specified in Section II, Part 3, Subpart I.


SUBPART J.    PSNS FOR THE ZIRCONIUM/HAFNIUM FORMING SUBCATEGORY

The standards for chromium, cyanide, nickel, ammonia, fluoride,
hafnium, and zirconium are the same as specified in Section II,
Part 3, Subpart J.
SUBPART K.    PSNS FOR THE IRON AND STEEL/COPPER/ALUMINUM METAL
       POWDER PRODUCTION AND POWDER METALLURGY SUBCATEGORY

The standards for copper, cyanide, lead, aluminum, and iron are
the same as specified in Section II, Part 3, Subpart K.
7.  BCT is proposed based on the treatment effectiveness
    achievable by the application of chemical precipitation and
    sedimentation with the addition of filtration (lime, settle,
    and filter) technology and in-process flow reduction control
    methods for four of the eleven subcategories.  BCT is
    proposed based on the treatment effectiveness achievable by
    the application of chemical precipitation and sedimentation
    (lime and settle) technology and in-process flow reduction
    control methods for the Lead/Tin/Bismuth Forming,
    Zirconium/Hafnium Forming, and Iron And Steel/Copper/Aluminum
    Metal Powder Production And Powder Metallurgy Subcategories.
    BCT is proposed based on the treatment effectiveness achievable
    by the application of chemical precipitation and sedimentation
    (lime and settle) technology for the Beryllium Forming,
    Precious Metala Forming, Refractory Metala Forming, and Zinc
    Forming Subcategories.  The following effluent limitations are
    proposed for existing sources:
                               161

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SUBPART A.    BCT MASS LIMITATIONS FOR THE BERYLLIUM FORMING
              SUBCATEGORY

The limitations for TSS, oil and grease, and pH are the same as
specified in Section II, Part 2, Subpart A.
SUBPART B.    BCT MASS LIMITATIONS FOR THE LEAD/TIN/BISMUTH
              FORMING SUBCATEGORY

      (a)  Rolling Spent Emulsions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of lead/tin/bismuth rolled with
       emulsions

     OIL & GREASE               470                           280
     TOTAL SUSPENDED            960                           45O
       SOLIDS
     pH             Within the range of 7.5 to 10.O at all times.
        Rolling Spent Soap Solutions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
  mg/kkg (Ib/billion Ibs) of lead/tin/bismuth rolled with soap
     solutions

     OIL 6, GREASE               860                           520
     TOTAL SUSPENDED          1,800                           84O
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all times.
      (c)  Drawing Spent Neat Oils

There shall be no discharge of process wastewater pollutants,
                              162

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      (d)  Drawing Spent Emulsions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Iba) of lead/tin/bismuth drawn with
       emulsions

     OIL 6, GREASE               330                           200
     TOTAL SUSPENDED            680                           330
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
        Extrusion Press And Solution Heat Treatment Contact
              Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg 
-------
        Extrusion Preaa Hydraulic Fluid Leakage
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of lead/tin/biamuth extruded

     OIL & GREASE               990                           59O
     TOTAL SUSPENDED          2,OOO                           96O
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
        Continuous Strip Casting Contact Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg 
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      (3>  Shot Casting Contact Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion lba> of lead/tin/biamuth shot cast

     OIL & GREASE                84                            50
     TOTAL SUSPENDED            170                            82
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
      
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      <»>  Alkaline Cleaning Rinsewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of lead/tin/bismuth alkaline cleaned

     OIL & GREASE            13,OOO                         7,800
     TOTAL SUSPENDED         26,OOO                        13,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all timea.
      (n)  Swaging Spent Emulsions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of lead/tin/biamuth swaged with
      "emulaiona

     OIL & GREASE                35                            21
     TOTAL SUSPENDED             73                            35
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all timea.
      Co)  Degreasing Spent Solvents

There shall be no discharge of process wastewater pollutants.


      

Miscellaneous Nondescript Wastewater Sources Pollutant or Maximum for Maximum for Pollutant Property Any One Day Monthly Average mg/kkg


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SUBPART C.    BCT MASS LIMITATIONS FOR THE MAGNESIUM FORMING
              SUBCATEGORY

      (a)  Rolling Spent. Emulsions

There shall be no discharge of process wastewater pollutants.


        Forging Spent Lubricants

There shall be no discharge of process wastewater pollutants.


        Forging Wet APC Blowdown


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


    mg/kkg (Ib/billion Ibs) of magnesium forged

     OIL & GREASE         2,7OO,OOO                     2,700,000
     TOTAL SUSPENDED      4,OOO,OOO                     3,2OO,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.


        Forging Solution Heat Treatment Contact Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of forged magnesium heat treated

     OIL & GREASE             6,3OO                         6,3OO
     TOTAL SUSPENDED          9,50O                         7,6OO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
                              167

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           Forging Equipment Cleaning Waatewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of magnesium forged

     OIL E, GREASE             1,600                         1,600
     TOTAL SUSPENDED          2,400                         1,9OO
       SOLIDS
     pH           ,  Within the range of 7.5 to 10.0 at all times.
      (f)  Direct Chill Casting Contact Cooling Water

There shall be no discharge of process wastewater pollutants,


      (g)  Surface Treatment Spent Baths
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of magnesium surface treated

     OIL 6, GREASE             4,700                         4,70O
     TOTAL SUSPENDED          7,000                         5,600
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
      (h)  Surface Treatment Rinsewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of magnesium surface treated

     OIL & GREASE            18,OOO                        18,000
     TOTAL SUSPENDED         27,OOO                        21,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
                             168

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      (i)  Sawing/Grinding Spent Lubricants

There ahall be no diacharge o£ proceaa waatewater pollutants.


        Sanding And Repairing Wet APC Slowdown
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of magnesium sanded and repaired

     OIL & GREASE             4,3OO                         4,30O
     TOTAL SUSPENDED          6,400                         5,100
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
      (k)  Degreasing Spent Solvents

There shall be no discharge of process wastewater pollutants.



SUBPART D.    BCT MASS LIMITATIONS FOR THE NICKEL/COBALT FORMING
              SUBCATEGORY

        Rolling Spent Neat Oils

There shall be no discharge of process wastewater pollutants.


      
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           Rolling Contact Lubricant-Coolant Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of nickel/cobalt rolled with contact
       lubricant-coolant water

     OIL & GREASE            13,000                        13,000
     TOTAL SUSPENDED         20,OOO                        16,OOO
       SOLIDS
     pH             Within tha range of 7.5 to 10.0 at all times.
      (d)  Rolling Solution Heat Treatment Contact Cooling Water


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


  mg/kkg (Ib/billion Ibs) of rolled nickel/cobalt heat treated

     OIL £, GREASE               .30                           .30
     TOTAL SUSPENDED            .40                           .30
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all timea.


        Tube Reducing Spent Lubricants

There shall be no discharge of process wastewater pollutanta.


      (f)  Drawing Spent Neat Oils

There shall be no discharge of process wastewater pollutants.


        Drawing Spent Emulsions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of nickel/cobalt drawn with emulsions

     OIL & GREASE               950                           95O
     TOTAL SUSPENDED          1,4OO                         1,1OO
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all times.
                                170

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      (h)  Extrusion Spent Lubricants

There shall be no discharge of process wastewater pollutants.
	—	—	

      (i>  Extrusion Press And Solution Heat Treatment Contact
             Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of extruded nickel/cobalt heat treated

     OIL & GREASE               830                           830
     TOTAL SUSPENDED          1,2OO                         1,000
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
           Forging, Extrusion, And Isostatic Press Hydraulic
             Fluid Leakage
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
  mg/kkg (Ib/billion Ibs) of nickel/cobalt forged, extruded, or
     pressed

     OIL & GREASE             1,200                         1,200
     TOTAL SUSPENDED          1,900                         1,50O
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all times.
        Forging Equipment Cleaning Wastewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of nickel/cobalt forged

     OIL S. GREASE             1,600                         1,600
     TOTAL SUSPENDED          2,400                         2,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
                               171

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      (1)  Forging Die Contact Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg   Forging/Swaging Spent Neat Oils

There shall be no discharge of process wastewater pollutants.
        Casting Vacuum Melting Steam Condensate


   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of nickel/cobalt vacuum melted

     OIL & GREASE             1,700                         1,700
     TOTAL SUSPENDED          2,500                         2,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
                                172

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      (a)  Surface Treatment Spent Baths
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of nickel/cobalt surface treated

     OIL & GREASE             8,600                         8,6OO
     TOTAL SUSPENDED         13,OOO                        10,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all timea.
      (t)  Surface Treatment Rinsewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of nickel/cobalt surface treated

     OIL & GREASE            11,000                        11,OOO
     TOTAL SUSPENDED         16,OOO                        13,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all timea.
      (u)  Alkaline Cleaning Spent Batha
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of nickel/cobalt alkaline cleaned

     OIL S, GREASE               31O                           310
     TOTAL SUSPENDED            46O                           37O
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
                                174

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      (v)  Alkaline Cleaning Rinaewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of nickel/cobalt alkaline cleaned

     OIL & GREASE             5,000                         5,000
     TOTAL SUSPENDED          7,500                         6,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.


      (w)  Molten Salt Rinsewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of nickel/cobalt treated with molten
       salt

     OIL & GREASE            13,000                        13,000
     TOTAL SUSPENDED         19,000                        15,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
      (x)  Ammonia Rinae Waatewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
  mg/kkg (Ib/billion Ibs) of nickel/cobalt treated with ammonia
     aolution

     OIL & GREASE               160                           160
     TOTAL SUSPENDED            240                           19O
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
                            175

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      (y)  Sawing/Grinding Spent Lubricants
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Iba) of nickel/cobalt sawed or ground

     OIL & GREASE            10,000                        1O,000
     TOTAL SUSPENDED         15,000                        12,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.


      (z)  Steam Cleaning Condensate


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


    mg/kkg (Ib/billion Ibs) of nickel/cobalt steam cleaned

     OIL & GREASE               230                           230
     TOTAL SUSPENDED            35O                           28O
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.


      
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        ~-_ — — — — — —— — — — -
   Pollutant or          Maximum for                Maximum for
Pollutant Property       Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of  nickel/cobalt formed

     OIL & GREASE                580                           580
     TOTAL SUSPENDED             880                           700
       SOLIDS
     pH             Within the  range of  7.5 to 10.0 at all times.
SUBPART E.    BCT MASS LIMITATIONS  FOR  THE PRECIOUS METALS FORMING
             SUBCATEGORY

The limitations for TSS, oil  and  grease,  and pH are the same as
specified in Section  II, Part 2,  Subpart  E.
SUBPART F.    BCT MASS LIMITATIONS  FOR  THE  REFRACTORY METALS
              FORMING SUBCATEGORY

The limitations for TSS, oil and grease,  and  pH are the same as
specified in Section II, Part 2, Subpart  F.
SUBPART G.    BCT MASS LIMITATIONS FOR  THE  TITANIUM FORMING
              SUBCATEGORY

      Ca)  Cold Rolling Spent Lubricants
   Pollutant or         Maximum for                 Maximum for
Pollutant Property      Any One Day               Monthly Average
    mg/kkg (Ib/billion Ibs) of titanium  cold  rolled

     OIL 6, GREASE             3,3OO                          3,3OO
     TOTAL SUSPENDED          5,OOO                          4,OOO
       SOLIDS
     pH             Within the range of  7.5 to  10.0  at  all  times.
                       177

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        Hot Rolling Contact Lubricant-Coolant Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of titanium hot rolled with contact
       lubricant-coolant water

     OIL & GREASE             4,300                         4,300
     TOTAL SUSPENDED          6,50O                         5,2OO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all timea.
        Extrusion Spent Lubricants
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of titanium extruded

     OIL & GREASE             2,700                         2,700
     TOTAL SUSPENDED          4,100                         3,3OO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
      (d>  Forging Spent Lubricants

There shall be no discharge of process wastewater pollutants,


      (e>  Forging Die Contact Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of titanium forged

     OIL fi, GREASE             3,OOO                         3,OOO
     TOTAL SUSPENDED          4,50O                         3,GOO
       SOLIDS
     pH             Within the range of 7.5 to 10.O at all times.
                           178

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        Forging Wet APC Blowdown
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of titanium forged

     OIL & GREASE             2,000                         2,000
     TOTAL SUSPENDED          3,OOO                         2,4OO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
      (g)  Heat Treatment Contact Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of titanium heat treated

     OIL & GREASE             4,5OO                         4,5OO
     TOTAL SUSPENDED          6,800                         5,40O
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
      (h)  Surface Treatment Spent Baths
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of titanium surface treated

     OIL & GREASE             1,6OO                         1,600
     TOTAL SUSPENDED          2,400                         1,9OO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
                          179

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      (1)  Alkaline Cleaning Rinsewater
   Pollutant, or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of titanium alkaline cleaned

     OIL & GREASE             2,800                         2,800
     TOTAL SUSPENDED          4,100                         3,300
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.


      (n)  Tumbling Wastewater


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


    mg/kkg (Ib/billion Iba) of titanium tumbled

     OIL & GREASE               790                           79O
     TOTAL SUSPENDED          1,200                           950
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.


      (n)  Sawing/Grinding Spent Lubricants


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


    mg/kkg (Ib/billion Ibs) of titanium sawed or ground

     OIL & GREASE               500                           5OO
     TOTAL SUSPENDED            750                           600
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.


        Degreasing Spent Solvents

There shall be no discharge of procesa wastewater pollutants.
                             181

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SUBPART H.    BCT MASS LIMITATIONS FOR THE URANIUM FORMING
              SUBCATEGORY

      (a)  Extrusion Spent Lubricants

There shall be no discharge of process waatewater pollutants,


        Extrusion Tool Contact Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of uranium extruded

     OIL fi, GREASE               52O                           520
     TOTAL SUSPENDED            780                           62O
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
        Extrusion Press And Solution Heat Treatment Contact
             Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of extruded uranium heat treated

     OIL & GREASE             2,7OO                         2,7OO
     TOTAL SUSPENDED          4,1OO                         3,3OO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.


      
-------
        Forging Solution Heat Treatment Contact Cooling Water


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


    mg/kkg (Ib/billion Iba) of forged uranium heat treated

     OIL S, GREASE             2,800                         2,8OO
     TOTAL SUSPENDED          4,300                         3,400
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.


        Surface Treatment Rinaewater


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


    mg/kkg (Ib/billion Iba) of uranium aurface treated

     OIL & GREASE             1,500                         1,500
     TOTAL SUSPENDED          2,2OO                         1,8OO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all timea.
                                183

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        Sawing/Grinding Spent Emulsions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of uranium sawed or ground

     OIL & GREASE                31                            31
     TOTAL SUSPENDED             47                            37
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
      (j>  Post-Sawing/Grinding Rinsewater


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


    mg/kkg (Ib/billion Ibs) of sawed or ground uranium rinsed

     OIL & GREASE               380                           38O
     TOTAL SUSPENDED            570                           460
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
W _ imm, mm, —-.mm, mm, — _— — _ _ —. « «_ —~- mm, — —•.— -^ ^^M_ —_ _ — ^ 1_ miff —»^——. —^ —— —— i*_ — — «—. __^_^ ^K« —— ~_ -_ ~_ _ ^^_~<~- — H..^^^ — —•——

        Degreasing Spent Solvents

There shall be no discharge of process wastewater pollutanta.
                               184

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SUBPART I.    BCT MASS LIMITATIONS FOR THE ZINC FORMING
              SUBCATEGORY

The limitations for TSS, oil and grease, and pH are the same as
specified in Section II, Part 2, Subpart I.
SUBPART J.    BCT MASS LIMITATIONS FOR THE ZIRCONIUM/HAFNIUM
              FORMING SUBCATEGORY

      (a)  Drawing Spent Lubricants

There shall be no discharge of process wastewater pollutants.


      (b)  Extrusion Spent Emulsions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of zirconium/hafnium extruded with
       emulsions

     OIL & GREASE             1,5OO                           89O
     TOTAL SUSPENDED          3,000                         1,400
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.


        Extrusion Press Hydraulic Fluid Leakage


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


    mg/kkg 
-------
           Extrusion Press And Solution Heat Treatment. Contact
             Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billian Iba) o£ extruded zirconium/hafnium heat
       treated

     OIL & GREASE               570                           340
     TOTAL SUSPENDED          1,2OO                           56O
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at. all timea.
      Ce)  Tube Reducing Spent Lubricants

There shall be no discharge of process wastewater pollutants.


      (f)  Forging Solution Heat Treatment Contact Coo'ling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
  mg/kkg (Ib/billion Ibs) of forged zirconium/hafnium heat treated

     OIL & GREASE               700                           42O
     TOTAL SUSPENDED          1,400                           680
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all timea.


      (g)  Surface Treatment Spent Baths
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg 
-------
        Alkaline Cleaning Rinsewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg  of zirconium/hafnium alkaline cleaned

     OIL B. GREASE           11O,OOO                        66,OOO
     TOTAL SUSPENDED        230,000                       110,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
                                187

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      (k)  Sawing/Grinding Spent Lubricants
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of zirconium/hafnium sawed or ground

     OIL & GREASE               ISO                           110
     TOTAL SUSPENDED            37O                           18O
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
      (1)  Sawing/Grinding Wet APC Slowdown

There shall be no discharge of process wastewater pollutants,


      (m)  Degreasing Spent Solvents

There shall be no discharge of process wastewater pollutants,


      (n>  Degreasing Rinsewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
  mg/kkg (Ib/billion Ibs) of zirconium/hafnium degreased

     OIL £, GREASE             4,100                         2,4OO
     TOTAL SUSPENDED          8,3OO                         4,OOO
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all times.
                              188

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SUBPART K.    BCT MASS LIMITATIONS FOR THE IRON AND STEEL/COPPER/
       ALUMINUM METAL POWDER PRODUCTION AND POWDER METALLURGY
       SUBCATEGORY

      (a)  Metal Powder Production Atomization Waatewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of iron, copper, and aluminum powder
       wet atomized

     OIL & GREASE           100,000                        60,000
     TOTAL SUSPENDED        21O,OOO                        98,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
      
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        Steam Treatment Wet APC Slowdown
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs)  of iron, copper, and aluminum powder
       powder metallurgy parta ateam treated

     OIL & GREASE             5,700                         3,40O
     TOTAL SUSPENDED         12,000                         5,5OO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all timea.


      (g)  Tumbling, Burnishing And Cleaning Wastewater


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


    mg/kkg 
-------
        Degreasing Spent Solvents

There shall be no discharge of  process  wastewater pollutants.
8.  EPA is considering promulgating  BAT  effluent limitations which
are less stringent than the  limitations  now  proposed for BAT for
nine of the eleven subcategories.  The limitations would be based
on the treatment effectiveness  achievable  by the application of
chemical precipitation and sedimentation (lime and settle)
technology and in-process flow  reduction control methods.  In
addition, EPA is considering promulgating  BAT effluent limitations
more stringent than the limitations  now  proposed for BAT for the
Lead/Tin/Bismuth Forming and the  Iron And  Steel/Copper/Aluminum
Metal Powder Production And  Powder Metallurgy Subcategories.  The
limitations would be based on the treatment  effectiveness
achievable by the application of  chemical  precipitation and
sedimentation with the addition of filtration (lime, settle, and
filter) technology and in-process flow reduction control methods.
In the event that the Agency decides to  promulgate these alternate
BAT effluent limitations, the following  would apply for existing
sources:
                          191

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SUBPART A.    ALTERNATE BAT MASS LIMITATIONS FOR THE BERYLLIUM
              FORMING SUBCATEGORY

      (a)  Area Cleaning Wastewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Iba) of beryllium formed

117  BERYLLIUM               26,000                        11,OOO
120  COPPER                  40,000                        21,OOO
121  CYANIDE                  6,200                         2,6OO
     FLUORIDE             1,3OO,OOO                       560,000
      (b)  Billet Washing Waatewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Iba) of beryllium billets washed

117  BERYLLIUM                 47.O                          19.O
120  COPPER                    73.0                          38.O
121  CYANIDE                   11.0                           4.6
     FLUORIDE               2,300.0                       1,000.0
      (c)  Surface Treatment Spent Baths


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


    mg/kkg (Ib/billion Iba) of beryllium surface treated

117  BERYLLIUM                  380                           16O
120  COPPER                     590                           310
121  CYANIDE                     89                            37
     FLUORIDE                18,000                         8,100
                              192

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      (d)  Surface Treatment Rinsewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of beryllium surface treated

117  BERYLLIUM                  940                           390
120  COPPER                   1,5OO                           770
121  CYANIDE                    220                            92
     FLUORIDE                46,000                        20,000


      (e>  Sawing/Grinding Spent Lubricants
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of beryllium sawed or ground

117  BERYLLIUM                  520                           220
120  COPPER                     810                           420
121  CYANIDE                    120                            51
     FLUORIDE                25,000                        11,OOO


      (f>  Inspection/Testing Wastewater

There shall be no discharge of process wastewater pollutants.


        Degreasing Spent Solvents

There shall be no discharge of process wastewater pollutants.
                               193

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SUBPART B.    ALTERNATE BAT MASS LIMITATIONS FOR THE
              LEAD/TIN/BISMUTH FORMING SUBCATEGORY

      (a)  Rolling Spent Emulsions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of lead/tin/bismuth rolled with
       emulsions

114  ANTIMONY                  45.0                          20.0
122  LEAD                       6.5                           3.O
      
-------
      Ce)  Drawing Spent Soap Solutions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


   mg/kkg  of leadVtin/bismuth drawn with soap
      solutions

114  ANTIMONY                  14.0                           6.4
122  LEAD                       2.1                           1.0
      (f)  Extrusion Press And Solution Heat Treatment Contact
              Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of lead/tin/bismuth heat treated

114  ANTIMONY                   340                           150
122  LEAD                        49                            23
        Extrusion Press Hydraulic Fluid Leakage


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


    mg/kkg (Ib/billion lbs> of lead/tin/bismuth extruded

114  ANTIMONY                  95.O                          42.O
122  LEAD                      14.0                           6.4
                                 195

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      (h)  Continuoua Strip Casting Contact Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg 
-------
      (1)  Alkaline Cleaning Spent Baths
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
_ _	______ — ________ — ________-—___—»_ —_-_ — — __-____ — — —,____.— __ — — — — — — — — — — — — —

    mg/kkg (Ib/billion Iba) of lead/tin/biamuth alkaline cleaned

114  ANTIMONY                 1,200                           520
122  LEAD                       170                            79
      (m)  Alkaline Cleaning Rinaewater


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


    mg/kkg 
-------
      

MifiGellaneoua Nondescript Waatewater Sources Pollutant or Maximum for ~MaxImum~for Pollutant Property Any One Day Monthly Average mg/kkg (Ib/billion Iba) of lead/tin/bismuth formed 114 ANTIMONY 110.0 50.0 122 LEAD 16.0 7.6 SUBPART C. ALTERNATE BAT MASS LIMITATIONS FOR THE MAGNESIUM FORMING SUBCATEGORY (a) Rolling Spent Emulalona There shall be no diacharge of proceaa waatewater pollutants. (b> Forging Spent Lubricants There shall be no diacharge of proceaa waatewater pollutants. (c) Forging Wet APC Slowdown Pollutant or Maximum for Maximum for Pollutant Property Any One Day Monthly Average mg/kkg (Ib/blllion Iba) of magnesium forged 119 CHROMIUM 120,OOO 48,OOO 128 ZINC 39O,OOO 160,000 AMMONIA 35,000,000 16,OOO,OOO FLUORIDE 16,OOO,000 7,OOO,OOO MAGNESIUM 550,OOO 24O,OOO 198


-------
      (d)  Forging Solution Heat Treatment Contact Cooling Water


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


    mg/kkg (Ib/billion Ibs) of forged magnesium heat treated

119  CHROMIUM                   280                           110
128  ZINC                       920                           390
     AMMONIA                 84,000                        37,OOO
     FLUORIDE                38,000                        17,000
     MAGNESIUM                1,300                           580


      (e)  Forging Equipment Cleaning Wastewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of magnesium forged

119  CHROMIUM                    71                            29
128  ZINC                       240                            99
     AMMONIA                 22,000                         9,50O
     FLUORIDE                 9,600                         4,3OO
     MAGNESIUM                  330                           150
      (f)  Direct Chill Casting Contact Cooling Water

There shall be no discharge of process wastewater pollutants.


      (g)  Surface Treatment Spent Baths
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of magnesium surface treated

119  CHROMIUM                   200                            84
128  ZINC                       680                           280
     AMMONIA                 62,000                        27,000
     FLUORIDE                28,000                        12,OOO
     MAGNESIUM                  950                           42O
                           199

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         Degreasing Spent Solvents

There shall be no discharge of process wastewater pollutants.
SUBPART D.    ALTERNATE BAT MASS LIMITATIONS FOR THE NICKEL/COBALT
              FORMING SUBCATEGORY

      (a)  Rolling Spent Neat Oils

There shall be no discharge of process wastewater pollutants.
                         200

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       (b)   Rolling  Spent Emulsions
   Pollutant  or          Maximum for                Maximum for
Pollutant Property       Any  One Day              Monthly Average


    mg/kkg  (Ib/billion  lbs>  of  nickel/cobalt rolled with emulsions

119  CHROMIUM                   66O                           270
124  NICKEL                   2,9OO                         1,90O
     FLUORIDE                89,000                        39,000


         Rolling  Contact Lubricant-Coolant Water
   Pollutant or          Maximum  for                Maximum for
Pollutant Property       Any  One  Day              Monthly Average
    mg/kkg  (Ib/billion  Ibs) of  nickel/cobalt rolled with contact
       lubricant-coolant water

119  CHROMIUM                    590                            240
124  NICKEL                   2,60O                          1,7OO
     FLUORIDE                80,000                         35,OOO
      (d)  Rolling Solution Heat Treatment  Contact Cooling Water


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


  mg/kkg (Ib/billion Ibs) of rolled  nickel/cobalt heat  treated

119  CHROMIUM                   .00                            .OO
124  NICKEL                     .10                            .OO
     FLUORIDE                  1.60                            .70


        Tube Reducing Spent Lubricants

There shall be no discharge of process wastewater pollutants.
— — ^— — — — — — — — — "^ — — —•- — — ^—*.^~ —_ —— — ^_^..«.~_^^_• __ — — —.—•. _.^^ v-«> _—_ _— —— «»•_ w_—« _ __ « _ _ __ _ ™_ _• _^ __ ^ _ ^m _

      (f)  Drawing Spent Neat Oils

There shall be no discharge of process wastewater pollutants.
                        201

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        Drawing Spent Emulsions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Iba) of nickel/cobalt drawn with emulsions

119  CHROMIUM                    42                            17
124  NICKEL                     180                           120
     FLUORIDE                 5,7OO                         2,500


        Extrusion Spent Lubricants

There shall be no discharge of process wastewater pollutants.
         Forging, Extrusion, And Isostatic Press Hydraulic
             Fluid Leakage
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


  mg/kkg (Ib/billion Iba) of nickel/cobalt forged, extruded, or
     pressed

119  CHROMIUM                    55                            22
124  NICKEL                     240                           ISO
     FLUORIDE                 7,400                         3,3OO
                         202

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        Forging Equipment Cleaning Wastewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of nickel/cobalt forged

119  CHROMIUM                    72                            29
124  NICKEL                     310                           210
     FLUORIDE                 9,700                         4,300


      (!)  Forging Die Contact Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of nickel/cobalt forged

119  CHROMIUM                    55                            23
124  NICKEL                     24O                           16O
     FLUORIDE                 7,500                         3,300
      Cm)  Forging/Swaging Spent Neat Oila

There shall be no discharge of process wastewater pollutants.
      (n)  Stationary And Direct Chill Casting Contact Cooling
             Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of nickel/cobalt cast by the
       stationary or direct chill method

119  CHROMIUM                   780                           32O
124  NICKEL                   3,40O                         2,30O
     FLUORIDE               110,000                        47,000
                              203

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        Casting Vacuum Melting Steam Condenaate
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Iba) of nickel/cobalt vacuum melted

119  CHROMIUM                    74                            30
124  NICKEL                     320                           21O
     FLUORIDE                10,000                         4,400
      (p)  Metal Powder Production Atomization Wastewater


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


  mg/kkg (Ib/billion Ibs) of nickel/cobalt metal powder atomized

119  CHROMIUM                 1,200                           510
124  NICKEL                   5,50O                         3,600
     FLUORIDE               170,000                        75,000
      (q)  Annealing Solution Heat Treatment Contact Cooling
           Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Iba) of nickel/cobalt annealed

119  CHROMIUM                   2OO                            82
124  NICKEL                     880                           580
     FLUORIDE                27,OOO                        12,000
                              204

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      (r)  Wet APC Slowdown
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg 
-------
      (u)  Alkaline Cleaning Spent Baths
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg Clb/billion Iba) of nickel/cobalt alkaline cleaned

119  CHROMIUM                  13.0                           5.5
124  NICKEL                    59.0                          39.0
     FLUORIDE               1,80O.O                         81O.O
      (v)  Alkaline Cleaning Rinsewater


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


    mg/kkg (Ib/billion Iba) of nickel/cobalt alkaline cleaned

119  CHROMIUM                   22O                            89
124  NICKEL                     950                           63O
     FLUORIDE                30,OOO                        13,OGG


      (w)  Molten Salt Rinsewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg clb/billion Iba) of nickel/cobalt treated with molten
       salt

119  CHROMIUM                   56O                           23O
124  NICKEL                   2,500                         1,6OO
     FLUORIDE                76,000                        34,OOO
                              206

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        Ammonia Rinae Waatewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
  mg/kkg (Ib/billion Iba) of nickel/cobalt treated with ammonia
     solution

119  CHROMIUM                   6.9                           2.8
124  NICKEL                    30.0                          20.0
     FLUORIDE                 930.0                         410.0
      Cy)  Sawing/Grinding Spent Lubricants


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


    mg/kkg (Ib/billion Iba) of nickel/cobalt sawed or ground

119  CHROMIUM                   440                           180
124  NICKEL                   1,900                         1,3OO
     FLUORIDE                60,000                        26,000


      (z)  Steam Cleaning Condenaate
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of nickel/cobalt steam cleaned

119  CHROMIUM                  10.0                           4.2
124  NICKEL                    45.O                          29.O
     FLUORIDE               1,400.0                         610.0
                             207

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            Hydrostatic Tube Teat ing Waatewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Iba) of nickel/cobalt tube teated by the
       hydroatatic method

119  CHROMIUM                    59                            24
124  NICKEL                     260                           17O
     FLUORIDE                 8,000                         3,600
      (ab)  Degreaaing Spent Solventa

There shall be no discharge of proceaa waatewater pollutants.


      (ac>  Miscellaneous Nondeacript Waatewater Sources
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg 
-------
      (b)  Rolling Solution Heat Treatment Contact Cooling Water

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


   mg/kkg (Ib/billion lbs> of rolled precious metals heat treated

118  CADMIUM                    240                           11O
120  COPPER                   1,300                           700
121  CYANIDE                    200                            84
126  SILVER                     29O                           12O


      (c)  Drawing Spent Neat Oils

There shall be no discharge of process wastewater pollutants.


      
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      <£)  Extrusion Preaa And Solution Heat Treatment Contact
             Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


  mg/kkg (Ib/billion Iba) of extruded precious metals heat treated

118  CADMIUM                    470                           210
120  COPPER                   2,600                          1,400
121  CYANIDE                    4OO                           160
126  SILVER                     560                           230


      (g)  Seml-Continuoua And Continuous Casting Contact Cooling
              Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of precious metals cast by the
       semi-continuous or continuous method

118  CADMIUM                    380                           170
120  COPPER                   2,100                         1,100
121  CYANIDE                    320                           130
126  SILVER                     460                           19O
      (h)  Stationary Casting Contact Cooling Water-
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of precious metals cast by the
       stationary method

118  CADMIUM                   1.40                            .60
120  COPPER                    7.90                          4.2O
121  CYANIDE                   1.20                            .50
126  SILVER                    1.70                            .70
                         210

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        Direct Chill Casting Contact Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Iba) of precioua metals cast by the direct
       chill method

118  CADMIUM                    280                           120
120  COPPER                   1,600                           820
121  CYANIDE                    240                            98
126  SILVER                     340                           14O
      (j>  Shot Casting Contact Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of precious metals shot cast

118  CADMIUM                     30                            13
120  COPPER                     170                            89
121  CYANIDE                     26                            11
126  SILVER                      37                            15
      (k>  Casting Wet APC Slowdown


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


   mg/kkg (Ib/billion Ibs) of precioua metala cast

118  CADMIUM                   2.00                           .90
120  COPPER                   11.00                          5.9O
121  CYANIDE                   1.70                           .70
126  SILVER                    2.40                          l.OO
                              211

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      (1)  Metal Powder Production Atomization Wastewater


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


   mg/kkg (Ib/billion Iba) of precious metals powder wet atomized
118
120
121
126
CADMIUM
COPPER
CYANIDE
SILVER
2,300
13,000
1,900
2,700
1,000
6,700
800
1,100
      <*>  Metal Powder Production Ball Milling Wastewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of precious metals powder wet ball
       milled

118  CADMIUM                    740                           330
120  COPPER                   4,10O                         2,2OO
121  CYANIDE                    630                           260
126  SILVER                     890                           37O
      (n)  Pressure Bonding Contact Cooling" Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Iba) of precious metal and base metal
       pressure bonded

118  CADMIUM                     28                            13
12O  COPPER                     16O                            84
121  CYANIDE                     24                            10
126  SILVER                      34                            14
                             212

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        Annealing Solution Heat Treatment Contact Cooling
             Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Iba) of precious metals annealed

118  CADMIUM                    340                           150
120  COPPER                   1,900                         1,000
121  CYANIDE                    290                           120
126  SILVER                     41O                           170


      

Surface Treatment Spent Batha Pollutant or Maximum for Maximum for Pollutant Property Any One Day Monthly Average mg/kkg (Ib/billion Iba) of precious metals surface treated 118 CADMIUM 53 23 120 COPPER 290 160 121 CYANIDE 45 19 126 SILVER 64 26 (q> Surface Treatment Rinsewater Pollutant or Maximum for Maximum for Pollutant Property Any One Day Monthly Average mg/kkg (Ib/billion lbs> of precious metals surface treated 118 CADMIUM 970 430 120 COPPER 5,4OO 2,800 121 CYANIDE 82O 34O 126 SILVER 1,200 480 213


-------
      (r)  Alkaline Cleaning Spent Batha
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of precioua metala alkaline cleaned

118  CADMIUM                   1.20                           .60
120  COPPER                    7.OO                          3.7O
121  CYANIDE                   1.10                           .40
126  SILVER                    1.50                           .60
      (a)  Alkaline Cleaning Rinaewater


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


    mg/kkg   Pre-Bondlng Cleaning Waatewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Iba) of precioua metal and baae metal
       cleaned prior to bonding

118  CADMIUM                    120                            51
120  COPPER                     650                           340
121  CYANIDE                     89                            41
126  SILVER                     140                            58
                                214

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


    mg/kkg (Ib/billion Ibs) of precious metals burnished

118  CADMIUM                    870                           390
120  COPPER                   4,900                         2,600
121  CYANIDE                    750                           31O
126  SILVER                   1,10O                           440
      (w)  Sawing/Grinding Spent Emulsions


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


    mg/kkg (Ib/billion Ibs) of precious metals sawed or ground

118  CADMIUM                   2.10                           .90
120  COPPER                   11.00                          6.10
121  CYANIDE                   1.8O                           .70
126  SILVER                    2.50                          1.00


      
-------
SUBPART F.    ALTERNATE BAT MASS LIMITATIONS FOR THE REFRACTORY
              METALS FORMING SUBCATEGORY

      (a)  Rolling Spent Neat Oila

There shall be no discharge of process wastewater pollutants.


        Rolling Spent Emulsions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Iba) of refractory metals rolled with
       emulsions
120
124






COPPER
NICKEL
COLUMBIUM
FLUORIDE
MOLYBDENUM
TANTALUM
TUNGSTEN
VANADIUM
2,300
2,300
2,500
71,000
2,500
2,500
2,500
2,500
1,200
1,500
1,100
32,OOO
1,100
1,100
1,100
1,1OO
      (c)  Drawing Spent Lubricants

There shall be no discharge of process wastewater pollutants.
        Extrusion Press And Solution Heat Treatment Contact
             Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/bllllon Iba) of extruded refractory metals heat
       treated

120  COPPER                     660                           350
124  NICKEL                     660                           44O
     COLUMBIUM                  710                           310
     FLUORIDE                21,000                         9,1OO
     MOLYBDENUM                 710                           310
     TANTALUM                   710                           31O
     TUNGSTEN                   710                           310
     VANADIUM                   710                           31O
                                216

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      (e>  Extrusion Press Hydraulic Fluid Leakage
   Pollutant or
Pollutant Property
Maximum for
Any One Day
  Maximum for
Monthly Average
    mg/kkg (Ib/billion Ibs) of refractory metals extruded
120
124






COPPER
NICKEL
COLUMBIUM
FLUORIDE
MOLYBDENUM
TANTALUM
TUNGSTEN
VANADIUM
2,300
2,300
2,400
71,000
2,400
2,400
2,400
2,400
1,2OO
1,500
1,1OO
31,000
1,1OO
1,100
1,100
1,100
        Forging Solution Heat Treatment Contact Cooling Water
   Pollutant or
Pollutant Property
Maximum for
Any One Day
  Maximum for
Monthly Average
    mg/kkg (Ib/billion Ibs) of forged refractory metals heat
       treated
120  COPPER
124  NICKEL
     COLUMBIUM
     FLUORIDE
     MOLYBDENUM
     TANTALUM
     TUNGSTEN
     VANADIUM
      1,100
      1,1OO
      1,200
     34,OOO
      1,200
      1,20O
      1,200
      1,200
             580
             74O
             530
          15,000
             530
             530
             530
             53O
                             217

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       (h>  Extrusion And Forging Equipment Cleaning Wastewater-


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


  mg/kkg Clb/billion Iba) of refractory metala extruded or forged

120  COPPER                      79                            42
124  NICKEL                      80                            53
     COLUMBIUM                   85                            38
     FLUORIDE                 2,500                         1,100
     MOLYBDENUM                  85                            38
     TANTALUM                    85                            38
     TUNGSTEN                    85                            38
     VANADIUM                    85                            38


       (i)  Metal Powder Production Waatewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg   Metal Powder Preaaing Spent Lubricanta

There ahall be no diacharge of proceaa waatewater pollutanta.


      (1)  Caating Contact Cooling Water

There ahall be no diacharge of proceaa waatewater pollutanta.
                                218

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        Poat-Caating Billet Waahwater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
  mg/kkg (Ib/billion Ibs) of cast refractory metals billet washed

120  COPPER                      57                            30
124  NICKEL                      57                            38
     COLUMBIUM                   61                            27
     FLUORIDE                 1,800                           79O
     MOLYBDENUM                  61                            27
     TANTALUM                    61                            27
     TUNGSTEN                    61                            27
     VANADIUM                    61                            27
      (n>  Surface Treatment Spent Baths
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of refractory metals surface treated

120  COPPER                      24                            13
124  NICKEL                      24                            16
     COLUMBIUM                   26                            12
     FLUORIDE                   760                           34O
     MOLYBDENUM                  26                            12
     TANTALUM                    26                            12
     TUNGSTEN                    26                            12
     VANADIUM                    26                            12
                             219

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      (o)  Surface Treatment Rinsewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg 
-------
      (q>  Surface Coating Wet APC Slowdown
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg 
-------
      Ca)  Alkaline Cleaning Rinaewater
   Pollutant or
Pollutant Property
Maximum £or
Any One Day
  Maximum for
Monthly Average
    mg/kkg (Ib/billion Iba) of refractory metals alkaline cleaned
120
124






COPPER
NICKEL
COLUMBIUM
FLUORIDE
MOLYBDENUM
TANTALUM
TUNGSTEN
VANADIUM
2,700
2,7OO
2,9OO
83,000
2,900
2,90O
2,900
2,900
1,400
1,800
1,300
37,000
1,300
1,300
1,300
1,300
      (t)  Molten Salt Cleaning Rinsewater
   Pollutant or
Pollutant Property
Maximum for
Any One Day
  Maximum for
Monthly Average
  mg/kkg (Ib/billion Iba) of refractory metals cleaned with molten
     salt
120  COPPER
124  NICKEL
     COLUMBIUM
     FLUORIDE
     MOLYBDENUM
     TANTALUM
     TUNGSTEN
     VANADIUM
    170,000
    170,000
    180,000
  5,4OO,OOO
    180,OOO
    180,000
    180,000
    180,OOO
          9O,OOO
         110,000
          82,000
       2,400,000
          82,OOO
          82,OOO
          82,000
          82,OOO
                             222

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      (u)  Tumbling/Burnishing Wastewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of refractory metals tumbled or
       burnished
120
124






COPPER
NICKEL
COLUMBIUM
FLUORIDE
MOLYBDENUM
TANTALUM
TUNGSTEN
VANADIUM
4,200
4,20O
4,500
130,000
4,500
4,5OO
4,500
4,5OO
2,200
2,80O
2,000
5S,OOO
2,000
2,OOO
2,000
2,OOO
      (v>  Sawing/Grinding Spent Neat Oils

There shall be no discharge of process wastewater pollutants,


        Sawing/Grinding Spent Emulsions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of refractory metals sawed or ground
       with emulsions

120  COPPER                     410                           220
124  NICKEL                     420                           2SO
     COLUMBIUM                  440                           20O
     FLUORIDE                13,000                         5,7OO
     MOLYBDENUM                 440                           20O
     TANTALUM                   440                           200
     TUNGSTEN                   440                           200
     VANADIUM                   44O                           2OO
                            223

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      (x)  Sawing/Grinding Contact Lubricant-Coolant Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of refractory metala sawed or ground
       with lubricant-coolant water
120
124






COPPER
NICKEL
COLUMBIUM
FLUORIDE
MOLYBDENUM
TANTALUM
TUNGSTEN
VANADIUM
1,500
1,600
1,700
48,000
1,700
1,700
1,7OO
1,700
810
1,000
740
21,OOO
740
74O
740
740
      (y)  Sawing/Grinding Wet APC Slowdown
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Iba) of refractory metala sawed or ground

120  COPPER                     210                           110
124  NICKEL                     210                           14O
     COLUMBIUM                  220                            98
     FLUORIDE                 6,400                         2,900
     MOLYBDENUM                 22O                            98
     TANTALUM                   220                            98
     TUNGSTEN                   22O                            98
     VANADIUM                   220                            98
                            224

-------
      
-------
SUBPART G.    ALTERNATE BAT MASS LIMITATIONS FOR THE TITANIUM
              FORMING SUBCATEGORY

      (a)  Cold Rolling Spent Lubricants
Pollutant or
Pollutant Property
mg/kkg (Ib/billion
121 CYANIDE
122 LEAD
128 ZINC
AMMONIA
FLUORIDE
TITANIUM
 Hot Rolling
Pollutant or
Pollutant Property
Maximum for
Any One Day
Iba) of titanium
97
140
490
45,000
20,000
680
Maximum for
Monthly Average
cold rolled
4O
67
2OO
20,000
8,800
300
Contact Lubricant-Coolant Water
Maximum for
Any One Day
mg/kkg '(lb/billion Iba) of titanium
lubricant-coolant water
121 CYANIDE
122 LEAD
128 ZINC
AMMONIA
FLUORIDE
TITANIUM
120
180
630
57,OOO
26,OOO
880
Maximum for
Monthly Average
hot rolled with contact
52
86
26O
25,000
11,000
390

-------
      (d)  Forging Spent Lubricants

There ahall be no diacharege o£ process waatewater pollutants.
-» •_ _. •_ _ _«_ _ -«. _ •». — — — — ~- — —• — — ^ —«• — ^ — — — ^^^^— ^ _ _ ^_^ . ^ _ — ~_ ^__ ^^ -^ — _ _ — — _.^ ... _ ^ _ «_ « . ._ .

      (e>  Forging Die Contact Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of titanium forged

121  CYANIDE                     87                            36
122  LEAD                       130                            6O
128  ZINC                      . 440                           180
     AMMONIA                 4O,000                        18,OOO
     FLUORIDE                18,000                         7,900
     TITANIUM                   62O                           270
      (f)  Forging Wet APC Slowdown


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


    mg/kkg (Ib/billion Iba) of titanium forged

121  CYANIDE                     59                            24
122  LEAD                        85                            40
128  ZINC                       29O                           12O
     AMMONIA                 27,000                        12,OOO
     FLUORIDE                12,OOO                         5,300
     TITANIUM                   410                           180
                               227

-------
(g)   Heat Treatment Contact Cooling Water
Pollutant or
Pollutant Property
mg/kkg (Ib/billion
121 CYANIDE
122 LEAD
128 ZINC
AMMONIA
FLUORIDE
TITANIUM
(h) Surface Tret
Pollutant or
Pollutant Property
mg/kkg (Ib/billion
121 CYANIDE
122 LEAD
128 ZINC
AMMONIA
FLUORIDE
TITANIUM
( i ) Surface Tree
Pollutant or
Pollutant Property
mg/kkg (Ib/billion
121 CYANIDE
122 LEAD
128 ZINC
AMMONIA
FLUORIDE
TITANIUM
Maximum for
Any One Day
Iba) of titanium
130
19O
660
60,OOO
27,000
92O
itment Spent Bathe
Maximum for
Any One Day
Iba) of titanium
46
67
23O
21,OOO
9,500
330
itment Rinaewater
Maximum for
Any One Day
Iba) of titanium
610
890
3,100
280,000
130,000
4,300
Maximum for
Monthly Average
heat treated
54
9O
280
26,000
12,000
41O

Maximum for
Monthly Average
surface treated
19
32
98
9,4OO
4,20O
150

Maximum for
Monthly Average
surface treated
250
42O
1,300
120,000
56,OOO
1,900
                         228

-------
(j>   Surface Treatment Wet APC Slowdown
Pollutant or
Pollutant Property
mg/kkg  of titanium surface
4.9
7.1
25.0
2,30O.O
1,OOO.O
35.0
waning Spent Baths
Maximum for
Any One Day
Ibs) of titanium alkaline
19O
27O
930
85,000
38,000
1,300
waning Rinsewater
Maximum for
Any One Day
Ibs) of titanium alkaline
SO
120
400
37,000
16,000
570
Maximum for
Monthly Average
treated
2.0
3.4
10.0
1,000.0
450.0
15.0

Maximum for
Monthly Average
cleaned
77
13O
390
37,000
17,000
580

Maximum for
Monthly Average
cleaned
33
55
170
16,000
7,3OO
250
                         229

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        Tumbling Waatewater
   Pollutant or         Maximum  for                 Maximum for
Pollutant Property      Any One  Day               Monthly Average
    mg/kkg  (Ib/billion Ibs) of titanium  tumbled

121  CYANIDE                   23.0                            9.5
122  LEAD                      33.0                           16.0
128  ZINC                     120.0                           48.O
     AMMONIA               11,000.0                        4,600.0
     FLUORIDE               4,700.0                        2,100.O
     TITANIUM                 160.0                           72.O
      (n)  Sawing/Grinding Spent Lubricants


   Pollutant or         Maximum for                 Maximum for
Pollutant Property      Any One Day               Monthly Average
™~ •*~ •• — ^ — ~" -™- — — — —• — — — —" — — — — — — — — ^ ^ — — — — — —«• — — — —• — ^ — — — — — — -» — — —.— — •» — » — — —— —_ —— _— _ _» « _ «_ « -

    mg/kkg (Ib/billion Iba) of titanium sawed or  ground

121  CYANIDE                   14.0                            6.0
122  LEAD                      21.0                           10.0
12S  ZINC                      73.0                           30.0
     AMMONIA                6,600.O                        2,9OO.O
     FLUORIDE               3,OOO.O                        1,30O.O
     TITANIUM                 100.0                           45.O


      Co)  Degreasing Spent Solvents

There shall be no discharge of process wastewater pollutants.
SUBPART H.    ALTERNATE BAT MASS LIMITATIONS  FOR  THE  URANIUM
              FORMING SUBCATEGORY

      (a)  Extrusion Spent Lubricants

There shall be no discharge of process wastewater pollutants.
                                230

-------
       Concentration Value la 5 Picocuriea Per Liter

      (c)  Extrusion Preaa And Solution Heat Treatment Contact
             Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Iba) of extruded uranium heat treated

118  CADMIUM                     92                            41
12O  COPPER                     520                           270
124  NICKEL                     520                           350
     FLUORIDE                16,000                         7,20O
     RADIUM                     (1)                           (!)
     URANIUM                    560                           250

     (1) Concentration Value la 5 Picocuriea Per Liter

      (d)  Forging Spent Lubricants

There ahall be no discharge of process wastewater pollutants.
                                 231

-------
           Forging Solution Heat Treatment Contact  Cooling  Water
   Pollutant or         Maximum for                 Maximum for
Pollutant Property      Any One Day               Monthly  Average


    mg/kkg (Ib/billion Iba) of forged uranium  heat  treated

US  CADMIUM                     97                             43
120  COPPER                     540                            28O
124  NICKEL                     550                            360
     FLUORIDE                17,OOO                          7,5OO
     RADIUM                     (1)                            (1)
     URANIUM                    580                            26O

     (1) Concentration Value Is 5 Picocuries Per  Liter

      Cf)  Surface Treatment Spent Baths
   Pollutant or         Maximum for                 Maximum  for
Pollutant Property      Any One Day              Monthly  Average
    mg/kkg (Ib/billion Ibs) of uranium surface treated

118  CADMIUM                   12.0                            5.3
120  COPPER                    68.0                           36.O
124  NICKEL                    68.0                           45.0
     FLUORIDE               2,100.0                          940.O
     RADIUM                     <1)                            (1)
     URANIUM                   73.O                           32.O
— •— — — — ••— — —• — — — -•.— _ _ — _ _ _____ _ H _--»-»___.• _ _.. _ _ _ ^M—.__».«._.-..«. ^™_-_____	— — «__«__	— —. — -
     (1) Concentration Value Is 5 Picocuries Per Liter

        Surface Treatment Rinaewater
   Pollutant or         Maximum for                 Maximum  for
Pollutant Property      Any One Day              Monthly  Average


    mg/kkg (Ib/billion Ibs) of uranium surface  treated

118  CADMIUM                     50                             22
120  COPPER                     280                            15O
124  NICKEL                     280                            190
     FLUORIDE                 8,800                          3,9OO
     RADIUM                     <1>                            <1>
     URANIUM                    300                            13O

     (1) Concentration Value Is 5 Picocuries Per Liter
                                232

-------
        Surface Treatment Wet APC Slowdown
   Pollutant or         Maximum £or                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of uranium surface treated

118  CADMIUM                     25                             11
120  COPPER                     140                             74
124  NICKEL                     140                             94
     FLUORIDE                 4,400                         2,OOO
     RADIUM                     (1)                            (1)
     URANIUM                    150                             68

     (1) Concentration Value Is 5 Picocuriea Per Liter

      Ci)  Sawing/Grinding Spent Emulsions


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


    mg/kkg (Ib/billion Ibs) of uranium sawed or ground

118  CADMIUM                   1.10                            .50
120  COPPER                    5.90                          3.10
124  NICKEL                    6.00                          3.9O
     FLUORIDE                180.00                         82.OO
     RADIUM                     CD                            (1)
     URANIUM                   6.40                          2.8O

      (1) Concentration Value Is 5 Picocuries Per Liter

      C j )  Post-Sawing/Grinding Rinsewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of sawed or ground uranium rinsed

US  CADMIUM                   13.0                           5.7
120  COPPER                    72.0                          38.0
124  NICKEL                    73.0                          48.0
     FLUORIDE               2,300.0                       1,OOO.O
     RADIUM                     CD                           CD
     URANIUM                   78.0                          35.O

      (1) Concentration Value Is 5 Picocuries Per Liter
                                 233

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      ck)  Degreasing Spent Solvents

There shall be no discharge of process wastewater pollutants.



SUBPART I.    ALTERNATE BAT MASS LIMITATIONS FOR THE ZINC FORMING
              SUBCATEGORY

      (a)  Rolling Spent Neat Oils

There shall be no discharge of process wastewater pollutants.


        Rolling Spent Emulsions


   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
— — — — ^ — — — — — — — •— — —- — — —- —. ——— — w — — — ^w— ___^ _ __ __ «_ ^___ M. _ __ _ _» _ ^ w. ^ ^ _• _ _ _ .^ __ __ _ _ __ „ „ __ __ _ _

  mg/kkg (Ib/billion Ibs) of zinc rolled with emulsions

119  CHROMIUM                   .60                           .30
121  CYANIDE                    .40                           .2O
12S  ZINC                      2.00                           .80


        Rolling Contact Lubricant-Coolant Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of zinc rolled with contact
       lubricant-coolant water

119  CHROMIUM                  15.O                           6.2
121  CYANIDE                   10.0                           4.2
128  ZINC                      51.0                          21.0
                                234

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        Drawing Spent Emulsions
   Pollutant or         Maximum for.               Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of zinc drawn with emulsions

119  CHROMIUM                   3.5                           1.4
121  CYANIDE                    2.3                           1.0
128  ZINC                      12.0                           4.9
        Direct Chill Casting Contact Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
  mg/kkg (Ib/billion Ibs) of zinc cast by the direct chill method

119  CHROMIUM                  22.0                           9.1
121  CYANIDE                   15.0                           6.0
128  ZINC                      73.0                          31.0
      Cf>  Stationary Casting Contact Cooling Water

There shall be no discharge of process wastewater pollutants,


      Cg)  Heat Treatment Contact Colling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of zinc heat treated

119  CHROMIUM                  33.0                          14.0
121  CYANIDE                   22.0                           9.1
128  ZINC                     110.0                          46.0
                               235

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        Surface Treatment Spent Baths


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


    mg/kkg (Ih/billion Ibs) of zinc surface treated

119  CHROMIUM                   4.2                           1.7
121  CYANIDE                    2.8                           1.1
128  ZINC                      14.0                           5.8


        Surface Treatment Rinsewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of zinc surface treated

119  CHROMIUM                   210                            87
121  CYANIDE                    140                            58
128  ZINC                       710                           300
      (3)  Alkaline Cleaning Spent Baths


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


    mg/kkg (Ib/billion Ibs) of zinc alkaline cleaned

119  CHROMIUM                   .30                            . 1O
121  CYANIDE                    .20                            .1O
128  ZINC                      1.00                            .40
                                 236

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      (k)  Alkaline Cleaning Rinsewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of zinc alkaline cleaned

119  CHROMIUM                 2,500                         1,000
121  CYANIDE                  1,700                           69O
128  ZINC                     8,400                         3,500


      (1)  Sawing/Grinding Spent Lubricants


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


  mg/kkg (Ib/billion Ibs) of zinc sawed or ground

119  CHROMIUM                  24.0                          10.0
121  CYANIDE                   16.0                           6.6
128  ZINC                      80.O                          33.O


      
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      (b>  Extrusion Spent Emulsions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of zirconium/hafnium extruded with
       emulsions
119
121
124




CHROMIUM
CYANIDE
NICKEL
AMMONIA
FLUORIDE
HAFNIUM
ZIRCONIUM
33.0
21.0
140.0
9,90O.O
4,40O.O
150.0
150.0
13.0
8.9
94.0
4,300.0
2,000.0
67.0
67.0
      (c>  Extrusion Press Hydraulic Fluid Leakage
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of zirconium/hafnium extruded

119  CHROMIUM                   160                            67
121  CYANIDE                    11O                            44
124  NICKEL                     710                           47O
     AMMONIA                 49,OOO                        22,OOO
     FLUORIDE                22,000                         9,8OO
     HAFNIUM                    760                           34O
     ZIRCONIUM                  760                           34O
                                 238

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        Extrusion Press And Solution Heat Treatment Contact
             Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of extruded zirconium/hafnium heat
       treated
119
121
124




CHROMIUM
CYANIDE
NICKEL
AMMONIA
FLUORIDE
HAFNIUM
ZIRCONIUM
13.0
8.3
55.0
3,800.0
1,7OO.O
58.0
58.0
5.1
3.4
36.0
1,7OO.O
750.0
26. 0
26.0
      (e)  Tube Reducing Spent Lubricants
   Pollutant or         Maximum for                Maximum for

      Cf)  Forging Solution Heat Treatment Contact Cooling Water


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


  mg/kkg (Ib/billion Ibs) of forged zirconium/hafnium heat treated

119  CHROMIUM                  15.0                           6.3
121  CYANIDE                   10.0                           4.2
124  NICKEL                    67.0                          44.O
     AMMONIA                4,700.0                       2,OOO.O
     FLUORIDE               2,100.0                         92O.O
     HAFNIUM                   72.0                          32.0
     ZIRCONIUM                 72.0                          32.0
                                   239

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      (g)  Surface Treatment Spent Baths
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (lb/billion Iba) of zirconium/hafnium rolled with
      emulsions
119
121
124




CHROMIUM
CYANIDE
NICKEL
AMMONIA
FLUORIDE
HAFNIUM
ZIRCONIUM
180
120
770
53,000
24,OOO
820
820
72
48
510
23,000
11,000
360
360
      
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        Alkaline Cleaning Spent Baths
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of zirconium/hafnium alkaline cleaned
119
121
124




CHROMIUM
CYANIDE
NICKEL
AMMONIA
FLUORIDE
HAFNIUM
ZIRCONIUM
940
620
4,1OO
280,000
130,000
4,4OO
4,400
380
260
2,700
120,000
56,000
1,9OO
1,900
      (3)  Alkaline Cleaning Rinaewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Iba) of zirconium/hafnium alkaline cleaned

119  CHROMIUM                 2,400                         1,OOO
121  CYANIDE                  1,600                           66O
124  NICKEL                  11,000                         7,OOO
     AMMONIA                740,OOO                       32O,OOO
     FLUORIDE               330,000                       150,000
     HAFNIUM                 11,000                         5,000
     ZIRCONIUM               11,000                         5,000
                       241

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           Sawing/Grinding Spent Lubricanta
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of zirconium/hafnium sawed or ground

119  CHROMIUM                   4.0                           1.6
121  CYANIDE                    2.6                           1.1
124  NICKEL                    17.0                          11.0
     AMMONIA                1,200.0                         530.0
     FLUORIDE                 540.0                         240.0
     HAFNIUM                   18.0                           8.2
     ZIRCONIUM                 18.0                           8.2
      <1>  Sawing/Grinding Wet APC Slowdown

There shall be no discharge of process waatewater pollutants.


      (m)  Degreasing Spent Solvents

There shall be no discharge of process wastewater pollutants.


      (n.)  Degreaaing Rinaewater


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


  mg/kkg (Ifa/billion Ibs) of zirconium/hafnium degreased

113  CHROMIUM                    89                            37
121  CYANIDE                     59                            24
124  NICKEL                     390                           260
     AMMONIA                 27,OOO                        12,000
     FLUORIDE                12,000                         5,4OO
     HAFNIUM                    420                           ISO
     ZIRCONIUM                  420                           180
                            242

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SUBPART K.    ALTERNATE BAT MASS LIMITATIONS  FOR  THE  IRON  AND
       STEEL/COPPER/ALUMINUM METAL  POWDER  PRODUCTION  AND POWDER
       METALLURGY SUBCATEGORY

       (a)  Metal Powder Production  Atomization  Waatewater
   Pollutant or         Maximum for                 Maximum  for
Pollutant Property      Any One Day               Monthly  Average
    mg/kkg (Ib/billion Ibs) of iron, copper,  and  aluminum  powder
       wet atomized

120  COPPER                   6,500                          3,100
121  CYANIDE                  1,000                            4OO
122  LEAD                     1,4OO                            660
     ALUMINUM                31,OOO                         14,OOO
     IRON                     6,000                          3,1OO


      
-------
        Sizing/Repressing Spent Lubricants

There shall be no discharge o£ process waatewater pollutants.


        Steam Treatment Wet APC Slowdown
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of iron, copper, and aluminum powder
       powder metallurgy parts steam treated

120  COPPER                     360                           17O
121  CYANIDE                     57                            23
122  LEAD                        80                            37
     ALUMINUM                 1,700                           77O
     IRON                       34O                           170
                              244

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      (g)  Tumbling, Burnishing And Cleaning Wastewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of iron, copper, and aluminum powder
       metallurgy parts tumbled, burnished, or cleaned

120  COPPER                     920                           440
121  CYANIDE                    140                            57
122  LEAD                       200                            93
     ALUMINUM                 4,400                         1,9OO
     IRON                       860                           440
      (h)  Sawing/Grinding Spent Lubricants
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of iron, copper, and aluminum powder
       metallurgy parts sawed or ground

120  COPPER                   1,300                           610
121  CYANIDE                    2OO                            8O
122  LEAD                       280                           130
     ALUMINUM                 6,100                         2,700
     IRON                     1,2OO                           61O
      (i)  Degreasing Spent Solvents

There shall be no discharge of process wastewater pollutants.
9.  EPA is considering promulgating NSPS which are less stringent
than the standards now proposed for NSPS for nine of the eleven
subcategories.   The standards would be based on the treatment
effectiveness achievable by the application of chemical
precipitation and sedimentation (lime and settle) technology and
in-process flow reduction control methods.  In addition, EPA is
considering promulgating NSPS which are more stringent than the
standards now proposed for NSPS for the Lead/Tin/Bismuth Forming and
the Iron and Steel/Copper/Aluminum Metal Powder Production And
                                 245

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Powder Metallurgy Subcategories.  The standards would  be  based  on
the treatment effectiveness achievable by the application of
chemical precipitation and sedimentation with, the addition of
filtration (lime, settle, and filter) technology and in-process
flow reduction control methods.  In the event that the Agency
decides to promulgate these alternate NSPS, the following would
apply for new sources:
SUBPART A.    ALTERNATE NSPS FOR THE BERYLLIUM FORMING SUBCATEGORY

      (a)  Area Cleaning Wastewater
   Pollutant or
Pollutant Property
                   Maximum for
                   Any One Day
                         Maximum for
                       Monthly Average
117
120
121
    mg/kkg (Ib/billion Ibs) of beryllium formed
BERYLLIUM
COPPER
CYANIDE
FLUORIDE
OIL & GREASE
TOTAL SUSPENDED
  SOLIDS
PH
   26,OOO
   40,000
    6,200
1,3OO,000
  43O,OOO
  870,000
 11,OOO
 21,000
  2,600
560,000
260,000
420,000
                    Within the range of 7.5 to 10.O at all times.
        Billet Washing Wastewater
   Pollutant or
Pollutant Property
                   Maximum for
                   Any One Day
                         Maximum for
                       Monthly Average
    mg/kkg (Ib/billion Ibs) of beryllium billets washed
117  BERYLLIUM
120  COPPER
121  CYANIDE
     FLUORIDE
     OIL & GREASE
     TOTAL SUSPENDED
       SOLIDS
     PH
                          47.0
                          73.0
                          11.0
                       2,300.0
                         760.0
                       1,600.0
                                   19.0
                                   38.0
                                    4.6
                                1,000.0
                                  46O.O
                                  740.0
               Within the range of 7.5 to 10.0 at all times.
                                246

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        Surface Treatment Spent Baths
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of beryllium surface treated

117  BERYLLIUM                  380                           160
120  COPPER                     590                           310
121  CYANIDE                     89                            37
     FLUORIDE                18,000                         8,100
     OIL S, GREASE             6,200                         3,700
     TOTAL SUSPENDED         13,000                         6,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
      (d)  Surface Treatment Rinsewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of beryllium surface treated

117  BERYLLIUM                  940                           39O
120  COPPER                   1,500                           770
121  CYANIDE                    220                            92
     FLUORIDE                46,000                        2O,OOO
     OIL fi, GREASE            15,OOO                         9,200
     TOTAL SUSPENDED         31,000                        15,000
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
                             247

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      Ce)  Sawing/Grinding Spent Lubricants
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of beryllium sawed or ground

117  BERYLLIUM                  520                            220
120  COPPER                     810                            42O
121  CYANIDE                    120                            51
     FLUORIDE                25,000                        11,OOO
     OIL S, GREASE             8,500                         5,100
     TOTAL SUSPENDED         17,OOO                         8,3OO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
      (f)  Inspection/Testing Wastewater

There shall be no discharge of process waatewater pollutants.


      
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      (b)  Rolling Spent Soap Solutions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
  mg/kkg (Ib/billion Ibs) of lead/tin/bismuth rolled with soap
     solutions

114  ANTIMONY                  83.0                          37.0
122  LEAD                      12.0                           5.6
     OIL & GREASE             430.0                         430.0
     TOTAL SUSPENDED          650.0                         520.O
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
      (c)  Drawing Spent Neat Oils

There shall be no discharge of process wastewater pollutants.


      (d)  Drawing Spent Emulsions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of lead/tin/bismuth drawn with
       emulsions

114  ANTIMONY                  32.0                          14.0
122  LEAD                       4.7                           2.2
     OIL & GREASE             170.0                         170.O
     TOTAL SUSPENDED          25O.O                         2OO.O
       SOLIDS
     pH             Within the range of 7.5 to 10.O at all times.
                               249

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      (e)  Drawing Spent. Soap Solutions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
   mg/kkg (Ib/billion Ibs) of lead/tin/bismuth drawn with soap
      solutions

114  ANTIMONY                  14.0                           6.4
122  LEAD                       2.1                           l.O
     OIL S, GREASE              75.0                          75.0
     TOTAL SUSPENDED          110.0                          90.0
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at. all times.
        Extrusion Press Hydraulic Fluid Leakage
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of lead/tin/bismuth extruded

114  ANTIMONY                  95.0                          42.0
122  LEAD                      14.0                           6.4
     OIL & GREASE             490.0                         490.0
     TOTAL SUSPENDED          740.0                         590.0
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at. all times.
                                 250

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      Ch>  Continuoua Strip Casting Contact Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of lead/tin/bismuth caat by the
       continuoua atrip method

114  ANTIMONY                  1.9O                            .90
122  LEAD                       .30                            .10
     OIL £< GREASE             1O.OO                          1O.OO
     TOTAL SUSPENDED          15.00                          12.00
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.


      ti)  Semi-Continuoua Ingot Casting Contact Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of lead/tin/bismuth cast by the
       continuoua strip method

114  ANTIMONY                  5.7O                          2.5O
122  LEAD                       .80                            .40
     OIL 6. GREASE             29. OO                         29.OO
     TOTAL SUSPENDED          44.00                         35.00
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.


      (3y  Shot Casting Contact Cooling Water


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


    mg/kkg (Ib/billion Ibs) of lead/tin/bismuth shot cast

114  ANTIMONY                  8.1O                          3.oO
122  LEAD                      1.20                            .'SO
     OIL fi, GREASE             42.00                         42.»'0
     TOTAL SUSPENDED          63.OO                         50.CO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times,
                                251

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      (k)  Shot-Forming Wet APC Slowdown
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of lead/tin/bismuth shot formed

114  ANTIMONY                   .00                           .00
122  LEAD                       .00                           .OO
     OIL & GREASE               .10                           .10
     TOTAL SUSPENDED            .10                           .1O
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.


      <1)  Alkaline Cleaning Spent Baths
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of lead/tin/bismuth alkaline cleaned

114  ANTIMONY                 1,200                           520
122  LEAD                       17O                            79
     OIL & GREASE             6,10O                         6,100
     TOTAL SUSPENDED          9,100                         7,3OO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
      (m)  Alkaline Cleaning Rinsewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg 
-------
      tn>  Swaging Spent Emulaiona
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg 
-------
       (c)  Forging Wet APC Slowdown
   Pollutant or
Pollutant Property
    Maximum for
    Any One Day
  Maximum for
Monthly Average
    mg/kkg (ib/billion Ibs) of magnesium forged
119  CHROMIUM
128  ZINC
     AMMONIA
     FLUORIDE
     MAGNESIUM
     OIL & GREASE
     TOTAL SUSPENDED
       SOLIDS
     pH
        120,000
        39O,OOO
     35,000,000
     16,000,000
        550,000
      5,300,000
     11,000,000
          48,OOO
         160,000
      16,OOO,OOO
       7,000,000
         240,000
       3,200,000
       5,2OO,OOO
Within the range of 7.5 to 10.0 at all times.
      
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           Forging Equipment Cleaning Waatewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of magnesium forged

119  CHROMIUM                    71                            29
128  ZINC                       240                            99
     AMMONIA                 22,OOO                         9,500
     FLUORIDE                 9,600                         4,3OO
     MAGNESIUM                  33O                           150
     OIL S. GREASE             3,2OO                         1,9OO
     TOTAL SUSPENDED          6,600                         3,200
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
      (f)  Direct Chill Casting Contact Cooling Water

There shall be no discharge of process wastewater pollutants.


      (g)  Surface Treatment Spent Baths
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of magnesium surface treated

119  CHROMIUM                   2OO                            84
128  ZINC                       680                           280
     AMMONIA                 62,000                        27,OOO
     FLUORIDE                28,000                        12,OOO
     MAGNESIUM                  95O                           42O
     OIL S, GREASE             9,3OO                         5,600
     TOTAL SUSPENDED         19,000                         9,100
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
                            255

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      (h)  Surface Treatment Rinsewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average

119
128







mg/kkg (Ib/billion Iba:
CHROMIUM
ZINC
AMMONIA
FLUORIDE
MAGNESIUM
OIL 6, GREASE
TOTAL SUSPENDED
SOLIDS
pH Within
» of magnesium aurfac
780
2,600
240,000
110,000
3,600
35,000
73,000

the range of 7.5 to
:e treated
320
1,100
100,000
47,OOO
1,60O
21,000
35,000

10.0 at all times.
      (i)  Sawing/Grinding Spent Lubricants

There shall be no discharge of process wastewater pollutants,


      (3)"  Sanding And Repairing Wet APC Slowdown
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Iba) of magnesium sanded and repaired

119  CHROMIUM                   19O                            77
128  ZINC                       620                           260
     AMMONIA                 57,000                        25,OOO
     FLUORIDE                25,000                        11,OOO
     MAGNESIUM                  88O                           39O
     OIL 6. GREASE             8,600                         5,10O
     TOTAL SUSPENDED         18,000                         8,3OO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.


        Degreaaing Spent Solvents

There ahsll be no discharge of process waatewater pollutants.
                           256

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SUBPART D.    ALTERNATE NSPS FOR THE NICKEL/COBALT FORMING
              SUBCATEGORY

      (a)  Rolling Spent Neat Oils

There shall be no discharge of proceaa waatewater pollutanta.


        Rolling Spent Emulsions


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


    mg/kkg (Ib/billion Ibs) of nickel/cobalt rolled with emulsions

119  CHROMIUM                   660                           270
124  NICKEL                   2,900                         1,900
     FLUORIDE                89,000                        39,OOO
     OIL & GREASE            3O,OOO                        1S,OOO
     TOTAL SUSPENDED         61,000                        29,000
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.


      (c>  Rolling Contact Lubricant-Coolant Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of nickel/cobalt rolled with contact
       lubricant-coolant water

119  CHROMIUM                   59O                           24O
124  NICKEL                   2,6OO                         1,7OO
     FLUORIDE                80,OOO                        35,OOO
     OIL & GREASE            27,OOO                        16,OOO
     TOTAL SUSPENDED         55,OOO  '                      26,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.O at all timea.
                           257

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      (d)  Rolling Solution Heat Treatment Contact Cooling Water


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


  mg/kkg (Ib/billion lba> of rolled nickel/cobalt heat treated

119  CHROMIUM                   .00                           .00
124  NICKEL                     .10                           .OO
     FLUORIDE                  1.60                           .70
     OIL & GREASE               .50                           .30
     TOTAL SUSPENDED           1.10                           .50
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.


      (e)  Tube Reducing Spent Lubricants

There shall be no discharge of process wastewater pollutants.


      (f),  Drawing Spent Neat Oils

There shall be no discharge of proceaa waatewater pollutants.


      Cg)  Drawing Spent Emulsions


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


    mg/kkg (Ib/billion Ibs) of nickel/cobalt drawn with emulsions

119  CHROMIUM                    42                            17
124  NICKEL                     180                           12O
     FLUORIDE                 5,700                         2,5OO
     OIL & GREASE             1,900                         1,10O
     TOTAL SUSPENDED          3,900                         1,900
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
                        258

-------
      (h)  Extrusion Spent Lubricants

There shall be no discharge of process wastewater pollutants.
      
-------
        Forging Equipment Cleaning Wastewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg   Forging/Swaging Spent Neat Oils

There shall be no discharge of process wastewater pollutants.
                               260

-------
      (n)  Stationary And Direct Chill Casting Contact Cooling
             Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg   Casting Vacuum Melting Steam Condensate
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of nickel/cobalt vacuum melted

119  CHROMIUM                    74                            3O
124  NICKEL                     320                           21O
     FLUORIDE                10,000                         4,400
     OIL S. GREASE             3,4OO                         2,OOO
     TOTAL SUSPENDED          6,900                         3,3OO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
                           261

-------
      

Metal Powder Production Atomization Wastewater Pollutant or Maximum for Maximum for Pollutant Property Any One Day Monthly Average mg/kkg Clb/billion lba> of nickel/cobalt metal powder atomized 119 CHROMIUM 1,200 510 124 NICKEL 5,50O 3,6OO FLUORIDE 170,000 75,000 OIL & GREASE 57,000 34,000 TOTAL SUSPENDED 120,000 55,000 SOLIDS pH Within the range of 7.5 to 10.0 at all times. Wet APC Slowdown Pollutant or Maximum for Maximum for Pollutant Property Any One Day Monthly Average mg/kkg (Ib/billion Iba) of nickel/cobalt formed 119 CHROMIUM 110 45 124 NICKEL 480 320 FLUORIDE 15,OOO 6,600 OIL & GREASE 5,000 3,000 TOTAL SUSPENDED 10,OOO 4,9OO SOLIDS pH Within the range of 7.5 to 10.0 at all times. 262


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           Surface Treatment Spent Batha
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of nickel/cobalt surface treated

119  CHROMIUM                   380                           150
124  NICKEL                   1,700                         1,100
     FLUORIDE                51,000                        23,000
     OIL & GREASE            17,OOO                        10,000
     TOTAL SUSPENDED         35,000                        17,000
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
      (t)  Surface Treatment Rinsewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of nickel/cobalt surface treated
119
124





CHROMIUM
NICKEL
FLUORIDE
OIL & GREASE
TOTAL SUSPENDED
SOLIDS
pH Within
470
2,000
63,000
21,000
43,000

the range of 7.5
190
1,300
28,000
13,OOO
21,000

to 10.0 at all times.
      (u)  Alkaline Cleaning Spent Baths
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of nickel/cobalt alkaline cleaned

119  CHROMIUM                  13.0                           5.5
124  NICKEL                    59.O                          39.O
     FLUORIDE               1,8OO.O                         810.0
     OIL & GREASE             61O.O                         370.O
     TOTAL SUSPENDED        1,3OO.O                         600.0
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
                           263

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        Alkaline Cleaning Rinsewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of nickel/cobalt alkaline cleaned

119  CHROMIUM                   220                            89
124  NICKEL                     950                           63O
     FLUORIDE                30,OOO                        13,000
     OIL 6. GREASE             9,9OO                         6,OOO
     TOTAL SUSPENDED         20,000                         9,700
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
      (w)  Molten Salt Rinaewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg 
-------
      Cy>  Sawingyurinding Spent Lubricants
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Iba) of nickel/cobalt sawed or ground

119  CHROMIUM                   440                           ISO
124  NICKEL                   1,900                         1,3OO
     FLUORIDE                60,000                        26,000
     OIL & GREASE            20,000                        12,000
     TOTAL SUSPENDED         41,OOO                        20,000
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.


        Steam Cleaning Condensate
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of nickel/cobalt steam cleaned

119  CHROMIUM                  10.0                           4.2
124  NICKEL                    45.0                          29.0
     FLUORIDE               1,4OO.O                         610.0
     OIL £< GREASE             460.0                         2SO.O
     TOTAL SUSPENDED          95O.O                         45O.O
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.


      (aa>  Hydrostatic Tube Testing Wastewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of nickel/cobalt tube tested by the
       hydrostatic method

119  CHROMIUM                    59                            24
124  NICKEL                     260                           170
     FLUORIDE                 8,000                         3,60O
     OIL & GREASE             2,700                         1,6OO
     TOTAL SUSPENDED          5,5OO                         2,600
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
                              265

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      (ab)  Degreasing Spent Solvents

There shall be no discharge of process wastewater pollutants.


      (ac)  Miscellaneous Nondescript Wastewater Sourcees
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly  Average


    mg/kkg (Ib/billion Ibs) of nickel/cobalt formed

119  CHROMIUM                    26                             11
124  NICKEL                     110                             74
     FLUORIDE                 3,500                          1,5OO
     OIL & GREASE             1,2OO                           700
     TOTAL SUSPENDED          2,400                          1,1OO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
SUBPART E.    ALTERNATE N5PS FOR THE PRECIOUS METALS FORMING
              SUBCATEGORY

      (a)  Rolling Spent Emulsions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


  mg/kkg (Ib/billion Ibs) of precious metals rolled with emulsions

118  CADMIUM                   12.0                           5.4
120  COPPER                    68.0                          36.0
121  CYANIDE                   10.0                           4.3
126  SILVER                    15.0                           6.1
     OIL fi, GREASE             720.0                         430.0
     TOTAL SUSPENDED        1,500.0                         700.0
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
                           266

-------
      (b)  Rolling Solution Heat Treatment Contact Cooling Water


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


   mg/kkg  of rolled precious metals heat treated

118  CADMIUM                    240                           110
120  COPPER                   1,300                           700
121  CYANIDE                    200                            84
126  SILVER                     290                           120
     OIL & GREASE            14,000                         8,400
     TOTAL SUSPENDED         29,000                        14,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.


      (c>  Drawing Spent Neat Oils

There shall be no discharge of process wastewater pollutants.


      (d)  Drawing Spent Emulsions


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


  mg/kkg Clb/billion Iba) of precious metals drawn with emulsions

118  CADMIUM                    7.2                           3.2
120  COPPER                    40.0                          21.0
121  CYANIDE                    6.2                           2.6
126  SILVER                     8.7                           3.6
     OIL & GREASE             430.0                         26O.O
     TOTAL SUSPENDED          870.O                         420.O
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
                               267

-------
      (e)  Drawing Spent Soap Solutions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
   mg/kkg (Ib/billion Iba) of precious metals drawn with soap
      solutions

118  CADMIUM                   2.40                          1.00
120  COPPER                   13.OO                          6.9O
121  CYANIDE                   2.00                           .80
126  SILVER                    2.SO                          1.2O
     OIL & GREASE            140.00                         83.OO
     TOTAL SUSPENDED         28O.OO                        140.OO
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all times.
      (f)  Extrusion Press And Solution Heat Treatment Contact
             Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


  mg/kkg (Ib/billion Ibs) of extruded precious metals heat treated

118  CADMIUM                    47O                           21O
12O  COPPER                   2,600                         1,4OO
121  CYANIDE                    400                           16O
126  SILVER                     56O                           23O
     OIL & GREASE            27,OOO                        16,OOO
     TOTAL SUSPENDED         56,OOO                        27,OOO
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all times.
                          268

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      <:g>  Se-mi-Continuous And Continuous Casting Contact Cooling
              Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of precious metals cast by the
       semi-continuous or continuous method

US  CADMIUM                    380                           170
120  COPPER                   2,100                         1,10O
121  CYANIDE                    320                           130
126  SILVER                     460                           190
     OIL & GREASE            22,000                        13,OOO
     TOTAL SUSPENDED        '46,000                        22,000
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
      (h)  Stationary Casting Contact Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of precious metals cast by the
       stationary method

118  CADMIUM                   1.40                            .60
120  COPPER                    7.90                          4. 2O
121  CYANIDE                   1.20                            .50
126  SILVER                    1.70                            .70
     OIL & GREASE             83.00                         50.00
     TOTAL SUSPENDED         170.00                         81.OO
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all times.

-------
        Direct Chill Casting Contact Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billlon Iba) of precious metals cast by the direct
       chill method

118  CADMIUM                    280                           120
120  COPPER                   1,600                           82O
121  CYANIDE                    240                            98
126  SILVER                     340                           140
     OIL & GREASE            16,OOO                         9,8OO
     TOTAL SUSPENDED         34,OOO                        16,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
                            270

-------
        Shot Casting Contact Cooling Water
   Pollutant or
Pollutant Property
    Maximum for
    Any One Day
                      Maximum for
                    Monthly Average
    mg/kkg (Ib/billion Iba) of precious metals shot cast
lid  CADMIUM
120  COPPER
121  CYANIDE
126  SILVER
     OIL & GREASE
     TOTAL SUSPENDED
       SOLIDS
     pH
             30
            170
             26
             37
          1,800
          3,700
                                  13
                                  89
                                  11
                                  15
                               1,100
                               1,700
Within the range of 7.5 to 10.0 at all times.
        Casting Wet APC Slowdown
   Pollutant or
Pollutant Property
    Maximum for
    Any One Day
                      Maximum for
                    Monthly Average
   mg/kkg (Ib/billion lbs> of precious metals cast
118  CADMIUM
120  COPPER
121  CYANIDE
126  SILVER
     OIL & GREASE
     TOTAL SUSPENDED
       SOLIDS
     pH
            .00
            .00
            .70
  2.
 11,
  1,
  2.40
120.00
240.00
   .90
  5.90
   .70
  1.00
 70.00
110.OO
Within the range of 7.5 to 10.0 at all times.
                            271

-------
      (!)  Metal Powder Production Atomization Wastewater
   Pollutant or
Pollutant Property
    Maximum for
    Any One Day
  Maximum for
Monthly Average
   mg/kkg (Ib/billion Ibs) of precious metals powder wet atomized
118  CADMIUM
120  COPPER
121  CYANIDE
126  SILVER
     OIL & GREASE
     TOTAL SUSPENDED
       SOLIDS
     pH
          2,300
         13,000
          1,900
          2,700
        130,000
        270,000
           1,000
           6,700
             SOO
           1,10O
          80,OOO
         130,OOO
Within the range of 7.5 to 10.0 at all times.
      (m)  Metal Powder Production Ball Milling Wastewater
   Pollutant or
Pollutant Property
    Maximum for
    Any One Day
  Maximum for
Monthly Average
    mg/kkg (Ib/billion Iba) of precious metals powder wet ball
       milled
US  CADMIUM
120  COPPER
121  CYANIDE
126  SILVER
     OIL 6, GREASE
     TOTAL SUSPENDED
       SOLIDS
     PH
            740
          4,1OO
            630
            890
         43,OOO
         89,OOO
             330
           2,2OO
             260
             37O
          26,OOO
          42,OOO
Within the range of 7.5 to 10.O at all times.
                           272

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      Cn>  Preaaure Bonding Contact Cooling Water
   Pollutant or
Pollutant Property
    Maximum for
    Any One Day
  Maximum for
Monthly Average
    mg/kkg (Ib/billion Ibs) of precious metal and base metal
       pressure bonded
118  CADMIUM
120  COPPER
121  CYANIDE
126  SILVER
     OIL & GREASE
     TOTAL SUSPENDED
       SOLIDS
             28
            160
             24
             34
          1,700
          3,400
              13
              84
              10
              14
           1,000
           1,600
                    Within the range of 7.5 to 10.0 at all times.
      f.o>  Annealing Solution Heat Treatment Contact Cooling
             Water
   Pollutant or
Pollutant Property
    Maximum for
    Any One Day
  Maximum for
Monthly Average
    mg/kkg (Ib/billion Ibs) of precious metals annealed
118  CADMIUM
120  COPPER
121  CYANIDE
126  SILVER
     OIL £< GREASE
     TOTAL SUSPENDED
       SOLIDS
     pH
            34O
          1,900
            290
            41O
         20,000
         41,000
             150
           1,000
             12O
             170
          12,000
          20,000
Within the range of 7.5 to 1O.O at all times.
                                 273

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        Surface Treatment Rinsewater
   Pollutant or  ,       Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of precious metals surface treated

118  CADMIUM                    970                           430
120  COPPER                   5,400                         2,8OO
121  CYANIDE                    820                           340
126  SILVER                   1,20O                           480
     OIL & GREASE            57,OOO                        34,OOO
     TOTAL SUSPENDED        120,000                        55,OOO
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all times.
                           274

-------
      (r)  Alkaline Cleaning Spent Baths
   Pollutant or         Maximum for                Maximum  for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of precious metals alkaline cleaned

IIS  CADMIUM                   1.20                            .60
120  COPPER                    7.00                           3.70
121  CYANIDE                   1.10                            .40
126  SILVER                    1.50                            .60
     OIL £, GREASE             73.00                          44.00
     TOTAL SUSPENDED         150.OO                          72.OO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all  times.


      (a)  Alkaline Cleaning Rinsewater
   Pollutant or         Maximum for                Maximum  for
Pollutant Property      Any One Day              Monthly Average

118
120
121
126



mg/kkg (Ib/billion 11
CADMIUM
COPPER
CYANIDE
SILVER
OIL £. GREASE
TOTAL SUSPENDED
SOLIDS
33) of precious metals
240
1,300
200
280
1 4,OOO
2S,OOO

alkaline cleaned
100
69O
83
120
8,30O
13,OOO

     pH             Within the range of 7.5 to  10.0 at all  times.
                           275

-------
      f.t>  Pre-Bonding Cleaning Waatewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of precious metal and base metal
       cleaned prior to bonding

118  CADMIUM                    120                            51
120  COPPER                     650                           34O
121  CYANIDE                     99                            41
126  SILVER                     140                            58
     OIL & GREASE             6,800                         4,1OO
     TOTAL SUSPENDED         14,000                         6,600
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
      (u)  Tumbling Waatewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Iba) of precious metala tumbled

118  CADMIUM                    150                            66
120  COPPER                     840                           440
121  CYANIDE                    130                            53
126  SILVER                     180                            75
     OIL & GREASE             8,8OO                         5,300
     TOTAL SUSPENDED         18,000                         8,600
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at. all times.
                            276

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        Rolling Spent Neat Oils

There shall be no discharge of process wastewater pollutants.
                            277

-------
      (b)  Rolling Spent Emulsions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of refractory metals rolled with
       emulsions

120  COPPER                   2,300                         1,2OO
124  NICKEL                   2,300                         1,5OO
     COLUMBIUM                2,500                         1,100
     FLUORIDE                71,000                        32,OOO
     MOLYBDENUM               2,500                         1,100
     TANTALUM                 2,5OO                         1,1OO
     TUNGSTEN                 2,500                         1,100
     VANADIUM                 2,50O                         1,1OO
     OIL & GREASE            24,000                        14,000
     TOTAL SUSPENDED         49,OOO                        23,OOO
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all times.


      (c)  Drawing Spent Lubricants

There shall be no discharge of process wastewater pollutants.
      (d)  Extrusion Press And Solution Heat Treatment Contact
             Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg clb/billion Iba) of extruded refractory metala heat
       treated

120  COPPER                     660                           35O
124  NICKEL                     660                           44O
     COLUMBIUM                  710                           31O
     FLUORIDE                21,000                         9,1OO
     MOLYBDENUM                 710                           31O
     TANTALUM                   71O                           31O
     TUNGSTEN                   71O                           310
     VANADIUM                   710                           31O
     OIL & GREASE             6,900                         4,200
     TOTAL SUSPENDED         14,000                         6,7OO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
                       278

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      (e)  Extrusion Preaa Hydraulic Fluid Leakage
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average

120
124










mg/kkg (Ib/billion Ibs)
COPPER
NICKEL
COLUMBIUM
FLUORIDE
MOLYBDENUM
TANTALUM
TUNGSTEN
VANADIUM
OIL & GREASE
TOTAL SUSPENDED
SOLIDS
pH Within
of refractory metals extruded
2,3OO
2,3OO
2,400
71,000
2,400
2,400
2,400
2,400
24,000
49,000

the range of 7.5 to 10.0 at all

1,200
1,500
1,100
31,OOO
1,100
1,1OO
1,100
1,100
14,000
23,OOO

times .
      (f>  Forging Spent Lubricants

There shall be no discharge of process wastewater pollutants.


      
-------
        Extrusion And Forging Equipment Cleaning Wastewater
   Pollutant or
Pollutant Property
Maximum for
Any One Day
  Maximum for
Monthly Average
  mg/kkg (Ib/billion Iba) of refractory metals extruded or forged
120
124










COPPER
NICKEL
COLUMBIUM
FLUORIDE
MOLYBDENUM
TANTALUM
TUNGSTEN
VANADIUM
OIL & GREASE
TOTAL SUSPENDED
SOLIDS
pH Within
79
SO
85
2,50O
85
85
85
85
830
1,700

the range of 7.5 to 1O.O at all
42
53
38
1,100
38
38
38
38
500
810

times .
        Metal Powder Production Wastewater
   Pollutant or
Pollutant Property
Maximum for
Any One Day
  Maximum for
Monthly Average

120
124










mg/kkg (Ib/billion Ibs)
COPPER
NICKEL
COLUMBIUM
FLUORIDE
MOLYBDENUM
TANTALUM
TUNGSTEN
VANADIUM
OIL & GREASE
TOTAL SUSPENDED
SOLIDS
pH Within
of refractory
3,100
3,1OO
3,400
98,OOO
3,40O
3,400
3,4OO
3,400
33,OOO
67,000

the range of 7
metals powder produced
1,600
2,1OO
1,500
43,OOO
1,5OO
1,500
1,500
1,5OO
20 , 000
32,000

.5 to 10.0 at all times.
      (3)  Metal Powder Production Wet APC Blowdown

There shall be no discharge of process wastewater pollutants,
                          280

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      (k)  Metal Powder Pressing Spent Lubricants

There ahall be no discharge of process wastewater pollutants
	

      (1)  Casting Contact Cooling Water

There shall be no discharge of process wastewater pollutants.


      Cm)  Post-Casting Billet Washwater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
  mg/kkg  of cast refractory metals billet washed
120
124










COPPER
NICKEL
COLUMBIUM
FLUORIDE
MOLYBDENUM
TANTALUM
TUNGSTEN
VANADIUM
OIL & GREASE
TOTAL SUSPENDED
SOLIDS
pH Within
57
57
61
1,800
61
61
61
61
6OO
1,200

the range of 7.5 to 10.0 at all
30
38
27
790
27
27
27
27
36O
580

times .
        Surface Treatment Spent Baths
   Pollutant or         Maximum for                Maximum ±~or
Pollutant Property      Any One Day              Monthly Average


    mg/kkg clb/bllllon Iba) of refractory metals surface treated

120  COPPER                      24                            13
124  NICKEL                      24                            16
     COLUMBIUM                   26  ,                          12
     FLUORIDE                   76O                           34O
     MOLYBDENUM                  26                            12
     TANTALUM                    26                            12
     TUNGSTEN                    26                            12
     VANADIUM                    26                            12
     OIL & GREASE               250                           150
     TOTAL SUSPENDED            520                           25O
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
                          281

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-------
        Surface Coating Wet APC Slowdown
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of refractory metals surface coated

120  COPPER                   2,100                         1,100
124  NICKEL                   2,100                         1,40O
     COLUMBIUM                2,200                           980
     FLUORIDE                64,000                        29,OOO
     MOLYBDENUM               2,200                           980
     TANTALUM                 2,200                           980
     TUNGSTEN                 2,200                           98O
     VANADIUM                 2,200                           980
     OIL & GREASE            22,000                        13,000
     TOTAL SUSPENDED         44,000                        21,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.


      
-------
      (s)  Alkaline Cleaning Rinsewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of refractory metals alkaline cleaned

120  COPPER                   2,700                          1,400
124  NICKEL                   2,700                          1,8OO
     COLUMBIUM                2,9OO                          1,3OO
     FLUORIDE                83,000                        37,OOO
     MOLYBDENUM               2,90O                          1,30O
     TANTALUM                 2,SOO                          1,3OO
     TUNGSTEN                 2,900                          1,300
     VANADIUM                 2,900                          1,3OO
     OIL & GREASE            28,OOO                        17,000
     TOTAL SUSPENDED         57,000                        27,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.O at all times.


      (t)  Molten Salt Cleaning Rinsewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


  mg/kkg (Ib/billion Iba) of refractory metals cleaned with molten
     salt

120  COPPER                 170,000                        9O,OOO
124  NICKEL                 170,000                       11O,OOO
     COLUMBIUM              180,000                        82,OOO
     FLUORIDE             5,400,000                     2,4OO,OOO
     MOLYBDENUM             18O,OOO                        82,OOO
     TANTALUM               180,000                        82,OOO
     TUNGSTEN               180,OOO                        82,OOO
     VANADIUM               180,OOO                        82,OOO
     OIL & GREASE         1,800,000                     1,100,000
     TOTAL SUSPENDED      3,700,OOO                     1,8OO,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
                           284

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        Tumbling/Burnishing Waatewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Iba) of refractory metals tumbled or
       burnished

12O  COPPER                   4,200                         2,200
124  NICKEL                   4,200                         2,8OO
     COLUMBIUM                4,500                         2,000
     FLUORIDE               130,000                        58,OOO
     MOLYBDENUM               4,500                         2,000
     TANTALUM                 4,500                         2,OOO
     TUNGSTEN                 4,50O                         2,OOO
     VANADIUM                 4,5OO                         2,OOO
     OIL & GREASE            44,000                        27,000
     TOTAL SUSPENDED         91,OOO                        43,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all timea.


      (v)  Sawing/Grinding Spent Neat Oils

There shall be no discharge of process wastewater pollutants.
      (w)  Sawing/Grinding Spent Emulsions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of refractory metals sawed or ground
       with emulsions

120  COPPER                     41O                           22O
124  NICKEL                     420                           28O
     COLUMBIUM                  44O                           2OO
     FLUORIDE                13,000                         5,7OO
     MOLYBDENUM                 44O                           2OO
     TANTALUM                   44O                           2OO
     TUNGSTEN                   44O                           200
     VANADIUM                   44O                           20O
     OIL & GREASE             4,3OO                         2,600
     TOTAL SUSPENDED          8,90O                         4,2OO
       SOLIDS
     pH             Within the range of 7.5 to 10.O at all timea.
                          285

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      (x)  Sawing/Grinding Contact Lubricant-Coolant Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of refractory metala sawed or ground
       with lubricant-coolant water

120  COPPER                   1,5OO                           S1O
124  NICKEL                   1,600                         1,OOO
     COLUMBIUM                1,700                           740
     FLUORIDE                48,000                        21,000
     MOLYBDENUM               1,700                           74O
     TANTALUM                 1,700                           740
     TUNGSTEN                 1,70O                           74O
     VANADIUM                 1,700                           740
     OIL & GREASE            16,OOO                         9,7OO
     TOTAL SUSPENDED         33,000                        16,000
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all times.


      ?y>  Sawing/Grinding Wet APC Slowdown
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg 
-------
      (z>  Post Sawing/Grinding Rinsewater
   Pollutant or
Pollutant Property
    Maximum for
    Any One Day
                 Maximum for
               Monthly Average
    mg/kkg (Ib/billion Ibs) of sawed  or  ground  refractory  metals
       rinsed
120  COPPER
124  NICKEL
     COLUMBIUM
     FLUORIDE
     MOLYBDENUM
     TANTALUM
     TUNGSTEN
     VANADIUM
     OIL & GREASE
     TOTAL SUSPENDED
       SOLIDS
     pH
             97
             98
            110
          3,10O
            110
            110
            110
            110
          1,000
          2,100
                             51
                             65
                             47
                          1,4OO
                             47
                             47
                             47
                             47
                            620
                          1,000
Within the range of 7.5 to 10.0 at all  times.
      (aa)  Product Testing Wastewater
   Pollutant or
Pollutant Property
    Maximum for
    Any One Day
                 Maximum for
               Monthly Average
    mg/kkg (Ib/billion Ibs) of refractory  metals  product  tested
120  COPPER
124  NICKEL
     COLUMBIUM
     FLUORIDE
     MOLYBDENUM
     TANTALUM
     TUNGSTEN
     VANADIUM
     OIL & GREASE
     TOTAL SUSPENDED
       SOLIDS
     PH
           15.0
           15
           16,
          460.
           16.
           16,
           16,
           16,
          160,
          320,
O
0
0
0
O
0
O
0
O
  7.8
 1O.O
  7.1
200.0
  7.1
  7.
  7,
  7.
 93.0
15O.O
1
,1
1
Within the range of 7.5 to 1O.O at all times.
      (ab)  Degreasing Spent Solvents

There shall be no discharge of proceaa waatewater  pollutants.
                       287

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SUBPART G.    ALTERNATE NSPS FOR THE TITANIUM FORMING 3UBCATEGQRY

      (a)  Cold Rolling Spent Lubricants


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


    mg/kkg  of titanium hot rolled with contact
       lubricant-coolant water

121  CYANIDE                    120                            52
122  LEAD                       180                            86
128  ZINC                       63O                           26O
     AMMONIA                 57,000                        25,OOO
     FLUORIDE                26,000                        11,OOO
     TITANIUM                   880                           39O
     OIL & GREASE             8,6OO                         5,2OO
     TOTAL SUSPENDED         18,000                         8,4OO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
                           288

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        Extrusion Spent Lubricants
   Pollutant or         Maximum for '               Maximum for
Pollutant Property      Any One Day              Monthly Average

121
122
128







mg/kkg (Ib/billion Ibs!
CYANIDE
LEAD
ZINC
AMMONIA
FLUORIDE
TITANIUM
OIL & GREASE
TOTAL SUSPENDED
SOLIDS
pH Within
) of titanium extruded
79
120
400
37,000
16,000
560
5,500
11,OOO

the range of 7.5 to 10. O at all

33
55
170
16,OOO
7,200
250
3,300
5,3OO

times .
      (d)  Forging Spent Lubricants

There shall be no discharge of process wastewater pollutants.


      
-------
      
-------
       (h>  Surface Treatment  Spent  Baths
   Pollutant or         Maximum  for                 Maximum for
Pollutant Property      Any  One  Day               Monthly Average
    mg/kkg  (Ib/billion  Ibs) of  titanium  surface treated

121  CYANIDE                      46                             19
122  LEAD                         67                             32
128  ZINC                        230                             98
     AMMONIA                 21,000                          9,400
     FLUORIDE                 9,500                          4,200
     TITANIUM                    330                            150
     OIL & GREASE             3,2OO                          1,9OO
     TOTAL SUSPENDED          6,60O                          3,10O
       SOLIDS
     pH             Within the  range  of  7.5  to  10.0  at  all  times.
      (i)  Surface Treatment Ririsewater
   Pollutant or         Maximum for                 Maximum  for
Pollutant Property      Any One Day               Monthly  Average


    mg/kkg (Ib/billion Ibs) of titanium surface  treated

121  CYANIDE                    610                            250
122  LEAD                       890                            42O
128  ZINC                     3,100                          1,300
     AMMONIA                280,000                       120,OOO
     FLUORIDE               130,000                         56,OOO
     TITANIUM                 4,300                          1,90O
     OIL 6. GREASE            42,000                         25,OOO
     TOTAL SUSPENDED         87,OOO                         41,OOO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all  times.
                         291

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           Surface Treatment Wet APC Slowdown
   Pollutant or
Pollutant Property
    Maximum for
    Any One Day
  Maximum for
Monthly Average
    mg/kkg (Ib/billion Iba) of titanium surface treated
121  CYANIDE
122  LEAD
128  ZINC
     AMMONIA
     FLUORIDE
     TITANIUM
     OIL 6, GREASE
     TOTAL SUSPENDED
       SOLIDS
     pH
            4.9
            7.1
           25.0
        2,300.0
        1,000.0
           35.0
          340.0
          70O.O
             2.0
             3.4
            10.0
         1,000.O
           450.0
            15.0
           200.0
           330.0
Within the range of V.5 to 10.O at all times.
       of titanium alkaline cleaned
121  CYANIDE
122  LEAD
128  ZINC
     AMMONIA
     FLUORIDE
     TITANIUM
     OIL 6, GREASE
     TOTAL SUSPENDED
       SOLIDS
     PH
            19O
            27O
            930
         85,OOO
         38,OOO
          1,300
         13,000
         26,OOO
              77
             13O
             39O
          37,OOO
          17,000
             58O
           7,7OO
          12,OOO
Within the range of 7.5 to 10.0 at all times.
                              292

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      (1)  Alkaline Cleaning Rinaewater
   Pollutant or         Maximum for                 Maximum  for
Pollutant Property      Any One Day              Monthly  Average
    mg/kkg (Ib/billion Ibs) of titanium alkaline cleaned

121  CYANIDE                     80                             33
122  LEAD                       120                             55
128  ZINC                       400                            170
     AMMONIA                 37,000                         16,OOO
     FLUORIDE                16,OOO                         7,300
     TITANIUM                   570                            25O
     OIL & GREASE             5,500                         3,300
     TOTAL SUSPENDED        . 11,OOO                         5,4OO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all  times.


        Tumbling Waatewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg 
-------
           Sawing/Grinding Spent Lubricants
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of titanium sawed or ground

121  CYANIDE                   14.0                           6.0
122  LEAD                      21.0                          1O.O
128  ZINC                      73.0                          30.0
     AMMONIA                6,600.0                       2,90O.O
     FLUORIDE               3,OOO.O                       1,30O.O
     TITANIUM                 100.0                          45.0
     OIL & GREASE             990.0                         600.0
     TOTAL SUSPENDED        2,OOO.O                         97O.O
       SOLIDS
     pH             Within the range of 7.5 to 10.O at all times.


        Extrusion Spent Lubricants

There shall be no discharge of process wastewater pollutants.


      (b)  Extrusion Tool Contact Cooling Water-
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg 
     URANIUM                  110.0                          47.0
     OIL 6, GREASE           1,000.0                         620.0
     TOTAL SUSPENDED        2,100.0                       1,OOO.O
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all times.

     (1) Concentration Value Is 5 Picocuries Per Liter
                                   294

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        Extrusion Press And Solution Heat Treatment Contact
             Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Iba) of extruded uranium heat treated

118  CADMIUM                     92                            41
120  COPPER                     520                           270
124  NICKEL                     52O                           35O
     FLUORIDE                16,000                         7,200
     RADIUM                     (1)                           <1>
     URANIUM                    56O                           250
     OIL & GREASE             5,40O                         3,3OO
     TOTAL SUSPENDED         11,000                         5,300
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.

     (1) Concentration Value Is 5 Picocuries Per Liter

        Forging Spent Lubricants

There shall be no discharge of process wastewater pollutants.


        Forging Solution Heat Treatment Contact Cooling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of forged uranium heat treated
118
120
124







CADMIUM
COPPER
NICKEL
FLUORIDE
RADIUM
URANIUM
OIL & GREASE
TOTAL SUSPENDED
SOLIDS
pH Within
97
54O
550
17,000
(!)
580
5,700
12,OOO

the range of 7.5 to
43
28O
360
7,5OO
(1)
26O
3,4OO
5,5OO

10.0 at all times.
     <1> Concentration Value Is 5 Picocuries Per Liter
                            295

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      (-f j  Surface Treatment Spent Bat ha
   Pollutant or         Maximum £or                Maximum  for
Pollutant Property      Any One Day              Monthly  Average

US
120
124







mg/kkg (Ib/billion Iba:
CADMIUM
COPPER
NICKEL
FLUORIDE
RADIUM
URANIUM
OIL & GREASE
TOTAL SUSPENDED
SOLIDS
pH Within
> of uranium surface treated
12.0
68.0
6S.O
2,100.0
(1)
73.0
710.0
1,500.0

the range of 7.5 to 10.0 at all

5.3
36.0
45.0
940.0
(1)
32. O
430.0
690.0

times .
     (I) Concentration Value Is 5 Picocuries Per Liter

      (g)  Surface Treatment Rinaewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Iba) of uranium surface treated

118  CADMIUM                     50                            22
12O  COPPER                     28O                           150
124  NICKEL                     2SO                           19O
     FLUORIDE                 8,800                         3,9OO
     RADIUM                     (1)                           (1)
     URANIUM                    300                           13O
     OIL & GREASE             3,OOO                         1,8OO
     TOTAL SUSPENDED          6,100                         2,9OO
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at. all times.

     (1) Concentration Value la 5 Picocuriea Per Liter
                                  296

-------
      (h)  Surface Treatment Wet  APC  Slowdown
   Pollutant or         Maximum  for                 Maximum for
Pollutant Property      Any One  Day               Monthly Average
    mg/kkg (Ib/billion Iba) of uranium surface  treated

118  CADMIUM                     25                             11
120  COPPER                     140                             74
124  NICKEL                     140                             94
     FLUORIDE                 4,400                          2,000
     RADIUM                     (1)                            (1)
     URANIUM                    150                             68
     OIL £. GREASE             1, 5OO                            890
     TOTAL SUSPENDED          3,000                          1,4OO
       SOLIDS
     pH             Within the range of 7.5 to  10.0 at all  times.
— — — — — — — •^ •^ — — — — — — — — — — — — — •— — •— — — — — — — — — — — — M —_ — ~ — •— — — —> — — — — — — — —V — -_> « _ ^ — » _ — ^ . _ «.
     (1) Concentration Value Is 5 Picocuries Per Liter
                                  297

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      (i)  Sawing/Grinding Spent Emulsions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion lbs> of uranium sawed or ground
118
120
124







CADMIUM
COPPER
NICKEL
RADIUM
FLUORIDE
URANIUM
OIL & GREASE
TOTAL SUSPENDED
SOLIDS
pH Within
1.10
5.90
6.00
(!)
180.00
6.40
62. OO
130.00

the range of 7.5 to
.50
3.10
3.9O
(1)
82. OO
2. SO
37.OO
60.00

10.0 at all times.
      <1> Concentration Value Is 5 Picocuries Per Liter

      (3)  Post-Sawing/Grinding Rinsewater


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


    mg/kkg (Ib/billion Iba) of sawed or ground uranium rinsed

118  CADMIUM                   13.0                           5.7
120  COPPER                    72.O                          38.O
124  NICKEL                    73.0                          48.O
     FLUORIDE               2 ,'300.0                       1,OOO.O
     RADIUM                     (1)                           <1>
     URANIUM                   78.0                          35.0
     OIL & GREASE             76O.O                         46O.O
     TOTAL SUSPENDED        1,60O.O                         74O.O
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.

      7l7 Concentration Value Is 5 Picocuries Per Liter

      (k)  Degreasing Spent Solvents

There shall be no discharge of process wastewater pollutants.
                                  298

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SUBPART I.    ALTERNATE NSPS FOR THE ZINC FORMING SUBCATEGORY

      (a)  Rolling Spent Neat Oils

There shall be no discharge of process wastewater pollutants.


        Rolling Spent Emulsions
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
  mg/kkg (Ib/billion Ibs) of zinc rolled with emulsions

119  CHROMIUM                   .60                            .30
121  CYANIDE                 '   .40                            .20
128  ZINC                      2.00                            .80
     OIL & GREASE             28.00                         17.00
     TOTAL SUSPENDED          57.00                         27.00
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
        Rolling Contact Lubricant-Coolant Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of zinc rolled with contact
       lubricant-coolant water

119  CHROMIUM                  15.0                           6.2
121  CYANIDE                   10.0                           4.2
128  ZINC                      51.O                          21.0
     OIL & GREASE             690.O                         42O.O
     TOTAL SUSPENDED        1,4OO.O                         68O.0
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
                                 299

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      (d)  Drawing Spent Emulsions
   Pollutant or         Maximum  for                 Maximum for
Pollutant Property      Any  One  Day               Monthly Average
    mg/kkg  (Ib/billion  Ibs)  of  zinc drawn with emulsions

119  CHROMIUM                    3.5                           1.4
121  CYANIDE                     2.3                           1.0
128  ZINC                       12.0                           4.9
     OIL & GREASE             160.0                          96.0
     TOTAL SUSPENDED          330.0                         160.0
       SOLIDS
     pH             Within the  range of  7.5 to 10.0 at all times.
        Direct Chill Casting  Contact  Cooling Water


   Pollutant or         Maximum  for                 Maximum for
Pollutant Property      Any One  Day               Monthly Average
—• — — — -» — — — •"- — — — »- — — — — — —— — — — — — — — — — — —	— — —• — — — — — .— —. — — _-_ — •_____._—_____.______.*-___„_..

  mg/kkg (Ib/billion Ibs) of zinc cast by the direct chill method

119  CHROMIUM                  22.0                            9.1
121  CYANIDE                   15.0                            6.O
126  ZINC                      73.0                           31.0
     OIL & GREASE           1,000.0                          60O.O
     TOTAL SUSPENDED        2,100.0                          98O.0
       SOLIDS
     pH             Within the range of  7.5  to 1O.O at all times.


      
-------
        Heat Treatment Contact Colling Water
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Ibs) of zinc heat treated

119  CHROMIUM                  33.0                          14.O
121  CYANIDE                   22.0                           9.1
128  ZINC                     110.0                          46.0
     OIL & GREASE           1,50O.O                         910.0
     TOTAL SUSPENDED        3,10O.O                       1,50O.O
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all times.
      (h)  Surface Treatment Spent Baths
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of zinc surface treated

119  CHROMIUM                   4.2                           1.7
121  CYANIDE                    2.8                           1.1
128  ZINC                      14.0                           5.8
     OIL & GREASE             190.0                         110.O
     TOTAL SUSPENDED          39O.O                         19O.O
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.
                          301

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      ti>  Surface Treatment Kinaewater
   Pollutant or         Maximum for                 Maximum for
Pollutant Property      Any One Day               Monthly  Average


    mg/kkg   of zinc alkaline cleaned

119  CHROMIUM                    .30                            .10
121  CYANIDE                     .20                            .10
128  ZINC                      l.OO                            .40
     OIL £ GREASE             14.00                           8.6O
     TOTAL SUSPENDED          29.00                          14.OO
       SOLIDS
     pH             Within the range of 7.5 to  10.0 at  all  times.


      
-------
      «. i )   Sawing/Grinding Spent Lubricants
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


  mg/kkg (Ib/billion Ibs) of zinc sawed or ground

119  CHROMIUM                  24.0                          1O.O
121  CYANIDE                   16.0                           6.6
128  ZINC                      aO.O                          33.0
     OIL & GREASE           1,100.0                         660.0
     TOTAL SUSPENDED        2,300.0                       1,100.0
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all times.


        Degreasing Spent Solvents

There shall be no discharge of process wastewater pollutants.
SUBPART J.    ALTERNATE NSPS FOR THE ZIRCONIUM/HAFNIUM FORMING
              SUBCATEGORY

The standards for chromium, cyanide, nickel, ammonia, fluoride,
hafnium and zirconium would be the same as specified in Section II,
Part 8, Subpart J.  The standards for TSS, oil and grease and pH
would be the same as specified in Section II, Part 7, Subpart J.
                         303

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SUBPART K.
ALTERNATE NSPS FOR THE IRON AND STEEL/COPPER/ALUMINUM
METAL POWDER PRODUCTION AND POWDER METALLURGY
SUBCATEGORY
        Metal Powder Production Atomization Wastewater
   Pollutant or
Pollutant Property
          Maximum for
          Any One Day
  Maximum for
Monthly Average
    mg/kkg (Ib/billion Iba) of iron, copper, and aluminum powder
       wet atomized
120
121
122






COPPER
CYANIDE
LEAD
ALUMINUM
IRON
OIL S, GREASE
TOTAL SUSPENDED
SOLIDS
pH Within
6,500
1,000
1,400
31,000
6,OOO
50,000
76,000

the range of 7.5 to
3,100
400
660
14,000
3,100
50,OOO
6O,OOO

10.0 at all times.
      (b)  Metal Powder Production Milling Waatewater
   Pollutant or
Pollutant Property
          Maximum for
          Any One Day
  Maximum for
Monthly Average
    mg/kkg 
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      CO  Metal Powder Production  Wet APC Slowdown
   Pollutant or
Pollutant Property
    Maximum for
    Any One Day
  Maximum for
Monthly Average
    mg/kkg  (Ib/billion  Ibs)  of  iron,  copper, and aluminum powder
       produced
120
121
122






COPPER
CYANIDE
LEAD
ALUMINUM
IRON
OIL S. GREASE
TOTAL SUSPENDED
SOLIDS
pH Within
3,400
530
740
16,000
3,200
26,000
40,000

the range of
1,600
210
340
7,200
1,600
26,000
32,OOO

7.5 to 10.0 at all times.
      (d)  Sizing/Repressing  Spent  Lubricants

There shall be no discharge of  process wastewater pollutants,


      (.e)  Oil-Resin  Impregnation Wastewater
   Pollutant or
Pollutant Property
    Maximum for
    Any One Day
  Maximum ±"or
Monthly Average
    mg/kkg  (Ib/billion  Iba)  of  iron,  copper,  and aluminum powder
       metallurgy parts impregnated with oil-resin
12O  COPPER
121  CYANIDE
122  LEAD
     ALUMINUM
     IRON
     OIL & GREASE
     TOTAL SUSPENDED
       SOLIDS
     Pri
           95.0
           15.0
           21 .0
          460. O
           89.0
          750. O
        1,100.0
            45.0
             6.O
            1O.O
           2OO.O
            45.0
           750. O
           89O.O
Within the range of 7.5  to  10.0  at  all  times.
                             305

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      (f)  Steam Treatment Wet APC Slowdown
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average


    mg/kkg (Ib/billion Ibs) of iron, copper, and aluminum powder
       powder metallurgy parts steam treated

120  COPPER                     360                           17O
121  CYANIDE                     57                            23
122  LEAD                        80                            37
     ALUMINUM                 1,700                           770
     IRON                       340                           17O
     OIL & GREASE             2,8OO                         2,80O
     TOTAL SUSPENDED          4,300                         3,40O
       SOLIDS
     pH             Within the range of 7.5 to 10.0 at all timea.


        Tumbling, Burnishing And Cleaning Waatewater
   Pollutant or         Maximum for                Maximum for
Pollutant Property      Any One Day              Monthly Average
    mg/kkg (Ib/billion Iba) of iron, copper, and aluminum powder
       metallurgy parts tumbled, burnished, or cleaned

120  COPPER                     920                           44O
121  CYANIDE                    140                            57
122  LEAD                       200                            93
     ALUMINUM                 4,400                         1,900
     IRON                       860                           440
     OIL & GREASE             7,200                         7,2OO
     TOTAL SUSPENDED         11,OOO                         8,60O
       SOLIDS
     pH             Within the range of 7.5 to 1O.O at all times.
                             306

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       (h)   Sawing/Grinding Spent Lubricants
    Pollutant  or          Maximum for                Maximum for
Pollutant  Property      Any One Day              Monthly Average
    mg/kkg  (Ib/billion Ibs)  of iron, copper, and aluminum powder
        metallurgy  parts sawed or ground

 120  COPPER                    1,300                           610
 121  CYANIDE                     200                             80
 122  LEAD                        280                           130
     ALUMINUM                  6,100                         2,70O
     IRON                      1,200                           610
     OIL & GREASE             10,OOO                         10,000
     TOTAL SUSPENDED         15,OOO                         12,000
        SOLIDS
     pH             Within the range of 7.5 to 1O.O at all  times.
       (i>   Degreasing  Spent Solvents

There  shall  be  no  discharge of process wastewater pollutants.
10.  EPA  is considering  promulgating PSES which are less stringent
than the  standards  now proposed for PSES for seven of the eleven
subcategories.   The standards would be based on the treatment
effectiveness achievable by  the application of chemical
precipitation and sedimentation (lime and settle) technology and
in-process flow  reduction control  methods.   In addition, EPA is
considering promulgating PSES which are more stringent than the
standards now proposed for PSES for the Lead/Tin/Bismuth Forming and
the Iron  And Steel/Copper/Aluminum Metal Powder Production And
Powder Metallurgy Subcategories.   The standards would be based on
the treatment effectiveness  achievable by the application of
chemical  precipitation and sedimentation with the additiojn of
filtration (lime, settle,  and filter) technology and in-process
flow reduction control methods.   In addition, EPA is considering
promulgating PSES for the Zinc Forming Subcategory.  The standards
would be based on the treatment effectiveness achievable by one of
the following:
  1. the application of  chemical  precipitation and sedimentation
     (lime and settle) technology;
  2. the application of  chemical  precipitation and sedimentation
     (lime and settle) technology  and in-process flow reduction
     control methods; or
  3. the application of  chemical  precipitation and sedimentation
     with the addition of  filtration (lime,  settle, and filter)
     technology and in-process flow reduction control methods.
In addition,  the Beryllium Forming  Subcategory would still be
excluded from PSES.  In  the  event  that the  Agency decides to
promulgate these alternate PSES,  the following would apply for
existing sources:


                           307

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3LJBPART A.    ALTERNATE PSES FOR THE BERYLLIUM  FORMING  SUBCATEGORY

[Reserved]
SUBPART B.    ALTERNATE PSES FOR THE LEAD/TIN/BISMUTH  FORMING
              SUBCATEGORY

The standards for antimony and lead would be  the  same  as specified
in Section II, Part 8, Subpart B.
SUBPART C.    ALTERNATE PSES FOR THE MAGNESIUM  FORMING  SUBCATEGORY

The standards for chromium, zinc, ammonia, fluoride,  and  magnesium
would be the same as specified in Section  II, Part  8, Subpart C.
SUBPART D.    ALTERNATE PSES FOR THE NICKEL/COBALT  FORMING
              SUBCATEGORY

The standards for chromium, nickel, and fluoride would  be the same
as specified in Section II, Part 8, Subpart D.
SUBPART E.    ALTERNATE PSES FOR THE PRECIOUS METALS  FORMING
              SUBCATEGORY

The standards £or cadmium, copper, silver, and cyanide  would  be the
same as specified in Section II, Part 8, Subpart E.


SUBPART F.    ALTERNATE PSES FOR THE REFRACTORY METALS  FORMING
              SUBCATEGORY

The standards for copper, nickel, columbium, fluoride,  molybdenum,
tantalum, tungsten, and vanadium would be the same as specified in
Section II, Part 8, Subpart F.
SUBPART G.    ALTERNATE PSES FOR THE TITANIUM  FORMING  SUBCATEGORY

The standards for cyanide, lead, zinc, ammonia,  fluoride,  and
titanium would be the same as specified  in Section  II,  Part  8,
Subpart G.
SUBPART H.    ALTERNATE PSES FOR THE URANIUM  FORMING  SUBCATEGORY

The standards for cadmium, copper, nickel,  fluoride,  radium,  and
uranium would be the same as specified in Section  II,  Part  8,
Subpart H.
                                308

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SUBPART I.    ALTERNATE PSES FOR  THE  ZINC  FORMING  SUBCATEGORY  BASED
              ON LIME AND SETTLE  TECHNOLOGY

The standards for chromium, cyanide,  and zinc  would  be  the same as
specified in Section II, Part 2,  Subpart I.
SUBPART I.    ALTERNATE PSES FOR  THE  ZINC  FORMING  SUBCATEGORY  BASED
              ON LIME AND SETTLE  TECHNOLOGY  AND  FLOW  REDUCTION

The standards for chromium, cyanide,  and zinc  would be  the  same  as
specified in Section II, Part 8,  Subpart I.
SUBPART I.    ALTERNATE PSES FOR THE ZINC FORMING  SUBCATEGORY  BASED
              ON LIME, SETTLE AND FILTER TECHNOLOGY  AND  FLOW
              REDUCTION

The standards for chromium, cyanide, and zinc  would  be the  same  as
specified in Section  II, Part 3, Subpart I.
SUBPART J.    ALTERNATE PSES FOR THE ZIRCONIUM/HAFNIUM  FORMING
              SUBCATEGORY

The standards for chromium, cyanide, nickel, ammonia, fluoride,
hafnium, and zirconium would be the same as specified in  Section  II,
Part 8, Subpart J.
SUBPART K.    ALTERNATE PSES FOR THE IRON AND STEEL/COPPER/ALUMINUM
              METAL POWDER PRODUCTION AND POWDER METALLURGY
              SUBCATEGORY

The standards for copper, cyanide, lead, aluminum, and  iron  would
be the same as specified in Section II, Part 3, Subpart K.
11.  EPA is considering promulgating PSNS which are  less stringent
than the standards now proposed for PSNS for nine of the eleven
subcategories.   The standards would be based on the  treatment
effectiveness achievable by the application of chemical
precipitation and sedimentation (lime and settle) technology and
in-process flow reduction control methods.  In addition, EPA is
considering promulgating PSNS which are more stringent than the
standards now proposed for PSNS for the Lead/Tin/Bismuth Forming and
the Iron And Steel/Copper/Aluminum Metal Powder Production And
                             309

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Powder Metallurgy Subcategories.  The standards would be based on
the treatment effectiveness achievable by the application of
chemical precipitation and sedimentation with the addition of
filtration (lime, settle, and filter) technology and in-process
flow reduction control methods.  In the event that the Agency
decides to promulgate these alternate PSNS, the following would
apply for new sources:
SUBPART A.    ALTERNATE PSNS FOR THE BERYLLIUM FORMING SUBCATEGORY

The standards for beryllium, copper, cyanide, and fluoride would be
the same as specified in Section II, Part 8, Subpart A.
SUBPART B.    ALTERNATE PSNS FOR THE LEAD/TIN/BISMUTH FORMING
              SUBCATEGORY

The standards for antimony and lead would be the same as specified
in Section II, Part 8, Subpart B.


SUBPART C.    ALTERNATE PSNS FOR THE MAGNESIUM FORMING SUBCATEGORY

The standards for chromium, zinc, ammonia, fluoride, and magnesium
would be the same as specified in Section II, Part 8, Subpart C.
      •*


SUBPART D.    ALTERNATE PSNS FOR THE NICKEL/COBALT FORMING
              SUBCATEGORY

The standards for chromium, nickel, and fluoride would be the same
as specified in Section II, Part 8, Subpart D.


SUBPART E.    ALTERNATE PSNS FOR THE PRECIOUS METALS FORMING
              SUBCATEGORY

The standards for cadmium, copper, silver, and cyanide would be the
same as specified in Section II, Part 8, Subpart E.
SUBPART F.    ALTERNATE PSNS FOR THE REFRACTORY METALS FORMING
              SUBCATEGORY

The standards for copper, nickel, columbium, fluoride, molybdenum,
tantalum, tungsten, and vanadium would be the same as specified in
Section II, Part 8, Subpart F.
                            310

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SUBPART G.    ALTERNATE PSNS FOR THE TITANIUM  FORMING 3UBCATEGORY

The standards for cyanide, lead, zinc, ammonia, fluoride,  and
titanium would be the same as specified  in Section  II,  Part  8,
Subpart G.
SUBPART H.    ALTERNATE PSNS FOR THE URANIUM FORMING SUBCATEGORY

The standards for cadmium, copper, nickel, fluoride, radium,  and
uranium would be the same aa specified in Section  II, Part  8,
Subpart H.
SUBPART I.    ALTERNATE PSNS FOR THE ZINC FORMING SUBCATEGORY

The standards for chromium, cyanide, and zinc would be the  same  aa
specified in Section II, Part 8, Subpart I.
SUBPART J.    ALTERNATE PSNS FOR THE ZIRCONIUM/HAFNIUM FORMING
              SUBCATEGORY

The standards for chromium, cyanide, nickel, ammonia, fluoride,
hafnium, and zirconium would be the same as specified in  Section  II,
Part 8, Subpart J.


SUBPART K.    ALTERNATE PSNS FOR THE IRON AND STEEL/COPPER/ALUMINUM
              METAL POWDER PRODUCTION AND POWDER METALLURGY
              SUBCATEGORY

The standards ±"or copper, cyanide, lead, aluminum, and iron  would
be the same as specified in Section II, Part 3, Subpart K.
                           311

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                            SECTION III

                            INTRODUCTION
LEGAL  AUTHORITY

The Federal Water  Pollution Control  Act  Amendments  of 1972
established a comprehensive program  to "restore and maintain the
chemical,  physical,  and  biological integrity  of the Nation's
waters," under Section 101(a).   By July  1,  1977,  existing indus-
trial  dischargers  were required  to achieve  "effluent limitations
requiring  the application of the best  practicable control tech-
nology currently available" (BPT), under Section 301(b)(1)(A);
and by July 1,  1983,  these  dischargers were required to  achieve
"effluent  limitations  requiring  the  application of  the best
available  technology  economically achievable  .  .  .  which will
result in  reasonable  further progress  toward  the  national goal of
eliminating the discharge of all pollutants"  (BAT),  under Section
301(b)(2)(A).   New industrial direct dischargers  were required to
comply with Section 306  new source performance  standards (NSPS),
based  on best  available  demonstrated technology;  existing and new
dischargers to publicly  owned treatment  works (POTW) were subject
to pretreatment standards under  Sections 307 (b)  (PSES) and (c)
(PSNS), respectively,  of the Act.  While the  requirements for
direct dischargers were  to  be incorporated  into National Pollu-
tant Discharge Elimination  System (NDPES) permits issued under
Section 402 of the Act,  pretreatment standards  were  made enforce-
able directly  against  discharges to  a  POTW  (indirect discharg-
ers).   Although Section  402(a)(l) of the 1972 Act authorized the
'setting of NPDES permit  requirements for direct dischargers  on a
case-by-case  basis,  Congress intended  that,  for the  most part,
control requirements  would  be based  on regulations  promulgated by
the Administrator  of  EPA.   Section 304(b) of  the  Act required the
Administrator  to promulgate regulations  providing guidelines for
effluent limitations  setting forth the degree of  effluent
reduction  attainable  through the application  of BPT  and  BAT.
Moreoever, Sections  304(c)  and 306 of  the Act required promulga-
tion of regulations  for  new sources  (NSPS);  and Sections 304(f),
307(b), and 307(c) required promulgation of regulations  for  pre-
treatment  standards.   In addition to these  regulations for desig-
nated  industry categories,  Section 307(a) of  the  Act required the
Administrator  to promulgate effluent standards  applicable to all
dischargers of toxic  pollutants.  Finally,  Section  301(a)  of the
Act authorized the Administrator to  prescribe any additional
regulations "necessary to carry  out  his  functions"  under the Act.

EPA was unable  to  promulgate many of these  regulations by the
dates  contained in the Act.   In  1976,  EPA was sued  by several
environmental  groups  and in settlement of this  lawsuit,  EPA  and
                               313

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the plaintiffs executed a "Settlement Agreement," which was
approved by the Court.  This Agreement required EPA to develop a
program and adhere to a schedule for promulgating for 21 major
industries' BAT effluent limitations guidelines, pretreatment
standards, and new source performance standards for 65 "priority"
pollutants and classes of pollutants.  See Settlement Agreement
in Natural Resources Defense Council  Inc. v. Train, 8 ERG 2120
(D.D.C. 1976), modified 12 ERG 1833  (D.D.C. 1979), and modified
by October 26, 1982, August 2, 1983, and January 6, 1984.

On December 27, 1977, the President  signed into law amendments to
the Federal Water Pollution Control Act (P.L. 95-217).  The Act,
as amended, is commonly referred to  as the Clean Water Act.
Although this Act makes several important changes in the federal
water pollution control program, its most significant feature is
its incorporation of several of the basic elements of the Settle-
ment Agreement program for toxic pollution control.  Sections
301(b)(2)(A) and 301 (b)(2)(C) of the Act now require the achieve-
ment, by July 1, 1984, of effluent limitations requiring applica-
tion of BAT for toxic pollutants, including the 65 priority pol-
lutants and classes  of pollutants (the same priority pollutants
as listed in Natural Resources Defense Council v. Train), which
Congress declared toxic under Section 307(a) of the Act.  Like-
wise, EPA's programs for new source performance standards and
pretreatment standards are now aimed principally at control of
these toxic pollutants.  Moreover, to strengthen the toxics con-
trol program, Congress added Section 304(e) to the Act, authoriz-
ing the Administrator to prescribe "best management practices"
(BMPs) to prevent the release of toxic and hazardous pollutants
from plant site runoff, spillage or  leaks, sludge or waste dis-
posal, and drainage  from raw material storage associated with, or
ancillary to, the manufacturing or treatment process.

The 1977 Amendments  added Section 301(b)(2)(E) to the Act estab-
lishing "best conventional pollutant control technology) (BCT)
for discharges of conventional pollutants from existing indus-
trial point sources.  Conventional pollutants are those mentioned
specifically in Section 304(a)(4) (biochemical oxygen demanding
pollutants (BODO, total suspended solids (TSS) , fecal
coliform, and pH)  and any additional pollutants defined by the
Administrator as  conventional."  (To date, the Agency has added
one such pollutant,  oil and grease, 44 FR 44501, July 30, 1979.)

BCT is not an additional limitation but replaces BAT for the
control of conventional pollutants.  In addition to other factors
specified in Section 304(b) (4) (B ) , the Act requires that BCT
limitations be assessed in light of  a two-part "cost-
reasonableness" test, American Paper Institute v. EPA, 660 F.2d
954 (4th Cir. 1981).  The first test compares the cost for
private industry to  reduce its conventional pollutants with the
                               314

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costs to publicly owned treatment works  for  similar  levels of
reduction in their discharge of these pollutants.  The second
test examines the cost-effectiveness of  additional industrial
treatment beyond BPT.  EPA must find that limitations are
"reasonable" under both tests before establishing them as BCT.
In no case may BCT be less stringent than BPT.

EPA published its methodology for carrying out the BCT analysis
on August 29, 1979 (44 FR 50372).  In the case mentioned above,
the Court of Appeals ordered EPA to correct  data errors underly-
ing EPA's calculation of the first test, and  to apply the second
cost test.   (EPA argued that a second cost test was not
required.)  On October 29, 1982, the Agency  proposed a revised
BCT methodology (47 FR 49176).

For nontoxic, nonconventional pollutants, Sections 301(b)(2)(A)
and (b)(2)(F) require achievement of BAT effluent limitations
within three years after their establishment  or July 1, 1984,
whichever is later, but not later than July  1, 1987.

The purpose of this document is to provide the supporting techni-
cal data regarding water use, pollutants, and treatment technolo-
gies for BPT, BAT, BCT, NSPS, PSES, and PSNS  effluent limitations
and standards that EPA is proposing for the nonferrous metals
forming category under Sections 301, 304, 306, 307, and 501 of
the Clean Water Act.

GUIDELINES DEVELOPMENT SUMMARY

EPA gathered and evaluated technical data in  the course of devel-
oping these guidelines in order to perform the following tasks:

     1.   To profile the category with regard  to the production,
         manufacturing processes, geographical distribution,
         potential wastewater streams, and discharge mode of
         nonferrous metals forming plants.

     2.   To subcategorize, if necessary, in order to permit
         regulation of the nonferrous metals  forming category in
         an equitable and manageable way.  This was done by
         taking all of the factors mentioned  above plus others
         into account.

     3.   To characterize wastewater, detailing water use, waste-
         water discharge, and the occurrence  of toxic, conven-
         tional,  and nonconventional pollutants,  in waste stream;
         from nonferrous metals forming processes.
                              315

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     4.  To select pollutant parameters--those  toxic, conven-
         tional, and nonconventional pollutants present at signi-
         ficant concentrations in wastewater  streams--that should
         be considered for regulation.

     5.  To consider control and treatment technologies and
         select alternative methods for reducing pollutant
         discharge in this category.

     6.  To consider the costs of implementing  the alternative
         control and treatment technologies.

     7.  To present possible regulatory alternatives.

Sources of Industry Data

Data on the nonferrous metals forming category  were gathered from
previous EPA studies, literature studies, inquiries to federal
and state environmental agencies, raw material  manufacturers and
suppliers, trade association contacts, wastewater treatment
equipment manufacturers, and the nonferrous metals forming
manufacturers themselves.  All known nonferrous metals formers
were sent a data collection portfolio (dcp) requesting specific
information concerning each facility.  Finally, a sampling
program was carried out at 17 plants.  The sampling program con-
sisted of screen sampling, performed under authority provided by
Section 308 of the Clean Water Act, and analysis to determine the
presence of a broad range of pollutants and quantification of the
pollutants present in nonferrous metals forming wastewater.  Spe-
cific details of the sampling program and information from the
above data sources are presented in Section V.

Literature Review.  EPA reviewed and evaluated  existing litera-
ture for background information to clarify and  define various
aspects of the nonferrous metals forming category and to deter-
mine general characteristics and trends in production processes
and wastewater treatment technology.  Review  of current litera-
ture continued throughout the development of  these guidelines.

Existing Data Review.  Information related to nonferrous metals
forming processes, wastewater, and wastewater treatment technol-
ogy was compiled from a number of sources.  Technical data
gathered for development of guidelines for related categories,
such as the aluminum forming, copper forming, metal finxshing,
nonferrous metals manufacturing, electroplating, and battery
manufacturing categories, were reviewed and incorporated into
this guideline, where applicable.

Frequent contact has been maintained with industry personnel.
Contributions from these sources were particularly useful for
clarifying differences in production processes.
                               316

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Plant Survey and Evaluation.  The nonferrous metals  forming
plants were surveyed to gather information regarding plant size,
age and production, the production processes used, and the quan-
tity, treatment, and disposal of wastewater generated at these
plants.

A listing of plants believed to be in the nonferrous metals  form-
ing category was compiled from a Dun and Bradstreet  computer
listing, publications and telephone contacts with various trade
associations believed to represent parts of the industry, the
Thomas Register, and telephone contacts with commodity special-
ists at the Bureau of Mines.  These sources resulted in the
identification of approximately 1,000 plants as being possibly
engaged in nonferrous metals forming activities.  The SIC codes
used were:  (1) 3356:  Rolling, Drawing, Extruding of Nonferrous
Metals; (2) 3357:  Drawing and Insulating Nonferrous Wire;
(3) 3463:  Nonferrous Forgings; and (4) 3497:  Metal, Foil,  and
Leaf.

A comprehensive telephone survey was undertaken in order to
determine which plants should comprise a final mailing list,
i.e., whether or not nonferrous metals forming operations were
present at each of the plants on the original list.  During  the
telephone survey, questions were asked concerning what metals are
formed at a particular plant, the type of forming operations
utilized^on the metal, i.e., rolling, drawing, extruding, forg-
ing, casting, cladding, or powder metallurgy and their associated
water usage, discharge, and treatment-in-place.  Respondents also
were asked what surface treatment, cleaning, washing, and/or
rinsing operations are utilized and their associated water usage,
discharge, and treatment-in-place.  At the conclusion of the
telephone survey, many of the plants on the original list were
determined not to be within the scope of the nonferrous metals
forming category.

A list of those plants believed to be a part of the  category was
then compiled in preparation for dcp distribution.   The results
of the telephone survey are documented in the administrative
record for this rulemaking.

During the first week of April 1983, the Office of Management and
Budget (OMB) approved the mailing of 365 data collection portfol-
ios to plants believed to be in the category.  On April 19,  1983,
these 365 dcp's were sent out under the authority of Section 308
of the Clean Water Act to companies on the mailing list.  The
dcp's were sent to the corporate office of each company and
addressed to the highest ranking corporate official which could
be identified.  The dcp instructions clearly stated  that the
portfolio was to be completed for each facility operated by  that
company which has operations which are defined in the instruc-
tions to be nonferrous metals forming.
                               317

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An additional 47 dcp's were sent out on June 21, 1983 when  the
Agency decided to include metal powder production and powder
metallurgy operations of all metals, including  iron and  steel,
copper, and aluminum in the scope of the category.  All  but five
of these dcp's were sent to companies which had been sent a non-
ferrous metals forming dcp on April 19, 1983.  Between April 19,
1983 and July 11, 1983, seven more dcp's were sent out,  as  addi-
tional facilities believed to be in the category were located.
All companies were allowed 30 days from receipt of the dcp  in
which to complete and return the portfolio.

In all, dcp's were sent to 377 firms.  Approximately 95  percent
of the companies responded to the survey.  In many cases, com-
panies contacted were not actually members of the nonferrous
metals forming category as it is defined by the Agency.  Where
firms had nonferrous metals forming operations at more than one
location, a dcp was returned for each plant.  A total of 294
dcp's applicable to the nonferrous metals forming category were
returned.  In cases where the dcp responses were incomplete or
unclear, additional information was requested by telephone  or
letter.

The dcp responses were interpreted individually, and the follow-
ing data were documented for future reference and evaluation:

        Company name,  plant address, and name of the contact
        listed in the dcp.

        Metal types formed at the plant.

        Plant discharge status as direct (to surface water),
        indirect (to POTW), or zero discharge by metal type.

        Production process streams present at the plant, as well
        as associated flow rates; production rates; operating
        hours; wastewater treatment, reuse, or disposal  methods;
        and the quantity and nature of process chemicals used.

        Plant age and number of employees.

        Availability of pollutant monitoring data provided  by the
        plant.

The summary listing of this information provided a consistent,
systematic method of evaluating and summarizing the dcp
responses.  In addition, procedures were developed to simplify
subsequent analyses.  The procedures developed had the following
capabilities:
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        Selection and listing of plants containing specific pro-
        duction process streams or treatment technologies.

        Summation of the number of plants containing specific
        process streams and treatment combinations.

        Calculation of the percent recycle present for specific
        streams and summation of the number of plants recycling
        this stream within various percent recycle ranges.

        Calculation of annual production values associated with
        each process stream and summation of the number of plants
        with these process streams having production values
        within various ranges.

        Calculation of water use and blowdown from individual
        process streams.

The calculated information and summaries were important and fre-
quently used in the development of this guideline.  Summaries
were used in the category profile, evaluation of subcategoriza-
tion, and analysis of in-place treatment and control technolo-
gies.  Calculated information was used in the determination of
water use and discharge values for the conversion of pollutant
concentrations to mass loadings.

Discharge Monitoring Reports.  To supplement existing data
regarding treatment-in-place and the long-term performance of
that treatment, the Agency collected discharge monitoring report
(DMR) data from state and EPA Regional offices for direct dis-
chargers.  DMR data are self-monitoring data supplied by permit
holders to meet state or EPA permit requirements.  These data
were available from 17 nonferrous metals forming plants; however,
the data vary widely in character and nature due to the dissimi-
lar nature of the monitoring and reporting requirements placed on
nonferrous metals forming plants by the NPDES permit issuing
authority.  These data were not used in the actual development of
the proposed limitations.

Engineering Site Visits and Sampling Trips.  In addition to the
above data sources,EPA sampled 17nonferrous metals forming
plants.  Plant visits were made to sample treated and untreated
wastewater and to gather additional information on manufacturing
processes, wastewater flows, and wastewater treatment technolo-
gies and associated costs.  Samples were collected at these 17
plants in order to characterize the wastewaters from the various
nonferrous metals forming manufacturing operations and to char-
acterize the performance of existing treatment systems.  The 17
plants selected for sampling practice some combination of hot
rolling, cold rolling, drawing, extrusion, forging, tube reduc-
ing, cladding, metal powder production and powder metallurgy, as
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well  as the associated operations of casting, heat treatment,
surface treatment, alkaline cleaning, sawing, grinding, tumbling,
burnishing, and product testing.  These plants were chosen  for
sampling because the flow rates and pollutant concentrations in
the wastewaters discharged from their manufacturing operations
are representative of the flow rates and pollutant concentrations
of wastewaters generated by similar operations at other plants in
the nonferrous metals forming industry.

Utilization of Industry Data

Data  from the previously listed sources were used to develop BPT,
BAT,  and BCT limitations and NSPS and pretreatment standards as
described in this document.  Subcategorization of the nonferrous
metals forming category, described in Section IV, was based on
information obtained from previous EPA studies and the technical
literature and our own sampling data.  Sampling results were used
to determine raw wastewater characteristics, presented in Section
V, and to select pollutant parameters for control, as described
in Section VI.  After determining the pollutants requiring
control and the concentrations at which they are commonly found,
applicable treatment technologies were identified.  The applica-
bility of wastewater treatment technologies currently in use at
nonferrous metals forming plants (reported in dcp's and observed
at sampled plants) was especially considered.  These technologies
are described in Section VII.   Section VIII describes the method
used  to estimate the cost of various treatment technology
options.   The cost estimates were based on data from the techni-
cal literature and from equipment manufacturers.  Finally, data
from dcp's and sampling, along with estimated treatment system
performance, were used to develop the limitations and standards
described in Sections IX, X, XI, XII, and XIII of this document.
The data were used first to select treatment technologies
applicable to the category and then to calculate achievable
effluent pollutant concentrations for each subcategory.

DESCRIPTION OF THE NONFERROUS  METALS FORMING CATEGORY

The nonferrous metals forming category is generally included
within SIC 3356, 3357, 3463, and 3497 of the Standard Industrial
Classification Manual, prepared in 1972 and supplemented in 1977
by the Office of Management and Budget, Executive Office of the
President.  These SIC codes are:  (1) 3356:   Rolling., Drawing,
Extruding of Nonferrous Metals; (2)  3357:   Drawing arid Insulating
Nonferrous Wire; (3) 3463:  Nonferrous Forgings; and (4) 3497:
Metal, Foil, and Leaf.  The category includes establishments
engaged in the forming of nonferrous metals and their alloys,
except for copper and aluminum for which separate regulations
have recently been promulgated [40 CFR Part 468 (48 FR 36942,
August 15, 1983), 40 CFR Part 467 (48 FR 49126,  October 24,
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1983)].  Separate regulations have been  or will be proposed  for
casting of parts [40 CFR Part 464  (proposed at 47 FR 51512 on
November 15, 1982)] and for casting which is  an integral  part  of
a nonferrous metal smelting and refining operation [40 CFR Part
421  (nonferrous metals manufacturing phase I, proposed at 40 CFR
7032, February 17, 1983, to be promulgated shortly; nonferrous
metals manufacturing phase II, scheduled for  proposal shortly)].

For  the purpose of this regulation, nonferrous metal has  been
defined as any pure metal other than iron, copper, or aluminum;
or metal alloy for which a metal other than iron, copper, or
aluminum is its major constituent by weight.  Alloys are  consid-
ered as only one metal type.  The metal  type  of any particular
alloy is defined to be the metal that is the  major component in
percent by composition.  Thus, an alloy which is 53 percent  lead
and 47 percent zinc is considered as lead, and an alloy which  is
40 percent nickel, 35 percent zinc, and 25 percent tin is consid-
ered as nickel.  Forming of an alloy which is greater than 50
percent iron, copper, or aluminum is not included in the
category.

Use  of the term "metal" throughout this document is not meant  to
imply pure metals only.  "Metal" means any substance having
metallic properties, including alloys composed of two or  more
chemical elements, of which at least one is an elemental  metal.
Thus "copper" means copper and its alloys (brass, bronze, nickel
silver, beryllium copper, etc.), "iron" means iron and its alloys
(including steel, an alloy of iron and carbon), and so forth.

Forming is the deformation of a metal into specific shapes by hot
or cold working.   The major forming operations include rolling,
extruding, forging, and drawing.  Minor forming operations
included in the category are cladding, tube reducing, metal
powder production and powder metallurgy.   Associated operations
performed as an integral part of the forming process are  also
included in the category.  These operations are casting for
subsequent forming, heat treatment, surface treatment, alkaline
cleaning, solvent degreasing,  sawing, grinding, tumbling,
burnishing, product testing, and air pollution controls on
forming operations and the associated operations.

Iron, copper, and aluminum powder manufacturing and powder metal-
lurgy are covered under the nonferrous metals forming category in
order to keep all of the powder operations under a single cate-
gory, although the other forming operations for these metals are
covered under separarate regulations [iron and Steel, 40 CFR Part
420; Copper Forming, 40 CFR Part 468 (48 FR 36942, August 15,
1983);  Aluminum Forming, 40 CFR Part 467  (48 FR 49126, October
24, 1983)].  Separate regulations have been or will be proposed
for metal powders produced as  an integral part of a nonferrous
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metal smelting and refining operation  (40 CFR Part 421;  see  full
citation above).  Only production of metal powders, ferrous  and
nonferrous, in operations which do not significantly increase
their purity are included in the nonferrous metals forming
category.

Casting which is an integral part of nonferrous metals  forming is
included in the nonferrous metals forming category, i.e., shot-
casting and casting of billets, ingots, bars, and strip  which are
subsequently formed on-site.

Wastewater discharges covered by the nonferrous metals  forming
point source category, as delineated above, are not subject  to
regulation under 40 CFR Part 413 (electroplating) or 40'CFR  Part
433 (metal finishing).

Historical

The nonferrous metals forming category covers forming operations
performed on 31 metals.  A group of nine of the metals has been
excluded from this regulation under Paragraph 8(a)(iv) of the
Settlement Agreement.  These metal types are listed in Table
III-l.  They are excluded from regulation because, according to
information reported on dcp's, they are not formed on a  produc-
tion scale in the United States or because the forming  operations
performed on them do not discharge wastewater.  The 22 nonferrous
metal types that are covered under this regulation are  listed in
Table III-2.

Employment data are given in the dcp responses for 235 plants (80
percent of the plants known to be engaged in nonferrous  metals
forming).  These plants report a total of 35,000 workers involved
in nonferrous metals forming.  At an average plant, 120  employees
are engaged in nonferrous metal forming.  The employment distri-
bution of nonferrous metals forming workers at the 235  plants is:
34 percent employ fewer than 25 people in nonferrous metals
forming operations; 68 percent employ  fewer than 100 people  in
this capacity; and 94 percent employ fewer than 500 people.

Nonferrous metals forming plants are not limited to any  one  geo-
graphical location.  As shown in Figure III-l, plants are found
throughout most of the United States, but the majority  are
located east of the Mississippi River.  Population density is not
a limiting factor in plant location.  Nonferrous metals  forming
plants tend to be more common in urban areas, but they  are
frequently found in rural areas as well.

The majority of the nonferrous metals  forming plants (57 percent)
that reported the age of their facilty indicated they were built
since 1954.  Table III-3 shows the age distribution of  nonferrous
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metals forming plants according  to  their  classification  as
direct, indirect, and zero discharge  type.

Product Description

Nonferrous metals are formed by  a variety  of  operations,
described in the second half of  this  section.   The  product  of  one
operation is often the starting  material  for  a  subsequent opera-
tion, as shown in Figure III-2.  Cast  ingots  and billets  are the
starting point for making sheet  and plate,  extrusions, and  forg-
ings, as well as rod, for use  in drawing  operations.  Rolled
sheet and plate can be used as stock  for  stampings, can blanks,
and roll formed products; as finished  products  in building, and
aircraft construction; or as foil.  Extrusions  can  be used  as  raw
stock for forging and drawing; or can  be  sold as final products,
such as beams or extruded tubing.  Forgings are either sold as
consumer products or used as parts  in  the  production of
machinery, aircraft, and engines.

Products manufactured by nonferrous metals  forming  operations
generally serve as stock for subsequent fabricating operations.
Because the 22 metals included in this category have a wide range
of physical, chemical, and electrochemical  properties, they are
used in a wide range of fabricated products.  The forming and
associated operations in common  use for a  particular metal  depend
on what is possible, given the physical properties  of the metal,
and what is required for a specific application.  For example:

        Beryllium, used in aerospace  applications because of its
        high strength and light  weight, is  rolled into sheet
        products.  Because it  is difficult  to cast, it is
        commonly consolidated  into billets  by powder metallurgy
        techniques.

        Bismuth has a low melting point and thus is rolled  into
        strip for use in fuses.  When  alloyed with  lead, tin,
        and/or cadmium, it is  also extruded and drawn into  solder
        wire.

        Cobalt is often alloyed with nickel,  and is formed by  the
        same method used to form steels.   It  is used for applica-
        tions requiring strength and corrosion resistance at high
        temperatures, such as  turbine  blades.

        Hafnium is formed into control rods for nuclear reactors
        because of its special properties.

        Lead is extruded and swaged into bullets because it is
        dense and inexpensive.  When alloyed  with tin, bismuth,
        and cadmium, it is extruded into solder, an application
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which makes use of its low melting point.  Lead  is  formed
into cases for automobile batteries because of its  elec-
trochemical properties and because it  is  inexpensive.

Magnesium is extruded into cases for batteries used in
portable communications equipment.  The application takes
advantage of the metal's electrochemical  properties and
light weight.

Nickel is often alloyed with chrome and iron to  make
stainless steel alloys, many greater than 50 percent
nickel.  It is formed by all major forming operations and
is used in applications requiring corrosion resistance at
high temperatures, such as tubing for  steam and  gas  tur-
bines and in jet engines.

Precious metals (silver, gold, platinum,  and palladium)
are corrosion-resistant and good electrical conductors.
Because of their expense, they are often  used as a  thin
layer clad to a layer of base metal (usually copper or
nickel) which is rolled into strip and stamped into
electrical contacts.   Pure and clad precious metals  are
also drawn to wire used to fabricate jewelry.  The
corrosion resistance of precious metals makes them  useful
in dentistry.

Refractory metals (columbium, molybdenum, rhenium,  tanta-
lum, tungsten, and vanadium) must be formed at high tem-
peratures (relative to other metals) or as powders
because they have melting points above 1,960°C.  Their
unique properties make them useful for specialized  appli-
cations.  Columbium is used as a structural material in
nuclear reactors.  Molybdenum is drawn into semiconductor
wires.  Tantalum is used in very small capacitors and
heat transfer and furnace equipment.   Tungsten finds wide
application as filaments for electric  light bulbs.   As
tungsten carbide, it is used in cutting tools and
abrasives because of its extreme hardness.

Tin is used in solder, usually alloyed with lead.

Titanium, used in aerospace applications  because of its
high strength and light weight, is formed by all major
forming techniques.  It is also used for  corrosion-resis-
tant hardware and surgical implants.

Uranium, when composed of 0.2 to 0.3 percent 235y (the
fissionable isotope), remainder 238u}  is  called
depleted uranium.  This material is extruded into armor
piercing projectiles because it is extremely dense.
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        Zinc is light weight and corrosion-resistant.  It  is
        rolled into sheet for architectural uses and stamped  into
        pennies.  Its chemical properties make  it useful for
        battery cases and lithographic plates.

        Zirconium is used to clad nuclear fuel  rods in water
        cooled reactors and as a construction material in
        chemical plants because of its high melting point  and
        corrosion resistance.  It is extruded into tubes and
        rolled into plate and sheet.

Some forming operations are more commonly used  on some metals
than others. For instance, 67 percent of plants which form lead,
tin, or bismuth extrude these metals.  Only 6 percent of lead
forming plants forge (swage) the metal.  Casting is not common at
refractory metals plants (8 percent of the plants) but powder
metallurgy is (63 percent of the plants).  Precious metals  are
commonly rolled (67 percent) and drawn (50 percent), but seldom
extruded (15 percent).

Production of formed nonferrous metal products  is tabulated in
Table III-4.  Production varies widely, from as little as  two and
a half million pounds of cobalt to 384 million  pounds of lead
products formed in 1981.  Approximately 203 million pounds of
iron, steel, copper, and aluminum powders and parts made from
powder were produced in 1981.  Reported production of formed
nonferrous metals at individual plant sites rangecl from 24 kg (53
pounds) to almost 23 million kg (51 million pounds) during 1981.

Wastewater Generation and Treatment

One hundred forty-eight plants indicated that no wastewater from
nonferrous metals forming operations is discharged to either
surface waters or a POTW.  Of the remaining 146 plants, 32 dis-
charge an effluent from nonferrous metals forming directly  to
surface waters, 107 discharge indirectly, sending nonferrous
metals forming effluent through a POTW, and seven plants dis-
charge both directly and indirectly.  The volume of nonferrous
metals forming wastewater discharged by plants  in this category
ranges from 0 to 680 million liters per year (0 to 180 million
gallons per year).  The mean volume is approximately 19 million
liters per year (5.0 million gallons per year)  for those plants
having discharges.  Only 84 of the discharging  plants provided
enough information to calculate the volume of wastewater dis-
charged.  Of these 84 plants, 20 percent discharge less than
38,000 liters per year (10,000 gallons per year); 55 percent
discharge less than 3,800,000 liters per year (1,000,000 gallons
per year);  and 81 percent discharge less than 38,000,000 liters
per year (10,000,000 gallons per year).  There  is no correlation
between overall water use and total nonferrous  metals production
for a plant as a whole.  However, correlations  can be developed
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between water use or wastewater discharge and production  on  a
process basis, as discussed in Section V.

Approximately 50 percent of the plants reported some form of
treatment of wastewater from nonferrous metals forming processes.
The most common forms of wastewater treatment are pH adjustment,
clarification, and gravity oil separation (skimming).  Recircu-
lation, including in-line filtration and cooling towers,  is
frequently used to control the volume of wastewater  generated.
Other flow reduction techniques demonstrated include countercur-
rent cascade and spray rinsing.  Oily wastes are separated into
oil and water fractions by emulsion breaking using heat, or chemi-
cals.  Gravity separation is frequently used to separate  neat oil
and broken emulsions from the water fraction.  The oil portion is
usually removed by a contractor, although some plants dispose of
it by land application or incineration.  Wastewater  treatment
sludges generally are not thickened, but are disposed of  without
treatment; however, vacuum and pressure filters, centrifuges, and
drying beds are occasionally used.  Sludge disposal  methods
include landfill and contractor removal.  Disposal of wastewater
is being accomplished by discharge to surface waters or a POTW,
by contractor removal, or by land application (lagoons and septic
tanks).

DESCRIPTION OF NONFERROUS METALS FORMING PROCESSES

In the remainder of this section, nonferrous metal forming opera-
tions and operations associated with nonferrous metal forming are
described in detail.  In these descriptions, particular emphasis
is placed on the use of water and generation of wastewater.   The
major nonferrous metals forming operations covered under  this
guideline include:

     1.  Rolling, drawing, extruding and forging of nonferrous
         metals other than copper and aluminum;

     2.  Cladding of any metals other than iron, steel, copper,
         and aluminum to any base metal (including iron,  steel,
         copper, and aluminum);

     3.  Production of powders of all metals (including iron,
         copper, and aluminum) by mechanical methods or atomiza-
         tion; and

     4.  Manufacture of parts from powders of all metals
         (including iron, copper, and aluminum).

Nonferrous metal forming operations which are associated  with the
above operations are also covered under this guideline.   These
include:
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     1.  Casting of  nonferrous  metals  for  subsequent  forming;

     2.  Heat treatment;

     3.  Chemical  surface  treatments  (acid,  caustic,  chromate);

     4.  Chemical  cleaning (molten  salt, alkaline);

     5.  Degreasing;

     6.  Mechanical  surface  treatments  (tumbling, burnishing,
         milling);

     7.  Sawing and  grinding; and

     8.  Product testing.

Water  is used in forming of  nonferrous  metals  to achieve  desired
metal  characteristics such as tensile  strength, malleability,
hardness, and specific surface  characteristics.  Water  can be
used without additives, as in contact  cooling  and rinsing; in
combination with soaps and oils, as in  lubricating various opera-
tions; and in combination  with  other  chemicals, as in surface
treatment and cleaning operations.  Water  is used in  vapor form
to steam clean and surface treat some  metals and as a high pres-
sure jet in the production of metal powders by atoraization.  In
addition to its use  in applications which  directly affect metal
properties, water  is used  in cleaning  nonferrous metal  forming
plants and equipment and in  devices used to  control air pollution
generated during forming.  A tally  of wastewater sources  in  the
nonferrous metals  forming  industry  is  presented in Section V.
Regulatory flow allowances for  waste streams under BPT, BAT,
NSPS,  pretreatment standards, and BCT  are  presented and discussed
in Sections IX, X, XI, XII,  and XIII,  respectively.

EPA recognizes that  plants sometimes combine wastewater from
nonferrous metals  forming  and other processes  and nonprocess
wastewater prior to  treatment and discharge.   Pollutant discharge
allowances will be established  by this  guideline only for nonfer-
rous metals forming  process wastewater.  The flows and wastewater
characteristics for  other  waste streams are  a  function  of the
plant  operations,  layout,  and water handling practices.  As  a
result, the pollutant discharge effluent limitation for waste-
water  streams other  than nonferrous metals forming process water
will be prepared by  the permitting  authority on a case-by-case
basis, applying other effluent  limitations and guidelines, if
appropriate.  These  wastewaters are not further discussed in this
document.
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Nonferrous Metals Forming Operations

Rolling.  Rolling is the process  of reducing  the  cross-sectional
area of metal stock, or otherwise shaping metal products,  through
the use of rotating rolls.  Cylindrical rolls  are used  to  produce
flat shapes; grooved rolls produce rounds, squares, and  struc-
tural shapes.  Two common roll  configurations  are shown  in Figure
III-3.  Because multiple passes through the rolls are often
required to reduce the metal to the desired thickness,  mills  are
frequently designed to allow rolling in the reverse direction.

Rolling employs either hot- or  cold-working techniques  depending
on the kind of metal or alloy,  and the properties desired  in  the
final product.  Hot rolling is  defined as rolling above  the
recrystallization temperature of  the metal and is typically the
first step in a series of operations to produce a rolled product.
Cast ingots or billets are usually reduced by  hot rolling  to
elongated forms, known as blooms or slags.  The rolling  mills
used for this operation are generally referred to as  "breakdown
mills" or "roughing mills."  Additional hot or cold rolling can
then follow the "breakdown" process.  A diagram of a  reversing
hot strip mill which would be used subsequent  to  a "breakdown"
operation is presented in Figure III-4.

Cold rolling is defined as rolling below the  recrystallization
temperature of the metal and may be carried out at temperatures
much higher than ambient and still be considered  "cold   rolling.
A diagram of a typical 4-high cold rolling mill is presented  in
Figure III-5.

The rolling process is used to  produce any one of a number of
intermediate or final products  from cast metal.  Rolling is used
to make flat products such as plate, sheet, strip, and  foil.
Plate is defined as being greater than or equal to 6.3 mm  (0.25
inch) thick, and is usually produced from ingots  by hot:  rolling.
Cold rolled flat products are generally classified as sheet [from
6.3 to 0.15 mm (0.249 to 0.007  inch) thick] and foil  [below 0.15
mm (0.006 inch) thick].

Rod, bar, and wire may be produced by either hot  or cold rolling
using grooved rolls.  Rod is defined as having a  solid  round
cross section 0.95 cm (3/8 inch) or more in diameter.  Bar is
also identified by a cross section with 0.95  cm (3/8  inch) or
more between two parallel sides, but it is not round.  Wire is
characterized by a diameter of  less than 0.95  cm  (3/8 inch).

A specialized cold rolling operation, called  tube reducing, is
used to reduce the diameter and wall thickness of tubing.  A
mandrel is inserted in the tubing which is then rolled between a
pair of rolls with tapered grooves.  This process is used  on
nickel, silver, zirconium, and  titanium tubing.
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As will be discussed  later  in  this  section, heat  treatment  is
usually required before and between stages of  the rolling pro-
cess.  Ingots are usually made homogeneous in  grain  structure
prior to hot rolling  in order  to remove the effects  of  casting  on
the metal's mechanical properties.   Annealing  is  typically
required between passes or  after cold rolling  to keep the metal
ductile and remove the effects of work hardening.  The  kind and
degree of heat treatment applied depends on the metal and alloy
involved, the nature  of the rolling operation, and the  properties
desired in the product.

It is necessary to use a cooling and lubricating compound during
rolling to prevent excessive wear on the rolls, to prevent  adhe-
sion of metal to the  rolls, and to  maintain a  suitable  and  uni-
form rolling temperature.  Water and oil-in-water emulsions,
stabilized with emulsifying agents  such as soaps and other  polar
organic materials, are used for this purpose in hot  rolling oper-
ations.  Emulsion concentrations usually vary  between 5 and 10
percent oil.  Evaporation of the lubricant as  it  is  sprayed on
the hot metal serves  to cool the rolling process.  Mist elimina-
tors may be used to recover rolling emulsions  that are  dispersed
to the atmosphere.  The emulsions are typically filtered to
remove metal fines and other contaminants and  recirculated
through the mills.  The use of deionized water to replace evapo-
rative and carryover  losses and the addition of bactericides and
antioxidizing agents  are practiced  at many plants to increase the
life of the emulsions.  Nevertheless, the emulsions  eventually
become rancid or degraded and must  be eliminated from circulation
either by continuous  bleed or periodic discharge.

Water without additives is also used as a coolant and lubricant
in hot rolling operations.  The water is typically not  recycled,
but used once and discharged.  Mineral oil or  kerosene-based
lubricants are used in cold rolling  operations.  Neat oils  are
used to roll nickel,  zinc, and refractory metals.  Kerosene-based
lubricants are used to roll precious metals.   Often a light  oil
or emulsion is used to lubricate the outside of a tube  during
tube reducing, while  the inside is  lubricated with a heavier oil
or grease.

The steel rolls used  in hot and cold rolling operations may
require periodic machining to remove metal buildup and  to grind
away any cracks or imperfections that appear on the  surface of
the rolls.  The survey of the industry indicated that roll
grinding with an oil-in-water emulsion is common practice.   This
emulsion is usually recycled and periodically  discharged after
treatment with other  emulsified waste streams  at the plant.

The surveyed plants have 131 rolling operations.  Wastewater is
discharged from lead, nickel/cobalt, zinc, precious metals,
titanium, and refractory metals rolling operations.
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Drawing.  Drawing is pulling of metal through a die or succession
of dies to reduce its diameter, alter the cross-sectional shape,
or increase its hardness.  This process is used to manufacture
tube, rod, bar, and wire.  In the drawing of tubing, one end of
an extruded tube is swaged to form a solid point and then passed
through the die.  A clamp, known as a bogie, grips the swaged end
of tubing, as shown in Figure III-6.  A mandrel is then  inserted
into the die orifice, and the tubing is pulled between the man-
drel and die, reducing the outside diameter and the wall thick-
ness of the tubing.  Wire, rod, and bar drawing is accomplished
in a similar manner, but the metal is drawn through a simple die
orifice without using a mandrel.  A diagram of a typical
hydraulic draw bench is presented in Figure III-7.

Drawing may be carried out hot or cold.  In order to ensure uni-
form drawing temperatures and avoid excessive wear on the dies
and mandrels used,  it is essential that a suitable lubricant be
applied during drawing.  A wide variety of lubricants are used
for this purpose.  Heavier draws, which have a higher reduction
in diameter, may require oil-based lubricants, but oil-in-water
emulsions are used for many applications.  Graphite, ground
glass,  soap powders, and soap solutions may also be used for some
of the lighter draws.  Drawing oils are usually recycled until
their lubricating properties are exhausted.

Intermediate annealing is frequently required between draws in
order to restore the ductility lost by cold working of the drawn
product.  Degreasing of the metal may be required to prevent
burning of heavy lubricating oils in the annealing furnaces.

The surveyed plants have 96 drawing operations.  Spent lubricants
are discharged from lead, nickel, zinc, and precious metals
drawing operations.

Extrusion.  In the extrusion process, high pressures are applied
to a cast metal billet, forcing the metal to flow through a die
orifice.  The resulting product is an elongated shape or tube of
uniform cross-sectional area.  If a piercing mandrel is used, or
if the center of the billet or round has been removed by boring
or trepanning, the extruded product is a tube.

There are two basic methods of extrusion practiced in the nonfer-
rous metals forming category:

        Direct extrusion, and

        Indirect extrusion.

The direct extrusion process is shown schematically in Figure
III-8.   A heated cylindrical billet is placed into the ingot
chamber, and the dummy block and ram are placed into position
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behind it.  Pressure  is  exerted  on  the  ram by hydraulic  or
mechanical means,  forcing the  metal  to  flow through  the  die  open-
ing.  The extrusion is sawed off next to  the die,  and  the dummy
block and ingot butt  are released.   Hollow shapes  are  produced
with the use of a  mandrel positioned in the die  opening  so that
the metal is forced to flow around  it.  A less common  technique,
indirect extrusion, is similar,  except  that in this  method,  the
die is forced against the billet  extruding the metal in  the  oppo-
site direction through the ram stem.  A dummy block  is not used
in indirect extrusion.  Diagrams  of  extrusion tooling  equipment
and a typical extrusion press  are presented in Figures III-9 and
111-10, respectively.

Although some metals, such as  lead,  can be extruded  cold,  most
metals are heated  first  to reduce adhesion of the  die  to the
extrusion and the  resulting cracks and  flakes in the extruded
product (galling).  Extrusion  at  elevated temperatures also
reduces the amount of work hardening that  will be  imposed  on the
product.  Heat treatment is frequently  used after  extrusion  to
attain the desired mechanical  properties  and will  be described,
in detail, later in this section.  At some plants, contact
cooling of the extrusion, sometimes  called press heat  treatment,
is practiced as the extrusion  leaves the  press.  This  can be done
in one of three ways:  with a  water  spray  near the die,  by
immersion in a water  tank adjacent  to the runout table,  or by
passing the metal  through a water wall.   Contact cooling water
may also be used to cool extrusion  dummy  blocks, though  no plants
in this category specifically  reported  its  use.  Following an
extrusion, the dummy  block drops  from the press  and  is cooled
before being used  again.  Air cooling is most  commonly  used for
this purpose, but  water may be used  to  quench the  dummy  blocks.

The extrusion process requires the use  of a lubricant  to prevent
adhesion of the metal to the die  and ingot  container walls.   In
hot extrusion, limited amounts of lubricant  are  applied  to the
ram and die ace or to the billet  ends.  For  cold extrusion,  the
the container walls,  billet surfaces, and  die orifice  must be
lubricated with a  thin film of viscous  or  solid  lubricant.   Many
lubricants are used in extruding  the metals  in this  category.
Neat oils are used to lubricate nickel  and  uranium extrusion,
emulsified oils for zirconium  and titanium.   Molten  glass  is also
used as a lubricant in nickel  extrusion;  it  acts as  a  heat insu-
lator as well as a lubricant.  Graphite and  molybdenum disulfide
in an oil or water base are other commonly used  lubricants.   Some
metals (zirconium, beryllium,  nickel) may  be  encased in  a copper
or steel can before extrusion.   The  can prevents galling of  the
core metal and is  reduced to a very  thin  shell as  a  result of the
extrusion.  The thin  shell is  then removed  from the  core metal  by
acid pickling and/or  machining.
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The steel dies used in the extrusion proces require  frequent
dressing and repairing to ensure the necessary dimensional pre-
cision and surface quality of the product.  The  metal  that has
adhered to the die orifice is typically removed  by grinding or
polishing, which is a dry process.

The surveyed plants have 81 extrusion operations.  Wastewater  is
discharged from lead, nickel, precious metals, titanium, refrac-
tory metals, zirconium, and uranium extrusion operations.

Forging.  Forging is deforming metal, usually hot, with  compres-
sive force into desired shapes, with or without  dies.  The actual
forging process is a dry operation.  Five types  of forging are
commonly practiced in the nonferrous metals forming  category:

        Closed die forging,

        Open die forging,

        Rolled ring forging,

        Impacting, and

     -  Swaging.

In each of these techniques, pressure is exerted on  dies or
rolls, forcing the heated stock to take the desired  shape.  The
first three processes are types of hot working;  the  other two are
cold working.

Closed die forging (Figure III-lla), the most prevalent  method,
is accomplished by hammering or squeezing the metal  between two
steel dies, one fixed to the hammer or press ram and the other to
the anvil.  Forging hammers, mechanical presses, and hydraulic
presses can be used for the closed die forging of nonferrous
metals.  The heated stock is placed in the lower die and, by one
or more blows of the ram, forced to take the shape of  the die
set.  In closed die forging, the metal is shaped entirely within
the cavity created by these two dies.  The die set comes together
to completely enclose the forging, giving lateral restraining to
the flow of the metal.

The process of open die forging (Figure Ill-lib) is  similar to
that described above, but in this method, the shape  of the forg-
ing is determined by manually turning the stock  and  regulating
the blows of the hammer or strokes of the press.  Open die forg-
ing requires a great deal of skill and only simple,  roughly
shaped forgings can be produced.  It is primarily used as a
breakdown process to improve the workability of  cast billets and
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to form them into rounds, octagons,  and  other  shapes.   Occasion-
ally the process is used in development  work in which  items  are
produced in small quantities making  the  cost of closed-type  dies
prohibitive.

The process of rolled ring forging is used  in  the  manufacture  of
seamless rings.  In one type of  ring rolling,  a hollow cylindri-
cal billet is rotated between a  mandrel  and pressure roll  to
reduce its thickness and increase  its diameter (Figure III-12a).
In another type of ring rolling, a hollow preform  is mounted on a
saddle/mandrel and reduced in wall thickness by the repeated
blows of a hammer (Figure III-12b).

Impacting, depicted in Figure 111-13, is a  combination of  cold
forging and cold extrusion.  The process is performed  by placing
a cut-off piece of metal in a bottom die.  A top die consisting
of a round or rectangular punch  is fastened to the press ram and
is driven into the metal slug.   This causes the metal  to be
driven up around the top punch.  Usually, the  metal adheres  to
the punch and must be stripped off as the press ram rises.

Swaging, the process of forming  a taper  or  a reduction on  metal
products such as rod and tubing, is  another type of forging.
When swaging is the initial step in  drawing tube or wire,  a  solid
point is formed by repeated blows of one or more pairs of  oppos-
ing dies (this process is also called pointing).   Swaging  can
also be used to reduce the diameter  of tube or wire without  a
subsequent drawing operation, especially when  the  metal being
worked is brittle (e.g., tungsten).  The process of making
tapered bullets from lead wire is also called  swaging.

Proper lubrication of the dies is essential in forging nonferrous
metals.  Colloidal graphite in either a  water  or an oil medium is
usually sprayed onto the dies for this purpose in  the  hot  working
types of forging.  For shallow impressions, a  single spray is
usually adequate.  Dies may be sprayed manually or with automatic
sprays timed with the press stroke.  Deeper cavities may require
a second manual spray or swabbing to ensure that all die surfaces
are covered.

Particulates and smoke may be generated  from the partial combus-
tion of oil-based lubricants as  they contact the hot forging
dies.  In those cases, air pollution controls  may  be required.
Baghouses, wet scrubbers, and commercially  available dry scrub-
bers are in use at nonferrous metals forming facilities.

Oil-in-water emulsions and neat  oils are used  as lubricants  in
swaging processes.   The lubricants are usually filtered to remove
metal fines and other contaminants and recirculated.   As the
lubricants become rancid or degraded they are  discarded, either
through continuous bleed or periodic batch  discharge.
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In addition to use in  lubricants  and  air pollution  control,  water
is used to cool forging dies, clean equipment, and  in heat  treat-
ment.  Quenching is employed to attain  desired metallurgical
properties, usually by plunging hot pieces in a water bath  imme-
diately after forging.  Titanium, refractory metals, zirconium,
magnesium, and uranium forgings are sometimes treated this  way.

The surveyed plants have 81 forging operations.  Wastewatter  is
discharged from lead, nickel, titanium, refractory  metals,
zirconium, magnesium, and uranium forging operations.

Cladding.  A clad metal is a composite  metal containing  two  or
morelayers that have been bonded together.  Some typical clad
configurations are shown in Figure 111-14.  The bonding  may  have
been accomplished by roll bonding (co-rolling), solder applica-
tion (brazing), or explosion bonding.

In the roll bonding process, a permanent bond between two metals
is obtained by rolling under high pressure in a bonding  mill.
The high pressure increases the temperature of the  metals,  pro-
moting codiffusion so that a metallurgical bond forms at the
interface.  In some cases a sintering step is required to
increase bond strength.  Clad metals  consisting of  a base metal
with an overlay or inlay of precious  metal are produced  for  the
electrical/electronics industry and for jewelery applications
(e.g., gold filled wire).  To produce an inlay, a ditch  is  skived
in the base metal, filled with a  strip  of precious  metal and
rolled to form a bond.

The solder application or brazing process is also used to make
clad metals.  The term soldering  is used where the  temperature
range falls below 425°C (800°F).   The term brazing  is used where
the temperature exceeds 425°C (800°F).  In this process, a  thin
layer (film or foil)  of a low melting point metal is placed
between two layers of metal to be bonded.  The three-layer
assembly is then placed into a furnace  at the melting temperature
of the filler metal.   Bonding results from the intimate  contact
produced by the dissolution of a small  amount of the base metal
and the top metal in the molten filler  metal, without direct
fusion of the two metal layers.   Upon cooling, the  clad  material
can be formed by any of the forming operations previously
described.

A third method of producing clad metals, pressure bonding,  is a
combination of roll bonding and solder  bonding.  A  three-layer
assembly of solder and the metals to be bonded is placed into a
furnace, just as in solder bonding.   However, the heating is
accompanied by the application of pressure, as in roll bonding.
The bonded metal may be cooled by a water spray after it is
removed from the bonding furnace.
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In explosion bonding, the metallurgical joining of two or more
metals is accomplished by the force of a carefully detonated
explosion.  The explosion moves progressively across the surface
of the cladder metal, accelerating it across a "standoff dis-
tance" and against the backer metal.  The force of the explosion
shears away the oxide- and nitride-containing surface layers of
both metals and causes them to behave as a fluid.  The sheared
away layers are jetted out ahead of the point where the two
metals collide.  As the collision point advances, the jetting
action produces metallurgically clean surfaces which, under
extreme pressure, allow normal interatomic and intermolecular
forces to create an electron-sharing bond.  The result is a cold
weld, with a characteristic wave pattern at the weld interface
caused by the turbulent plastic metal flow after collision.

Explosion bonding is used to produce clad plate, sheet and tubes,
and to form structural transition joints.  Clad plate can be used
in the gauge at which it is formed or it can be rolled down to
final gauge.

Except for pressure bonding which uses some contact cooling
water," all of the cladding processes described above are dry pro-
cesses.  The main source of process wastewater in metal cladding
operations is in cleaning the metal surfaces prior to bonding.
For small batch operations, the cleaning steps can involve dip-
ping the metal into small cleaning bath tanks and hand rinsing
the metal in a sink.  For larger continuous operations, the metal
may be cleaned in a power scrubline.  In a typical scrubline,
metal strip passes through a detergent bath, spray rinse, acid
bath, spray rinse, rotating abrasive scrub brushes, and a final
rinse.  The metal may then pass through a heated drying chamber
or may air dry.

Metal Powder Production.  For regulatory convenience, the produc-
tion of all metal powders, including iron, steel, copper, and
aluminum, has been included in this category.  Atomization,
depicted in Figure 111-15, is the most common method of producing
metal powders.  In this process, a stream of fluid, usually water
or gas, impinges upon a molten metal stream, breaking it into
droplets which solidify as powder particles.  The size and shape
of atomized powder is determined by jet configuration, jet
design, composition of the impinging medium, and composition of
the metal.  Generally, gas atomization is used to produce
spherical particles while water atomization is used to produce
irregularly shaped particles, required for powder metallurgy
applications in which a powder is cold pressed into a compact.
In addition, cooling times play an important role in determining
particle configuration.  Annealing usually accompanies atomiza-
tion for the purpose of rearranging internal crystal structures
of metal powders, and consequently improving strength.
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Powders are also produced by disintegration of  solid metal  into
powder by mechanical comminution.  This process is used  for brit-
tle ores or chemically embrittled metals.  It is also used  to
produce powder from turnings and other scrap of more ductile
metals.  The most commonly utilized pieces of mechanical  reduc-
tion equipment are ball mills, vortex mills, hammer mills,  disc
mills, and roll mills.  Powder production with  this type  of
machinery tends to produce angular, irregular, rod-like,  and
flaked physical structures.  Occasionally, powders are milled  in
a water slurry.

In addition to its use as an atomization medium and a milling
slurry, water is used in the equipment used to  control particu-
late air pollution from metal powder production operations  (wet
scrubbers and electrostatic, precipitators) .

Surveyed plants produce powders from all of the metals formed  by
traditional means except titanium and rhenium (see Table  III-4).
Iron, stainless steel, and copper alloy powders are produced in
the largest quantities and by the greatest number of manufac-
turers.  The high demand for these metal powders is caused by
their large-scale applications in the auto manufacturing  and
machining industries.  After iron and steel, copper, and  alumi-
num, and their alloys, the metal powders produced in the  largest
quantity are tungsten and tungsten carbide, lead and its  alloys,
and nickel and its alloys.  Wastewater is discharged from nickel,
precious metals, iron and steel, copper, aluminum, and refractory
metals powder production operations.

Production of Powder Metallurgy Parts.  Metal powders are formed
into parts by a "press and sinter" operation, consisting  of
blending metal powders, compacting the mixture in a die and then
heating or sintering the compacted powder in a controlled atmo-
sphere to bond the particles into a strong shape.  A diagram of
two pressing configurations is presented in Figure 111-16.
Compaction forces range from 1 to 350 kkg (1.1 to 385 tons).

Following compaction, "green" metal powder compacts are sent to a
furnace for sintering.  Furnace temperatures are held below the
melting point of the metal being sintered, from 1,000°C to
1,800°C.

To prevent formation of oxide films on particle surfaces  (which
inhibit formation of metallic bonds between particles) an inert
atmosphere or vacuum must be maintained inside the sintering
furnace.  Hydrogen,  although expensive, is the most commonly used
inert gas.  Alternatively, vacuum systems capable of maintaining
a pressure of 10 MPa (2.96 x 10~6 in Hg) are typically
employed.  As an extra precaution against contamination with air,
the vacuum furnace and its inlet and outlet ports may be  jacketed
with inert gas.
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During the sintering process, air present  in  the  metal  compacts
before sintering is exhausted, thus  decreasing the porosity  of
the compact and increasing  its strength.   Further strengthening
occurs as surface metal atoms recrystallize,  realigning  into  a
close crystal lattice pattern.

For some applications, porosity may  be  further decreased by  the
process of infiltration, in which a  liquid phase  is allowed  to
penetrate the pores between metal particles during sintering.
The liquid used may be a nonalloying metal with a lower  melting
point than the compacted metal, oil, or an anti-friction polymer
such as polytetrafluoroethylene.  Infiltration with copper is
commonly used in manufacturing tungsten and molybdenum  compacts
for electrical contacts.

In some cases, a final mechanical fabrication step, repressing or
coining, is used.  In this process,  the sintered  compact is
deformed in a closed die to produce  a final shape.  Pressures
applied during coining range up to 700  MPa (100,000 psi),
depending on the size and shape of the  die and the nature of  the
metal compact being formed.  In some cases a  lubricant  is used to
prevent the compact from adhering to the sizing die.  This
lubricant is usually not discharged  from the  process, but lost
through drag-out on the parts.  Sintered metal compacts  also  may
be rolled, extruded, or drawn.

Finishing operations used subsequent to the forming of parts  from
metal powder include deburring, steam oxidation,  and treatment
with rust inhibitor.  Deburring may  be  sand blasting or  shot
peening, both of which are dry, or tumbling with  grit suspended
in water.  Because of their porosity, parts made  from iron and
steel powders may oxidize excessively.  To prevent this, steam
treatment to produce a protective oxide layer or  treatment with
rust inhibitors are commonly used.   Air pollution from the steam
treatment operation is sometimes controlled by wet scrubbers.

As described above, process wastewater  is  generated in  the pro-
duction of powder metallurgy parts after the pressing and sinter-
ing steps.  In addition to tumbling  and steam treating,  the parts
may be cleaned or degreased (alkaline,  detergent, or solvent)
prior to packing and shipping.  These cleaning operations are
identical to those performed on other metal products and will be
described in detail later in this section.

Operations Associated With Nonferrous Metals Forming

Casting.  Casting consists of filling a shaped container or mold
with molten metal so that upon solidification, the shape of the
mold is reproduced.  Only casting which is an integral part of
nonferrous metals forming is included in the category, that is,
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shot-casting and casting of billets,  ingots, bars,  and  strip
which are subsequently formed on-site.  Casting performed  as  part
of a smelting or refining operation  is  included in  the  nonferrous
metals manufacturing point source category, 40 CFR  Part 421.
Casting of parts is included in 40 CFR  Part 464, proposed  on
November 15, 1982 at 47 FR 51512.

The choice of casting method depends  on the metal or  alloy being
cast and the ultimate use of the cast form.  The casting methods
used in nonferrous metals forming can be divided into four
classes:

        Stationary casting;

        Direct chill casting, including arc casting;

        Continuous casting;

        Shot casting.

The method of casting most widely practiced at nonferrous  metals
forming plants is stationary or pig  casting which allows for
recycle of in-house scrap.  In this  process, molten metal  is
poured into cast iron molds and allowed to air cool.  Lubricants
are not usually required.  Although  water may be sprayed onto the
molten metal to increase the cooling  rate, this generally  does
not result in any discharge.

Direct chill casting is characterized by continuous solidifica-
tion of the metal while it is being  poured.  The length of an
ingot cast using this method is determined by the vertical
distance it is allowed to drop rather than by mold  dimensions.

As shown in Figures 111-17 and 111-18,  molten metal is  tapped
from the melting furnace and flows through a distributor channel
into a shallow mold.  Noncontact cooling water circulates  within
this mold, causing solidification of  the metal.  The  base  of  the
mold is attached to a hydraulic cylinder which is gradually
lowered as pouring continues.  As the solidified metal  leaves the
mold, it is sprayed with contact cooling water to reduce the  tem-
perature of the forming ingot.  The  cylinder continues  to  descend
into a tank of water, causing further cooling of the  ingot as it
is immersed.  When the cylinder has  reached its lowest  position,
pouring stops and the ingot is lifted from the pit.   The
hydraulic cylinder is then raised and positioned for  another
casting cycle.

In direct chill casting, lubrication  of the mold is required  to
ensure proper ingot quality.  Lard or castor oil is usually
applied before casting begins and may be reapplied  during  the
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drop.  Much of the lubricant volatilizes  on  contact with  the
molten metal, but contamination of the contact cooling water with
oil and oil residues does occur.

Arc casting is a form of direct chill casting used for refractory
metals, metals with melting points too high  to easily cast by
conventional techniques  (tungsten, molybdenum, tantalum,
columbium, vanadium, and rhenium).  The bars serve as consumable
electrodes in an arc-melting process.  The end product of refin-
ing these metals is a powder which can be compacted and sintered
into solid bars.  Under vacuum, in an appropriate furnace con-
sisting of a water-cooled copper crucible, the preformed  bars
form an electrode for striking a high current, low voltage arc
between the bar and a starting pad of metal.  As the bar  is
progressively melted, molten metal falls  through the arc  and
forms an ingot which gradually freezes into  solid form.   The
ingot may be remelted to improve purity or directly fabricated  to
product form.

Many nonferrous metals forming plants use continuous casting
instead of, or in addition to, direct chill  casting methods.
Unlike direct chill casting, no restrictions are placed on the
length of the casting, and it is not necessary to interrupt pro-
duction to remove the cast product.  The use of continuous
casting eliminates or reduces the degree  of  subsequent rolling
required.

A relatively new technology, continuous casting of metal  first
came into practice in the late 1950's.  Since then, improvements
and modifications have resulted in the increased use of this pro-
cess.  Current applications in this category include the  casting
of sheet and strip.  Because continuous casting affects the
mechanical properties of the metal cast,  the use of continuous
casting is limited by the metals and alloys used, the nature of
subsequent forming operations, and the desired properties of the
finished product.  In applications where continuous casting can
be used, the following advantages have been  cited:

        Increased flexibility in the dimensions of the cast
        product;

        Low capital costs, as little as 10 to 15 percent  of the
        cost of conventional direct chill casting and hot rolling
        methods;  and

        Low energy requirements, reducing the amount of energy
        required to produce comparable products by direct chill
        casting and rolling methods by 35 to 80 percent,  depend-
        ing on the product being cast.
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In addition, the use of continuous casting techniques has been
found to significantly reduce or eliminate the use of contact
cooling water and oil lubricants.

Two continuous casting processes are commonly used in the indus-
try.  Methods in use at a particular plant will vary somewhat,
but they are similar in principle to the processes diagrammed
schematically in Figures 111-19 and 111-20.  Continuous sheet
casting, shown in Figure 111-19, substitutes a single casting
process for the conventional direct chill casting, scalping,
heating, and hot rolling sequence.  The typical continuous  sheet
casting line consists of melting and holding furnaces, a caster,
pinch roll, shear, bridle, and coiler.  Molten metal flows  from
the holding furnace to the caster headbox.  The level of molten
metal maintained in the headbox causes the metal to flow upwards
through the top assembly, which distributes it uniformly across
the width of the casting rolls.  The metal solidifies as it
leaves the tip and is further cooled and solidified as it passes
through the internally water-cooled rolls.  It leaves the caster
as a formed sheet and successively passes through pinch rolls, a
shear, and a tension bridle before being wound into a coil.  The
cooling water associated with this method of continous sheet
casting never comes into contact with the metal.

Continuous strip casting is pictured in Figure 111-20.  Molten
metal flows from a casting pot through an open-ended die.  The
die is water cooled and has the same cross-section as the cast
strip.  As the metal leaves the die, it descends vertically past
water sprays, guided by rolls.  The strip can be coiled as  it is
cast, or small sections can be cut from the end as the strip
continues to grow.

Metal shot is commonly produced by casting of a number of metals,
including lead and precious metals.  In the shot casting process
pictured in Figure 111-21, metal ingots are melted in a furnace,
the furnace is tapped, and the molten metal is poured down a
trough or into a heated mold.  At the bottom of the trough  or
mold is a shot mold plate, typically made of steel or a ceramic
material, which has holes punched in it.  The size of the shot
pellets is determined by the size of the holes.

As the molten metal flows through the holes in the shot mold it
forms droplets.  The droplets become round as they descend
through several inches of air, then fall into a tank of water for
quick quenching.  This water may be stagnant or circulating.  In
some shot casting operations a wetting agent is added to the
quench water, altering the surface tension and ensuring the
formation of spherical shot particles.  To prevent excessive loss
of quench water through evaporation and to maintain the water
temperature required by some operations, the quench water may be
cooled using noncontact cooling water in a jacket around the
tank.
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Cast shot may be processed through a sizing operation to  remove
the irregular shaped particles.  Reject shot is usually remelted
and recast.

In addition to its use to cast metal, water is used  in equipment
which controls air pollution from stationary casting and  shot-
sizing operations.  Water is also used to wash billets immedi-
ately after casting.  In vapor form, water is used to draw  a
vacuum from some melting furnaces.  The condensed steam,  which
may carry any material volatilized during melting, is
recirculated with a periodic blowdown.

The surveyed plants have 88 casting operations.  Wastewater is
discharged from lead, nickel, zinc, precious metals, and
refractory metals casting operations.

Heat Treatment.  Heat treatment is an integral part  of nonferrous
metals forming practiced at nearly every plant in the category.
It is frequently used both in-process and as a final step in
forming to give the metal the desired mechanical properties.
There are four general types of heat treatment:

        Homogenizing, to increase the workability and help  con-
        trol recrystallization and grain growth following
        casting;

        Annealing, to soften work-hardened and heat-treated
        metals, relieve stress, and stabilize properties  and
        dimens ions;

        Solution heat treatment, to improve mechanical properties
        by maximizing the concentration of hardening contaminants
        in solid solution; and

        Artificial aging, to provide hardening by precipitation
        of constituents from solid solution.

Homogenizing, annealing, and aging are dry processes, while solu-
tion heat treatment typically involves significant quantities of
contact cooling water.

During casting, large crystals of intermetallic compounds are
distributed heterogeneously throughout the ingot.  Homogeni-
zation of the cast ingot provides a more uniform distribution of
the soluble constituents within the metal.  By reducing the brit-
tleness caused by casting, homogenization prepares the ingot for
subsequent forming operations.  The need for homogenization and
the time and temperatures required are dependent on  the metal and
alloy involved, the ingot size, the method of casting used, and
the nature of the subsequent forming operations.  Typically, the
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ingot is heated to an appropriate temperature and held at  that
temperature for four to 48 hours.  The ingots are then allowed to
air cool.

Annealing is used by plants in the nonferrous metals forming
category to remove the effects of.strain hardening or solution
heat treatment.  In the annealing operation, the metal is  raised
to its recrystallization temperature.  Nonheat-treatable,  strain-
hardened metals need only be held in'the furnace until the
annealing temperature is reached; heat-treatable metals usually
require a detention time of two to three hours.  In continuous
furnaces such as that pictured in Figure 111-22, the metal is
raised to higher temperatures and detained in the furnace  for 30
to 60 seconds.  Once removed from the annealing furnace, it is
essential that the heat-treatable metals be cooled at a slow,
controlled rate.  After annealing, the metal is in a ductile,
more workable condition suitable for subsequent forming opera-
tions.  Some metals are annealed in a protective (nonoxidizing)
atmosphere to prevent discoloration of the bright surface.  This
process is called bright annealing and is commonly used to anneal
silver and its alloys.  Typical protective atmospheres are
dissociated ammonia,  hydrogen, and nitrogen.

Solution heat treatment, also referred to as solution annealing,
is accomplished by raising the temperature of a heat-treatable
metal to the eutectic temperature, where it is held for the
required length of time, then quenching it rapidly.  As a  result
of this process, the metallic constituents, in the metal are held
in a super-saturated solid solution, improving the mechanical
properties of the metal.  The required length of time the  metal
must be held at the eutectic temperature varies from one to 48
hours.  Certain nonferrous metal alloys can be solution heat
treated immediately following extrusion and forging.  In this
procedure, known as press heat treatment, the metal is extruded
or forged at the required temperatures and quenched with contact
cooling water as it emerges from the die or press.

The quenching techniques used in solution heat treatment are fre-
quently critical in achieving the desired mechanical properties.
The sensitivity of metals and alloys to quenching varies,  but
delays in transferring the product from the furnace to the
quench, a quenching rate that is incorrect or not uniform, and
the quality of the quenching medium used can all have serious
detrimental effects.   With few exceptions, contact cooling water
is used to quench solution heat treated products.  Spray or flush
quenching is sometimes used to quench thick products.  Solution
heat treated forgings of certain metals can be quenched using an
air blast rather than a water medium.  Air quenching can also be
used for certain extrusions following press heat treatment.  The
continuous annealing operation depicted in Figure 111-22 contains
a spray quench zone.
                               342

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Artificial aging, also known as precipitation heat  treatment,  is
applied to some nonferrous metals in order to cause precipitation
of super-saturated constituents in  the  metal.  The  metal  is
heated to a relatively low temperature  for several hours  and then
air cooled.  Artificial aging is frequently used  following solu-
tion heat treatment to develop the  maximum hardness and ultimate
tensile and yield strength in the metal.  For certain  metals,  the
mechanical properties are maximized by  sequentially applying
solution heat treatment, cold working,  and artificial  aging.

Chemical Surface Treatments.  Surface treatment operations per-
formed as an integral part of forming processes are within the
scope of the nonferrous metals forming  category.  For  the pur-
poses of this regulation, surface treatment of nonferrous metals
is considered to be an integral part of nonferrous  metals forming
whenever it is performed at the same plant site at which
nonferrous metals are formed.

A number of chemical treatments may be  applied to nonferrous
metals after they are formed.  The  objective of these  treatments
is to in some way alter the surface of  the metal, either  by
removing some of it or changing its characteristics.   Wastewater
discharges from these operations are generated when these solu-
tions must be replaced with fresh chemicals and in rinsing opera-
tions used to remove residual solution  from the formed metal
after treatment.  The contaminants  in the spent solution  and
rinse water are a function of the chemicals used  to make  the
solutions and the metal treated.  Most  of the contaminants are
acids, bases, and metal salts.

The most frequently used chemical surface treatments are  designed
to remove the surface layer of oxidized metal created  during
forming of nonferrous metals at elevated temperatures.  The most
common method of removing this layer is to dissolve it in acid in
an operation known as pickling, brightening, etching,  or  acid
surface treatment.  In addition to  removing the oxide  layer from
a metal surface, this treatment will remove burned-on  lubricants
and any other substances not entirely removed by  solvent  or
alkaline cleaning.

Pickling operations can be batch operations in which formed parts
are moved from tank to tank to be dipped in acid baths, overflow-
ing rinse tanks and spray chambers.  The rinses are usually plain
water, but occasionally ammonia solutions are used.  A diagram of
a bulk product pickling tank is presented in Figure I11-23.  A
continuous surface treatment linet  consisting of a series of
tanks, can be used to provide strip metal with a  series of
treatments.  A diagram of a typical continuous strip pickling
line is presented in Figure 111-24.
                               343

-------
Sulfuric, hydrochloric, ammonium bifluoride, hydrofluoric,  phos-
phoric, nitric, and chromic acids or acid mixtures are commonly
used as pickling solutions.  The pickling process may be  chemical
(formed metal is immersed in a tank of pickling solution  and held
until scale is removed) or electrochemical  (electric current is
forced through the pickling bath to speed up the pickling
process).  Acid concentration, bath temperature, and process time
depend on the type of metal or alloy being  treated, the compo-
nents of the pickling solution, and the amount of scale to  be
removed.

Acid consumed during pickling operations must be periodically
replenished.  Dissolved metal salts in the  pickling solution
gradually reduce pickling efficiency.  Spent pickle liquor  may be
concentrated by high temperature precipitation of metal salts and
recycled to minimize acidic waste discharge.

Brightening solutions for nonferrous metals and alloys usually
contain mixtures of two or more acids:  sulfuric, phosphoric,
nitric, chromic, or hydrochloric.  Acid ratios and concemtrations
vary widely.  Dipping times range from 5 seconds to greater than
5 minutes.   Other chemicals such as metal salts, glycerol,  or
ethylene glycol also may be added to brightening solutions.

The layer of oxide scale formed on nickel,  cobalt, and certain
refractory metals is very difficult to remove with acid surface
treatments alone.  Consequently these metals are treated  by
dipping the formed parts into molten salts  (usually sodium
chloride, potassium chloride, and sodium hydroxide) at 480  to
540°C for 15 minutes or more, then rinsing  and quenching  them in
a water bath.  The scale loosened by the salt treatment is
removed by acid surface treatment followed  by a rinse.

Anodizing and chemical conversion coating are used to change the
characteristics of the surface of formed metal by chemically or
electrochemically depositing an inorganic coating to the  metal.
These coatings are applied for corrosion protection and in
preparation for painting.

Anodizing is an electrochemical oxidation process which forms an
insoluble oxide of the metal on the formed  metal surface.   The
oxide coating is used to provide corrosion  resistance, decorative
surfaces, a base for applying other coatings, and special elec-
trical or mechanical properties.  Anodizing is applied by immers-
ing the metal form in an acid solution (containing fluoride,
phosphate,  chromate, and/or sodium ions) and passing a direct or
alternating electrical current through the  metal form.  After
anodizing,  parts are rinsed in cold then hot water to facilitate
drying.
                               344

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The metal oxide  layer  formed on  the  metal  surface  (anode)  is
extremely thin and nonporous.  Electrolytic anodizing solutions
are composed of  dilute sulfuric  acid or  dilute  chromic  acid.

Chemical conversion  coatings are applied to previously-deposited
metal or base metal  for increased protection, lubricity, or in
preparation for  another special  coating  or to achieve a special
surface appearance.  Typical operations  include  chromating to
form a protective  film, and phosphating which is used to provide
a good base for  paints and other  organic coatings, to lubricate
the metal surface  before cold  forming or drawing,  and to impart a
corrosion resistance.  When chromating,  the formed metal surface
is coated by immersion or wetting with a solution  containing
hexavalent chromium  and active organic and inorganic compounds.
When phosphating,  the  metal surface  is wetted,  usually  by  immer-
sion, with a phosphate solution  which reacts with  the metal
surface.

Surface treatments and their associated  rinses  are usually
combined in a single line of successive  tanks.   In some  cases,
rinsewater from  one  treatment  is  reused  in the  rinse of  another.
Surface treatment  rinses are the  major source of wastewater in
the nonferrous metals  forming  category.  The surveyed plants have
142 surface treatment  operations, many plants having several.
Wastewater is discharged from  operations used to treat  nickel,
cobalt, zinc, beryllium, precious metals, titanium, refractory
metals, zirconium, hafnium, magnesium, and uranium.  Wastewater
is also generated by the equipment used  to control air  pollution
from surface treatment of nickel, titanium, refractory  metals,
and uranium.

Alkaline Cleaning.  Alkaline cleaning involves  the removal of
oil, grease,and dirt  from the surface of a formed metal product
using water with a detergent or  other dispersing agent.  Ultra-
sonic vibration  is sometimes used in conjunction with chemical
cleaners to clean wire and other  fine parts.

Alkaline cleaners are  formulations of alkaline  salts, water, and
surfactants.   Salts used include  sodium hydroxide, sodium ortho-
silicate, trisodium phosphate,  sodium metaborate, sodium carbon-
ate, and sodium polyphosphates.  Frequently, two or more of these
salts are blended to form the  cleaning solution.

Uninhibited alkaline cleaners will attack many  nonferrous metals.
Therefore, inhibiting  compounds  which coat the  metal with a thin
film to prevent etching, pitting, or  tarnishing are typically
added to the cleaning  solution.

Alkaline solutions are commonly  used to  clean formed metal parts
prior to chemical treatment or as a  final step before packaging
                               345

-------
the product.  The type of solution used depends on the  metal  to
be cleaned and the contaminant to be removed.  Alkaline cleaning
is generally preceded by solvent cleaning via vapor degreasing or
cold cleaning.  Following this step, formed metal parts are
immersed in or sprayed with the alkaline cleaning solution.
Solution concentration, temperature, and immersion time vary  with
metal type.

Following alkaline treating, metal parts are rinsed with water.
Rinsewater is often warm, to decrease drying time and reduce
water spotting.  Spent solutions and rinses are discharged from
alkaline cleaning processes.  Streams are frequently combined
with acid waste streams to adjust wastewater pH prior to
discharge.  In addition to cleaning nonferrous metals after they
are formed, alkaline cleaning is used to prepare metals for
cladding.  The process may be hand cleaning or use a power
scrubline, as described in the cladding discussion above.

Alkaline cleaning is associated with lead, nickel, zinc, precious
metals, titanium, refractory metals, and zirconium forming
operations.

Decreasing.  Solvent cleaners are used to remove lubricants (oils
ana greases) applied to the surface of nonferrous metals during
mechanical forming operations.  Basic solvent cleaning  methods
include straight vapor degreasing, immersion-vapor degreasing,
spray-vapor degreasing, ultrasonic vapor degreasing, emulsified
solvent degreasing, and cold cleaning.

Solvents most commonly used for all types of vapor degreasing are
trichloroethylene, 1,1,1-trichloroethane, methylene chloride,
perchloroethylene, and various chlorofluorocarbons.  Solvent
selection depends on the required process temperature (solvent
boiling point), product dimension, and metal characteristics.
Contaminated vapor degreasing solvents are frequently recovered
by distillation.  The sludge residue generated is toxic and may
be flammable, requiring appropriate handling and disposal pro-
cedures .

Straight vapor degreasing uses hot vapors of chlorinated solvents
to remove oils, greases, and waxes.  A vapor degreasing unit
typically consists of an open steel tank as shown in Figure
111-25.  Solvent at the bottom of the tank is heated to boiling,
generating hot vapors.  The heavy vapors fill the tank and are
condensed at the top of the tank by cooling coils, thus contain-
ing the solvent vapors below the condensing coil level.  Cooled
nonferrous metal forming products are lowered into the hot vapor
bath where solvent vapors condense onto the metal surface.  Oils
and greases are dissolved from the metal surface by the solvent.
                               346

-------
Immersion-vapor degreasing is used  to  clean  metal parts  coated
with large quantities of oil, grease,  or hard-to-remove  soil.
Solvents used are the same as those used in  straight vapor
degreasing.  Metal parts are first  immersed  in boiling solvent,
then in a clean cool solvent rinse, and finally  in  solvent
vapors.  Immersion in cool solvent  rinses residual  matter left
from the first cleaning and lowers  the metal  temperature so  that
vapor rinsing will be effective.  Clean solvent  for the  cool
rinse is supplied by condensation of pure vapors in the  condenser
section of the degreaser.  From the condenser, solvent flows  into
the cool rinse chamber and overflows into the sump  where it  is
again vaporized.

When mild scrubbing action is required to remove grease  or dirt,
spray-vapor degreasing is used.  In this process, clean  solvent
is pumped from the degreaser condenser to a  spray lance.  Parts
are impingement-sprayed with clean  solvent to loosen soil and
insoluble material.  Spray lances may  be fixed so that parts  move
in front of them for impingement, or may be  hand-held so that an
operator may direct the spray.  Parts  enter  the  degreaser's vapor
phase, pass through the spray bank, and finally  go  through a
final vapor rinse.

Ultrasonic vapor degreasing is similar to immersion-vapor
degreasing, with ultrasonic transducers built into  the clean
solvent rinse tank.  Metal parts are initially cleaned by immer-
sion in boiling solvent, then immersed in cool solvent for ultra-
sonic scrubbing, followed by a vapor or spray-vapor rinse.

During ultrasonic scrubbing, high frequency  sound waves  are
transmitted through the solvent to  the part,  producing rapid
agitation and cavitation (formation/implosion of solvent
bubbles).  The scrubbing action caused by solvent cavitation
efficiently removes particulate and insoluble materials  from  the
metal surface.

The ultrasonic frequency used depends  on the  type of part being
cleaned, the degree of soil contamination, and the  solvent used.
The most commonly used frequency range is 20,000 to 50,000 cycles
per second.

Emulsified solvent degreasing is primarily used  to  remove both
water- and oil-soluble soils from complex mechanical parts.
Chlorofluorocarbons are typically employed as solvents in this
process.  Reclamation of emulsified solvents  is  generally not
economical.

Water contaminated with salts and other water-soluble contami-
nants is periodically removed from  the system and replaced with
clean water to renew the system's cleaning strength.
                               347

-------
Cold solvent cleaning involves hand wiping,  spraying,  and  immer-
sion of metal parts in solvents to remove oil, grease, and  other
contaminants from the metal surface.  Petroleum and  chlorinated
hydrocarbons are typically used in cold cleaning operations.
Contaminated solvents are reclaimed by distillation  or are  dis-
posed of via contractor.

Mechanical Surface Treatments.  Mechanical surface treatments  are
used,like chemicalsurface treatments, to alter the surface of
formed nonferrous metals.  Machining, grinding, polishing,  tumbl-
ing  (barrel finishing),  and burnishing are commonly  used
mechanical surface treatments.

Machining is the general process of removing stock,  in the  form
of chips, from a workpiece by forcing a cutting tool through the
workpiece.  Machining operations such as turning, milling,  drill-
ing, boring, tapping, planing, broaching, sawing and cutoff,
slitting, shaving, threading, reaming, shaping, slotting,
hobbing, filing, and chamfering are included in this definition.

Grinding is the process  of removing stock from a workpiece  by  the
use of a tool consisting of abrasive grains held by  a  rigid or
semirigid binder.  The tool is usually in the form of  a disk (the
basic shape of grinding wheels), but may also be in  the form of a
cylinder, ring, cup, stick, strip, or belt.  The most  commonly
used abrasives are aluminum oxide, silicon carbide,  and diamond.
The processes included in this unit operation are sanding  (or
cleaning to remove rough edges or excess material),  surface
finishing, and separating (as in cut-off or  slicing  operations).

Polishing is an abrading operation used to remove or smooth out
surface defects (scratches, pits, tool marks, etc.)  that
adversely affect the appearance or function  of a part.  Polishing
is usually performed with either a belt or wheel to  which an
abrasive such as aluminum oxide or silicon carbide is  bonded.
Both wheels and belts are flexible and will conform  to irregular
or rounded areas where necessary.  The operation usually referred
to as buffing is included in the polishing operation.

Burnishing is the process of finish sizing or smooth finishing a
workpiece (previously machined or ground) by displacement,  rather
than removal, of minute surface irregularities.  It  is accom-
plished with frictional  contact between the workpiece  and some
hard material, such as hardened metal balls.

Machining, grinding, polishing, and burnishing operations com-
monly use a recirculated oil-water emulsion  to cool  and lubri-
cate the contact between metal and finishing tool.   Spent or
rancid lubricant is discharged periodically.
                               348

-------
Tumbling or barrel finishing  is a  controlled  method  of  processing
parts to remove burrs, scale, flash, and oxides as well  as  to
improve surface finish.  Widely used as a  finishing  operation  for
many parts, it obtains a uniformity of surface  finish not possi-
ble by hand finishing.  For large  quantities  of small parts  it is
generally the most economical method of cleaning and surface
conditioning.

Parts to be finished  are placed in a rotating barrel or  vibrating
unit with ceramic or  metal slugs or abrasive  media, water or oil,
and usually some chemical compound to assist  in the  operation.
As the barrel rotates slowly, the  upper layer of the work is
given a sliding movement toward the lower  side  of the barrel,
causing the abrading  or polishing  action to occur.  The  same
results may also be accomplished in a vibrating unit, in which
the entire contents of the container are in constant motion.
VThen the parts have been sufficiently deburred  they  are  drained
in a basket or shaker table and transferred to  an oven  for
drying.  The tumbling solution is  usually  used  once  and  then
discarded.

Sawing.  Sawing is cutting a workpiece with a band, blade,  or
circular disc having  teeth.   It may be required for  a number of
metal forming processes.  Before ingots can be used as  stock for
rolling or extrusion, the ingot may require scalping or  sawing to
a suitable length.  Following processes such  as rolling, extru-
sion, and drawing, the metal  products may  be  sawed.  The circular
saws and band saws used generally  require  a cutting  lubricant  in
order to minimize friction and act as a coolant.  Oil-in-water
emulsions or mineral-based oils are usually applied  to  the  sides
of the blade as a spray.  In  some  cases, a heavy grease  or  wax
may be used as a saw  lubricant.  Normally, saw  oils are  not
discharged as a wastewater stream.  The lubricants frequently  are
carried over on the product or removed together with the saw
chips for reprocessing.  In some cases, however, recycle and
discharge of a low-volume saw lubricant stream  is practiced.

Product Testing.  Various product  testing  operations are used  to
check nonferrous metals parts for  surface  defects or subsurface
imperfections.  Parts are submerged in a water bath and  subjected
to ultrasonic signals, or in  the case of tubing, pressurized with
air.  Piping and tubing may also be filled with water and pres-
surized to test their integrity.   Product  testing operations are
sources of wastewater because the  spent water bath or test  media
must be periodically  discarded due to the  transfer into  the
testing media of oil  and grease, solids, and  suspended  and  dis-
solved metals from each product tested.
                               349

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B.  THREE-HIGH  CONTIGUOUS  ROLLING  MILL
             Figure III-3



   COMMON  ROLLING MILL CONFIGURATIONS
                  352

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            DIRECT EXTRUSION
                   357

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                  PISTON  ROD
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                    TOP  DIE
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                     ANVIL
A. CLOSED  DIE FORGING
B. OPEN  DIE  FORGING
                  Figure III-ll
                    FORGING
                       360

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EDGING
ROLLS
                                  PRESSURE ROLL
                     MANDREL
              A,   ROLLED RING FORGING
                                     It
             B,   SADDLE/MANDREL FORGING
                   Figure 111-12

                   RING ROLLING
                       361

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Figure 111-13
  IMPACTING
     362

-------
           INLAY EDGE STRIPE
            STRIPE INLAY
             2-PLY CLAD
             4-PLY CLAD
      Figure  111-14



SOME CLAD CONFIGURATIONS
           363

-------
         MOLTEN METAL
                ATOMIZING AGENT,
                GAS OR LIQUID
                    QUENCHING MEDIUM
Figure  111-15
 ATOMIZATION
     364

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 A.   Pressing  In Single-End  Die
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          Figure 111-16



POWDER METALLURGY DIE COMPACTION
              365

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                  Coreless Induction Furnace
                          L
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                                                    Equipment
                                   Er     Water Cooled Molds
                                        Mold Table
Tank Water
                      Hydraulic Ram
                    Figure III-18

         DIRECT  CHILL  (B.C.)  CASTING UNIT
                          367

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        Figure  111-20
  CONTINUOUS STRIP  CASTING
             369

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MELTING POT
                           MOLLEN METAL
                              SHOT MOLD
                                 WATER LEVEL
                                __  RECIRCULATING WATER
         DRAIN
                                      RECIRCULATION PUMP
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                   Figure 111-21
                   SHOT CASTING
                        370

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                                                  Ventilation
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                             Figure 111-23

                         BULK PICKLING TANK
                                 372

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      CONDENSATE-
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                                         WATER JACKET
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                                   _, -SOLVENT
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                      Figure 111-25
                     VAPOR DECREASING
                            374

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               Table III-l

METAL TYPES EXCLUDED FROM REGULATION UNDER
 PARAGRAPH 8 OF THE SETTLEMENT AGREEMENT
            Cadmium (Cd)

            Chromium (Cr)

            Gallium (Ga)

            Germanium (Ge)

            Indium (in)

            Lithium (Li)

            Manganese (Mn)

            Neodymium (Nd)

            Praseodymium  (Pr)
                   375

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                        Table III-2

          METAL TYPES COVERED UNDER THE NONFERROUS
                  METALS FORMING CATEGORY
Beryllium (Be)

Bismuth (Bi)

Cobalt (Co)

Columbium (Niobium) (Cb (Nb))

Gold  (Au)

Hafnium (Hf)

Lead  (Pb)

Magnesium (Mg)

Molybdenum  (Mo)

Nickel (Ni)

Palladium (Pd)
Platinum (Pt)

Rhenium (Re)

Silver (Ag)

Tantalum (Ta)

Tin (Sn)

Titanium (Ti)

Tungsten (W)

Uranium-Depleted (U)

Vanadium (V)

Zinc (Zn)

Zirconium  (Zr)

Iron and and Steel, Copper,
  and Aluminum Metal Powder
  Production and Powder
  Metallurgy Operations
                            376

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                                                                     378

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                            Section IV

                    INDUSTRY SUBCATEGORIZATION
In developing regulations for the nonferrous metals forming
category, the Agency considered whether different  effluent limi-
tations and standards are appropriate for different segments of
the category.  The regulations are technology based.  If uniform
regulations are to be applied to the entire category, the tech-
nology upon which they are based must be available and appropri-
ate for every segment of the category.  If not, subcategoriza-
tion is required.  Subcategorization is also appropriate if
different pollutants are regulated in various segments of the
category.

EPA considers several factors to determine the appropriate sub-
categorization of a category.  These include plant location and
nonwater quality environmental impacts, including  energy costs
and solid waste generation.  These factors affect  the availabil-
ity of wastewater treatment technology.  Other Subcategorization
factors which must be considered are raw materials, manufacturing
processes, products manufactured, plant size and age, and process
water use.  These factors may influence wastewater characteris-
tics and thus determine the appropriateness of wastewater treat-
ment technologies and the presence of pollutants to be regulated.

EVALUATION AND SELECTION OF SUBCATEGORIZATION FACTORS

Factors Considered

The analysis of potential Subcategorization factors was carried
out in the context of the scope of the nonferrous  metals forming
category.  The manufacturing activities included in the category
are:

     1.  Forming of nonferrous metals other than copper and
         aluminum by rolling, drawing, extruding,  and forging
         operations;

     2.  Production of ferrous and nonferrous metal powders;

     3.  Production of ingots and metal parts from ferrous and
         nonferrous metal powders; and

     4.  Production of clad metals and bimetallics from
         nonferrous metals other than copper and aluminum.
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The following factors were considered as a basis for subcategori-
zation:

     1.  Metal formed and raw materials used;
     2.  Manufacturing processes;
     3.  Products manufactured;
     4.  Process water use;
     5.  Plant size;
     6.  Plant age;
     7.  Plant location;
     8.  Solid waste generation and disposal, air emissions,
         and energy usage; and
     9.  Individual waste streams generated by manufacturing
         activities.

In addition to considering how the individual factors influenced
siibcategorization,  the interrelationship between different fac-
tors was evaluated.  An evaluation of these factors is presented
below.

Metal Formed and Raw Materials Used.  The raw materials used in
the nonferrous metalsforming category can be classified as
follows:

        Metal and metal alloys;
        Lubricants  and additives to lubricants; and
        Surface treatment, degreasing, and furnace fluxing
        chemicals.

The pollutants discharged from a particular forming operation are
dependent on the metal formed and other raw materials used in
that operation.   For example, nickel forming wastewater will
contain nickel and  any lubricants or surface treatment chemicals
used in forming and associated process steps.  Nickel is probably
present in all nickel forming wastewater but the presence of
other pollutants varies from plant to plant and operation to
operation.

All of the manufacturing activities in this category, with the
exception of metal  cladding, can easily be divided into subcate-
gories according to the metal formed.  The metal formed and the
metallurgical properties that are required in the final product
will determine the  other raw materials used during the forming
process itself and  associated process steps.  The metal formed
will also determine the manufacturing processes used, the
products manufactured, and the amount and type of process water
use.

Because the type of metal formed will have a major impact on
wastewater flow and characteristics, subcategorization of manu-
facturing activities by the type of metal formed is appropriate.
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Additionally, if two or more metals are formed by identical or
very similar operations, generating wastewaters of similar
characteristics, it is appropriate to group the metals into one
subcategory.  One such grouping is the precious metals (gold,
silver, platinum, and palladium).

Pollutants generated by the production of clad metals and
bimetallics are dependent on the metals processed, just as are
discharges from other nonferrous metals forming processes.
However, because cladding involves more than one type of metal,
the categorization of this forming operation in a subcategoriza-
tion scheme based on the type of metal formed is not straight-
forward.

Of the 22 surveyed plants which reported clad metal production,
15 apply precious metal to a base metal.  These plants use very
similar manufacturing operations and similar materials.  Typi-
cally a gold or silver overlay or inlay is roll-bonded to a
copper-alloy base.  Nickel and stainless steel are also used as
base metals.

The cladding of precious metals to base metals is closely asso-
ciated with precious metal forming.  All but three of the 15
plants engaged in precious metal cladding also reported forming
precious metals.  The clad metals are formed by the same tech-
niques and on the same equipment as pure metals.  Therefore, it
is appropriate to group precious metal cladding with precious
metals forming.

Three plants reported cladding nonferrous metals other than pre-
cious metals to base metals in processes generating wastewater.
Just as cladding precious metals to base metal can be grouped
with precious metal forming, other cladding operations can be
grouped with the forming of the surface metal of the clad prod-
uct.  For example, manufacture of nickel clad molybdenum would be
considered nickel forming but manufacture of molybdenum clad
nickel would be considered molybdenum forming.

The Agency does not consider the type of lubricant or surface
treatment, degreasing, and furnace fluxing chemicals to have a
major, organizing impact on the category's wastewater character-
istics.  Subcategorization based on these raw materials would not
adequately distinguish the type of pollutants likely to be pres-
ent in waste streams from the resulting subcategories.  For
instance, beryllium is likely to be present in wastewater gener-
ated from surface treatment of beryllium but is not expected to
be present in nickel surface treatment wastewater.  Thus, raw
materials other than the metal formed are not appropriate
Subcategorization criteria.
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Manufacturing Processes.  As discussed above, there are four
major manufacturing activities included in the nonferrous metals
forming category, each of which uses one or more distinct manu-
facturing processes.  Subcategorization on the basis of manufac-
turing process would group all rolling operations, all drawing
operations, all extrusion operations, etc., together.  The Agency
does not believe this is an appropriate basis for subcategoriza-
tion because it does not adequately distinguish the type of pol-
lutants likely to be present in waste streams from the resulting
subcategories.  For instance, lead is likely to be present in
lead rolling wastewater but is not expected to be present in
nickel rolling wastewater.

Products Manufactured.  Another approach is subcategorization
based on the products manufactured, as listed below:
Product

Plate
Sheet
Strip
Foil
Rod and bar
Tubing
Wire and cable
Other (L shapes, I-beams, etc)
Clad metals
Metal powders

Miscellaneous shapes
      Associated
Manufacturing Process

Rolling
Rolling
Rolling
Rolling
Rolling, extrusion, drawing
Extrusion or drawing
Drawing or extrusion
Drawing or extrusion
Roll bonding, solder
application, explosion
bonding, co-drawing
Water atomization, gas
atomization, grinding, etc.
Forging, powder metallurgy
The product manufactured would be an excellent basis for subcate-
gorization if waste characteristics and the process to produce a
given item were the same from plant to plant; however, this is
not true for many formed metal products.  For example, rods can
be produced by two different production processes which generate
similar wastewater (i.e., rolling and drawing), but the mass of
pollutants generated per unit of rod produced by rolling will be
different than the amount generated by drawing the rod.  Further-
more, rods formed from different metals but produced by the same
process may use different lubricants, therefore generating a
waste with different characteristics.  Because the type and mass
of pollutant generated per unit of product will be different
depending on the metal formed and type of forming operation^
employed, the type of products manufactured is an inappropriate
basis for subcategorizing the nonferrous metals forming category.
                               382

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Process Water Use.  Major differences in water use  (volume of
water applied to a process per mass of product) between facili-
ties with large and small production could be considered  as  a
factor in the development of subcategories.

A high water use per mass of product from a particular operation
would lead to a waste stream with  lower pollutant concentration
than a lower production normalized water use (assuming the mass
of pollutant generated in a given  process is dependent on the
mass of material processed).  The  differences in pollutant con-
centration may lead to differences in wastewater treatability  and
required treatment technology.  If the differences  in process
water use are related to total plant production (if, for  example,
small production requires a large  amount of process water,
resulting in high production normalized water use and a low
pollutant concentration), process water use could be a basis for
subcategorization.

However, as will be discussed in Section V, analysis of the  data
indicates that production normalized water use (i.e., gallons  per
ton of metal formed) for a given unit operation is  usually
independent of production volume.  For example, a large direct
chill casting operation will use about the same amount of water
per ton of ingot produced as an operation casting much less
nonferrous metal by the same method.  Production normalized  water
use appears to be relatively constant over a wide range of pro-
ductions and therefore process water use is not an  appropriate
parameter for subcategorization.

Plant Size.  The number of employees and amount of  metal  pro-
cessed can be used as relative measures of the size of nonferrous
metals forming plants.

Wastewaters produced by a production process are largely  indepen-
dent of the number of plant employees.  Variations  in staff  occur
for many reasons, including shift  differences, clerical and
administrative support, maintenance workers, efficiency of plant
operations, and market fluctuations.  Due to these  and other
factors, the number of employees is constantly fluctuating,  mak-
ing it difficult to develop a correlation between the number of
employees and wastewater generation.

Subcategorization based on size in terms of production of non-
ferrous metals would group plants by the off-pounds of extru-
sions, sheets, rods, etc.  This method of subcategorization  does
not adequately distinguish between waste streams of differing
treatability nor does it determine a given plant's  ability to
achieve effluent limitations.

Subcategorization based on size in terms of volume  of wastewater
generated would be appropriate if  the applicability of a  parti-
cular treatment technology was dependent on the volume of water
                               383

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to be treated.  However, this is not the case for wastewater
generated in the nonferrous metals forming category.

For the reasons discussed above, subcategorization on the basis
of size (number of employees, production, or volume of wastewater
generated) is not appropriate.

Plant Age.  Most nonferrous metals forming plants have been built
in the past 30 years.  Since metal forming technologies are
developing and changing rapidly, most plants have also been mod-
ernized frequently in order to remain economical.  Therefore,
determination of a particular plant's technological age is very
difficult.  Accordingly, plant age is not an appropriate basis
for subcategorization.

The potential subcategorization schemes presented above attempt
to create subcategories with similar waste characteristics.
Other factors which may affect 'the availability of wastewater
treatment technology must also be evaluated.

Plant Location.  The geographical distribution of the nonferrous
metalsforming plants which responded to the dcp is presented in
Figure III-l.  The plants are not limited to any one geographical
location,  but they are generally located east of the Mississippi
River.  Although some cost savings may be realized for facilities
located in nonurban settings where land is available to install
lagoons, equivalent control of wastewater pollutant discharge can
be achieved by urban plants with the use of physical and chemical
treatment systems that have smaller land requirements.  Since
most plants are located in the eastern part of the United States
(an area where precipitation exceeds evaporation) or in urban
areas, evaporation and land application of the wastewater are not
commonly used.  Thus, location does not appear to be a signifi-
cant factor on which to base subcategorization.

Solid Waste Generation and Disposal, Air Emissions and Energy
Usage.Certain manufacturingplantsmay belimitedin the waste-
water treatment technology available to them by their patterns of
solid waste generation and disposal, air emissions or energy us-
age.   However, after a review of all available information, the
Agency was unable to identify any plant or type of plant which
has any unusual energy requirements or any unusual limitations in
available energy, solid waste disposal, or air emissions.

Individual Waste Streams Generated by Manufacturing Activities.
Most of the potential subcategorization schemes described above
attempt to create subcategories with similar waste characterist-
ics.   An alternative to subcategorizing by a factor which only
indirectly influences wastewater characteristics is to consider
                               384

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each waste stream  (such as nickel rolling spent emulsions, lead
shot casting contact cooling water, etc.) a separate subcategory.
The waste streams  generated by the manufacturing activities
included in the nonferrous metals forming category are presented
in Section V of this document.

Use of this scheme will yield subcategories of homogeneous char-
acter and treatability.  The principal benefit from using waste
streams as a basis for subcategorization is that an appropriate
effluent limitation or standard could be established for each
stream.  For each  regulated pollutant, a specific pollutant mass
discharge value could be calculated for each waste stream present
at the facility.   These values would be summed to determine the
total mass discharge allowed for that pollutant at that facility.

The difficulties with this approach are the large number of sub-
categories - approximately 175 - that it would generate.  The
Agency believes that a guideline with this many subcategories
would be extremely difficult to administer.  However, waste
stream by waste stream analysis of production, flow, and
pollutants present was used to calculate pollutant mass
limitations for each subcategory.

Summary of Subcategorization

The nonferrous metals forming category can be subcategorized on
the basis of metal type formed. Based on information reported by
294 surveyed plants, 11 subcategories which have plants that
discharge process water to surface waters or a POTW can be
established.  These subcategories are:

     o  Lead/Tin/Bismuth Forming,
     o  Nickel/Cobalt Forming,
     o  Zinc Forming,
     o  Beryllium Forming,
     o  Precious Metals Forming,
     o  Iron and Steel/Copper/Aluminum Metal Powder Production
        and Powder Metallurgy
     o  Titanium Forming,
     o  Refractory Metals  Forming,
     o  Zirconium/Hafnium Forming,
     o  Magnesium Forming, and
     o  Uranium Forming.

The iron and steel/copper/aluminum metal powder production and
powder metallurgy subcategory includes only manufacturing opera-
tions which involve metal  powders.  Forming of these metals is
covered by separate regulations.  [iron and Steel, 40 CFR Part
420; Copper Forming, 40 CFR Part 468 (48 FR 36942, August 15,
1983); Aluminum Forming,  40 CFR Part 467 (48 FR 49126,  October
24, 1983).]
                               385

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PRODUCTION NORMALIZING PARAMETER SELECTION

The objective of effluent limitations and standards is to reduce
the total quantity of pollutants discharged into surface waters.
Because plants could meet a concentration-based standard by dilu-
tion rather than treatment, mass limitations have been developed
for the nonferrous metals forming industry.  In order for regula-
tions to be equitable for plants with large productions and. small
productions, the mass limitations must be normalized by an appro-
priate unit of production called a production normalizing param-
eter (PNP).  That is, pollutant discharge limitations are written
as allowable mass of pollutant discharge per PNP (mg/PNP).
Therefore, for a PNP to be appropriate, mg/PNP must be indepen-
dent of both production and wastewater volume, for a particular
waste stream.  Mass of metal, number of pieces, surface area, and
mass of process chemicals used were considered as possible PNP's.
An evaluation of these alternatives follows.

Mass of Metal Processed.  The nonferrous metals forming category
typically maintains production records of the pounds of metal
processed.  Availability of these production data and lack of
data for other production parameters, such as number of pieces
produced, makes this the most convenient parameter to use.   The
nonferrous metals forming dcp requested three production values:
the capacity production rate for specific unit operations,  the
average production rate for 1981 in off-lbs/hr, and the total
off-pounds of final product formed in 1981.  A PNP based on mass
of metal processed would use the average production rates
reported in the dcp.

Number of Pieces Processed.  The number of pieces processed by a
given plant would not account for the variations in size and
shape typical of formed products.  Forgings, for instance,  are
produced in a wide range of sizes.   It would be unreasonable to
expect the quenching of a large forging to use the same amount of
water required for a smaller forged product and yield a constant
mass of pollutant per piece.  Therefore, the Agency concluded
that the number of pieces processed is not an appropriate PNP.

Surface Area of Metal Processed.  Surface area may be an appro-
priate production normalizing parameter for formed metal which is
rinsed (i.e., the mass of pollutants generated may correlate with
surface area).  However, the mass of pollutants generated by
other metal forming operations, such as cooling, is unrelated to
surface area.  Hence, surface area might be an adequate PNP for
some processes but would be wholely inappropriate for others.  In
addition, records of the area of metal processed are not gen-
erally kept by industry.  In some cases, such as forging of
miscellaneous shapes, surface area would be very difficult to
                              386

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determine.  In any case, surface  area  data would  be  difficult  to
collect.  For these reasons, surface area is  an inappropriate  PNP
for the nonferrous metals  forming category.

Mass of Process Chemicals  Used.   The mass of  pollutants  dis-
charged is more dependent  on the  processes which  the  metal under-
goes than on the amount of process  chemical used  in  the  process.
Some operations, such as heat treatment with  contact  cooling
water, generate pollutants but  do not  use any process  chemicals.
In addition, the use of this parameter as the production normal-
izing parameter would tend to discourage regeneration  and reuse
of process chemicals.  For these  reasons, mass of process chemi-
cals used is an inappropriate PNP for  the nonferrous  metals
forming category.

Selection of the Production Normalizing Parameter

For the reasons outlined above, the Agency has selected  mass of
product formed as the most appropriate PNP.   The  mass  of pollu-
tants can be related to the mass  of metal processed  and  most
companies keep production  records in terms of mass.

The PNP for nonferrous metals forming  is "off-kilograms" or the
kilograms of product removed from a machine at the end of a pro-
cess cycle.  For example,  in the  rolling process, an  ingot enters
the mill to be processed.  Following one process  cycle which may
substantially reduce the ingot's  thickness, the metal  is removed
from the rolling mill where it  may be processed through  another
operation, such as annealing, sizing, cleaning, or it  may simply
be stored before being brought  back to the rolling mill  for
another process cycle, further  reducing the thickness.   The mass
of metal removed from the  rolling mill after  each process cycle
multiplied by the number of process cycles is  the PNP  for that
process.

DESCRIPTION OF SUBCATEGORIES

The nonferrous metals forming category was divided into 11 sub-
categories, based on type  of metal  formed.  Five  of  these sub-
categories cover forming operations for more  than one  metal.
This subcategorization allows separate limitations to  be estab-
lished for groups of metals whose wastewater  is similar, are
formed by similar processes, and  would be expected to  utilize
similar or identical wastewater treatment within the subcategory.

The iron and steel/copper/aluminum metal powder production and
powder metallurgy subcategory covers only metal powder production
and production of iron,  copper, and aluminum  metal parts from
powder.  All other subcategories  cover traditional forming opera-
tions (rolling, drawing,  extruding, forging), powder metallurgy
                               387

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processes  (powder production and compaction), and ancillary  oper-
ations integral to the production of formed metal (heat treat-
ment, chemical and mechanical surface treatment, and casting).
Cladding operations are included in the subcategory of the
surface metal of the clad product.

The number of surveyed plants in each subcategory and the number
of plants  in each subcategory discharging process wastewater
(directly  to surface streams and to a POTW; are listed in Table
IV-1.

Lead/Tin/Bismuth Forming.  This subcategory includes the pro-
duction of three major products:  bullets, made by extrusion and
swaging lead; solder, formed by extrusion and drawing of lead,
tin, and bismuth in various alloy combinations; and insulated
cable, in which lead is extruded over copper cable.   Smaller
amounts of lead sheet and pipe are produced by rolling and
extrusion, respectively.

Of the surveyed plants, 63 form lead.   Twenty-one of these plants
discharge process wastewater, three directly to surface water and
18 to a POTW.

Nickel/Cobalt Forming.   Nickel and cobalt are formed by rolling,
drawing, extrusion, and forging, with extrusion the least common
forming process.   The two metals were grouped together because
the metals are formed by identical processes.  Also, 15 of the 16
surveyed plants which form cobalt also form nickel.

Of the surveyed plants, 73 form nickel and/or cobalt, making this
the largest subcategory in the category.  Forty-two plants dis-
charge process wastewater, 14 directly to surface water, 26  to a
POTW, and two both directly and to a POTW.

Zinc Forming.  Zinc is formed by rolling, drawing, and forging.
It is surface treated and cleaned with alkaline detergents
following forming.  Ten of the surveyed plants form zinc.  Three
plants discharge process wastewater, one directly to surface
water and two to a POTW.

Beryllium Forming.  After pressing beryllium powder into bricks,
the metal is sintered,  and rolled to sheet between sheets of
stainless steel.   Billets and sheets are pickled in acid and
rinsed with water.  One surveyed plant forms beryllium amd it
discharges process wastewater directly to surface water.

Precious Metal Forming.  This subcategory includes manufacturing
processes used to form gold, silver, platinum, and palladium.
The Agency believes that it would be very difficult to subcate-
gorize by the individual precious metals because most plants in
                              338

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this subcategory form all of the precious metals using the  same
equipment and cleaning operations.  In addition, the metals are
alloyed with each other in many combinations,  some of which have
no one constituent that is greater than 50 percent of the alloy.
As described above, this subcategory also includes production  and
forming of clad precious metals.

The most common forming operations are rolling and drawing.
Extrusion and forging are practiced to a much  smaller extent.
Fifty of the surveyed plants form precious metals.  Thirty-four
of these plants discharge process water, six directly to surface
water, 27 to a POTW, and one both directly and to a POTW.

Iron and Steel/Copper/Aluminum Metal Powder Production and Metal
Powder Metallurgy.Thissubcategoryincludesoperationsfor
producing metal powders and metal parts from powder for  iron,
steel, copper, and aluminum.  Powders are produced by wet or dry
atomization and mechanical grinding.  Pressing and sintering,  the
major manufacturing processes in powder metallurgy, usually use
no process water.  Most of the wastewater from operations in this
subcategory is generated by post-forming surface treatment.

Sixty surveyed plants are engaged in powder production or powder
metallurgy of iron, steel, copper, or aluminum.  Twenty-three  of
these plants discharge process wastewater, three directly to
surface water and 20 to a  POTW.

Titanium Forming.  Titanium is formed by rolling, drawing, extru-
sion, and forging.  Forging is practiced by many plants, many  of
which primarily forge steel.  Rolling is the second most common
forming operation, drawing the least.  Titanium is often acid
etched to remove a hard surface layer which forms at elevated
temperatures.

Forty-one of the surveyed plants form titanium.  Twenty-seven  of
these plants discharge process wastewater, 11  directly to surface
streams, 15 to a POTW, and one both directly and to a POTW.

Refractory Metal Forming.  This subcategory includes processes
used to form molybdenum, tungsten, vanadium, rhenium, tantalum,
and columbium.  The Agency believes that it is unnecessary  to
subcategorize by the individual refractory metals.  The  metals
are processed and fabricated by similar methods because  of  their
common characteristics.  The end product of refining these metals
is metal powder which is consolidated into finished products or
mill shapes.  Only production of metal powders, ferrous  and non-
ferrous, in operations which do not significantly increase  their
purity are included in this category.  Production of nonferrous
metals powders in operations which significantly increase their
                               389

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purity is covered by the guidelines for nonferrous metals manu-
facturing, 40 CFR Part 421  (phase I, proposed at 40 CFR 7032,
February 17, 1983, to be promulgated shortly; and phase II,
scheduled for proposal shortly).  The powders can also be arc or
electron beam melted and cast into  ingots.  The mill shapes and
ingots are shaped into finished form by rolling, drawing,
extruding, and forging.  A  second reason that subcategorization
by individual refractory metal is unnecessary is that most of the
plants which form one refractory metal also form one or more
other refractory metals and waste streams are commonly
commingled.

Fifty-two of the surveyed plants reported forming one or more of
the refractory metals.  Thirty-five of these plants discharge
process wastewater, six directly to surface streams, 27 to a
POTW, and two both directly and to  a POTW.

Zirconium/Hafnium Forming.  Zirconium and hafnium are formed by
rolling, drawing, and extrusion.  One common manufacturing
process is tube-reducing (roll-rocking or pilgering), a special
type of cold rolling.  Post-forming operations include annealing
and sand blasting (dry), acid and alkaline cleaning, and conver-
sion coating.  All of the plants which form hafnium also form
zirconium by similar processes.

Ten of the surveyed plants report forming zirconium.  Seven of
these plants discharge process wastewater, three directly to
surface water,  three to a POTW,  and one both directly and to a
POTW.

Magnesium Forming.  Magnesium forming processes consist of forg-
ing, rolling, and extrusion.  Water is used in post-extrusion
etching, chromating, and rinsing processes.  Eight of the sur-
veyed plants form magnesium.  Five plants discharge process
water, three directly to surface streams and two to a POTW.

Uranium Forming.   Uranium forming processes consist of forging
and extrusion,  both of which use contact cooling water.  Water
is also used in post-forming surface treatment steps.  Three sur-
veyed plants report forming uranium.  One plant discharges
process water directly to a surface stream and one both directly
and to a POTW.
                               390

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                                                              391

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                             SECTION V

             WATER USE AND WASTEWATER  CHARACTERISTICS
This section presents a summary  of the analytical  data  that  char-
acterize  the raw wastewater  in the category.  Flow data that
serve as  the basis  for developing regulatory  flow  allowances in
the nonferrous metals forming category are  also  summarized  in
this section.  The  analytical and flow data were obtained from
four sources:  information obtained  during  a  telephone  survey;
data collection portfolios (dcp's);  sampling  and analysis pro-
grams; and long-term or historical data.  Confidential  informa-
tion was  handled in accordance with  40 CFR  Part  2.

DATA SOURCES

Telephone Survey

As described in Section III  of this  document, a  comprehensive
telephone survey was undertaken  in order to determine which
plants should comprise a final dcp mailing  list, i.e.,  whether or
not operations within the scope  of this category were present at
the plants contacted.  In the telephone survey,  the contact  at
each plant was asked what metals were formed, the  type  of forming
operations the plant employed, i.e., rolling, drawing,  extruding,
forging,  casting, cladding,  or powder metallurgy and their asso-
ciated water usage, discharge, and treatment-in-place.  The  plant
contact was also asked what  surface  treatment, cleaning, washing,
and/or rinsing operations were utilized and their  associated
water usage, discharge, and  treatment-in-place.  In addition to
the telephone contacts made  during the comprehensive survey,  many
plants were contacted by telephone to clarify dcp  responses.

Data Collection Portfolios

Data collection portfolios (dcp's) are questionnaires which  were
developed by the Agency to obtain extensive data from plants  in
the nonferrous metals forming category.  The  dcp's, sent to  all
facilities known or believed to be engaged in nonferrous metals
forming, requested  information under the authority of Section 308
of the Clean Water Act.   The information requested included  plant
age, production,  number of employees, water usage, manufacturing
processes, raw material and process  chemical usage, wastewater
treatment technologies,  and  the presence (known or believed)  of
toxic pollutants  in the plant's raw  and treated process
wastewaters.

Complete dcp responses supplied the  following information for
each operation present at the responding plant:   the total
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production in 1981, the average production rate  (Ib/hr), produc-
tion rate at full capacity, and the quantity and rate of waste-
water discharge.  As discussed in Section IV, a  mass-based
regulation must relate water use and raw waste characteristics to
some production normalizing parameter.  The average production
rate is considered to be the parameter most applicable to opera-
tions in this category, and has been used to normalize the water
and wastewater flows discussed in this section.

Two production normalized flows (PNF's) were calculated for each
operation reported in the dcp's.  The first is production normal-
ized water use, defined as the volume of water or other fluid
(e.g., emulsions, lubricants) required per mass  of metal pro-
cessed through the operation.  Water use is based on the sum of
recycle and make-up flows to a given process.  The second PNF
calculated for each operation is production normalized water
discharge, defined as the volume of wastewater discharged from a
given process to further treatment, disposal, or discharge per
mass of nonferrous metal processed.  Differences between the
water use and wastewater flows associated with a given stream
result from recycle, evaporation, and carryover  on the product.
The production values used in calculation correspond to the
production normalizing parameter, PNP, assigned  to each stream,
as outlined in Section IV.

The production normalized flows from similar sources were com-
piled and statistically analyzed.  Wastewater sources with
similar production normalized flows and physical and chemical
characteristics were grouped together (e.g., spent baths from
acid pickling, acid etching, chromating and phosphating were
grouped together as "surface treatment spent baths.").  These
groupings are referred to as "waste streams" in  this document.
It should be noted that one nonferrous metals forming or asso-
ciated operation can generate more than one waste stream.  Each
distinct waste stream will have different production normalized
flows, physical and chemical characteristics, or both.  The pro-
duction normalized flow information for each waste stream is
presented in the administrative record which accompanies this
rulemaking package.  An analysis of factors affecting the waste-
water flows is presented in Sections IX, X, XI,  and XII where
representative BPT, BAT, NSPS,  and pretreatment  discharge flow
allowances are selected for use in calculating the effluent
limitations and standards.

Sampling and Analysis Program

The sampling and analysis program was undertaken primarily to
identify pollutants of concern in the industry,  with emphasis on
toxic pollutants.  Samples were collected at 17  nonferrous metals
forming facilities.
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This section summarizes the activities undertaken  during  the  sam-
pling trips and identifies the types of sites  sampled and param-
eters analyzed.  It also presents  an overview  of sample collec-
tion, preservation, and transportation techniques.  Finally,  it
describes the pollutant parameters quantified,  the methods  of
analyses and laboratories used, the detectable  concentration  of
each pollutant, and the general approach used  to ensure the
reliability of the analytical data produced.

Site Selection.  Seventeen plants  engaged in manufacturing  opera-
tions included in this category were sampled.   Four of these
plants were sampled in data gathering efforts  supporting  the
development of guidelines for other industrial  categories
(nonferrous metals manufacturing and battery manufacturing).
Information on nonferrous rnetals forming operations was collected
incidentally to the major sampling effort at these plants.  Thir-
teen plants were sampled specifically to gather data to support
guidelines and standards for this  category.  These plants were
selected to be representative of the industry,  based on informa-
tion obtained during the telephone survey.  Considerations
included how well each facility represented the subcategory as
indicated by available data, potential problems in meeting
technology-based standards, differences in production processes
used, and wastewater treatment-in-place.  With  the exception  of
the uranium forming subcategory, at least one  plant in every
subcategory was sampled.  Two plants provided  data for more than
one subcategory.

As indicated in Table V-l, the plants selected  for sampling were
typically plants with multiple forming operations  and associated
surface and heat treatment operations.  The flow rates and  pollu-
tant concentrations in the wastewaters discharged  from the  manu-
facturing operations at these plants are believed  to be repre-
sentative of the flow rates and pollutant concentrations which
would be found in wastewaters generated by similar operations at
any plant in the nonferrous metals forming industry.  The 17
sampled plants have a variety of treatment systems in place,
ranging from plants with no treatment to plants using the
advanced technologies considered as the basis  for  regulation.

Field Sampling.  After selection of the plants  to  be sampled^
each plant was contacted by telephone, and sent a  letter notify-
ing the plant when a visit would be expected as authorized  by
Section 308 of the Clean Water Act.  In most cases, a preliminary
visit was made to the plant to select the sources  of wastewater
to be sampled.   The sample points  included, but were not  limited
to, untreated and treated discharges, process wastewater, par-
tially treated wastewater, and intake water.  The  actual  sampling
visit was also scheduled during the preliminary visit.
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Sample Collection, Preservation, and Transportation.  Collection,
preservation,and transportation of samples were accomplished in
accordance with procedures outlined in Appendix III of "Sampling
and Analysis Procedures for Screening of Industrial Effluents for
Priority Pollutants"  (published by the Environmental Monitoring
and Support Laboratory, Cincinnati, Ohio, March 1977, revised,
April 1977), "Sampling Screening Procedure for the Measurement of
Priority Pollutants"  (published by the EPA Effluent Guidelines
Division, Washington, D.C.. October 1976), and in the proposed
304(h) methods (44 FR 69464, December 3, 1979).  The procedures
are summarized in the paragraphs that follow.

Whenever practical, samples were taken from mid-channel at mid-
depth in a turbulent, well-mixed portion of the waste stream.
Periodically, the temperature and pH of each waste stream sampled
were measured on-site.

Each large composite  (Type 1) sample was collected in a 9-liter,
wide-mouth pickle jar that had been washed with detergent and
water, rinsed with tap water, rinsed with distilled water, and
air dried at room temperature.

Before collection of Type 1 samples, new Tygon® tubing was cut to
minimum lengths and installed on the inlet and outlet (suction
and discharge) fittings of the automatic sampler.  Two liters
(2.1 quarts; of blank water, known to be free of organic com-
pounds and brought to the sampling site from the analytical
laboratory, were pumped through the sampler and its attached
tubing; the water was then discarded.

A blank (control sample) was produced by pumping an additional 2
liters of blank water through the sampler and into the original
blank water bottle.  The blank sample was sealed with a Teflon®-
lined cap, labeled, and packed in ice in a plastic foam-insulated
chest.  This sample was subsequently analyzed to determine any
contamination contributed by the automatic sampler.

During collection of each Type 1 sample, the pickle jar was
packed in ice in a plastic foam-insulated container to cool the
sample.  After the complete composite sample had been collected,
it was mixed and a 1-liter aliquot to be used for metals analysis
was dispensed into a plastic bottle.  The aliquot was preserved
on-site by the addition of nitric acid to pH less than 2.  Metals
samples were stored at room temperature until the end of the
sampling trip at which time they were shipped to the appropriate
laboratory for analysis.

After removal of the 1-liter metals aliquot, the balance of the
composite sample was  divided into aliquots to be used for analy-
sis of nonvolatile organics, conventional parameters, and noncon-
ventional parameters.  If a portion of the composite sample was
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requested by a representative of the sampled plant for  indepen-
dent analysis, an aliquot was placed in a sample container
supplied by the representative.

Water samples to be analyzed for cyanide, total phenol, oil and
grease, and volatile organics were not obtained from the compos-
ite sample.  Water samples for these analyses were taken as
one-time grab samples during the time that the composite sample
was collected.

The cyanide, total phenol, and oil and grease samples were stored
in new bottles which had been iced and labeled, 1-liter (33.8
ounce) plastic bottles for the cyanide sample, 0.95-liter  (1
quart) amber glass bottles for the total phenol sample, and
0.95-liter (1 quart) wide-mouth glass bottles with a Teflon® lid
liner for the oil and grease sample.  The samples were preserved
as described below.

Sodium hydroxide was added to each sample to be analyzed for
cyanide, until the pH was elevated to 12 or more (as measured
using pH paper).  Where the presence of chlorine was suspected,
the sample was tested for chlorine (which would decompose most of
the cyanide) by using potassium iodide/starch paper.  If the
paper turned blue (indicating chlorine was present), ascorbic
acid crystals were slowly added and dissolved until a drop of the
sample produced no change in the color of the test paper.  An
additional 0.6 gram (0.021 ounce) of ascorbic acid was  added, and
the sample bottle was sealed (by a Teflon®-lined cap),  labeled,
iced, and shipped for analysis.

Sulfuric acid was added to each sample to be analyzed for total
phenol, until the pH was reduced to 2 or less (as measured using
pH paper).  The sample bottle was sealed, labeled, iced, and
shipped for analysis.

Sulfuric acid was added to each sample to be analyzed for oil and
grease, until the pH was reduced to 2 or less (as measured using
pH test paper).  The sample bottle was sealed (by a Teflon® lid
liner), labeled, iced, and shipped for analysis.

Each sample to be analyzed for volatile organic pollutants was
stored in a new 125-ml (4.2-ounce) glass bottle that had been
rinsed with tap water and distilled water, heated to 105°C
(221°F) for one hour,  and  cooled.  This method was also used to
prepare the septum and lid for each bottle.  When used, each
bottle was filled to overflowing, sealed with a Teflon®-faced
silicone septum (Teflon® side down), capped, labeled, and iced.
Hermetic sealing was verified by inverting and tapping  the sealed
container to confirm the absence of air bubbles.  (If bubbles
were found, the bottle was opened, a few additional drops of
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sample were added, and a new seal was installed.)  Samples were
maintained hermetically sealed and iced until analyzed.

Sample Analysis.  Samples were sent by air to one of the labora-
tories listed in Table V-2.  The samples were analyzed for 21
metals, including seven of the priority metal pollutants (beryl-
lium, cadmium, chromium, copper, nickel, lead, and zinc) using
inductively-coupled argon plasma emission spectroscopy (ICAPES)
as proposed in 44 FR 69464, December 3, 1979.  The remaining six
priority metal pollutants,  with the exception of mercury, were
analyzed by atomic absorption spectroscopy (AA) as described in
40 CFR Part 136.  Mercury analysis was performed by automated
cold vapor atomic absorption.  Analysis for the seven toxic
metals analyzed by ICAPES was also performed by AA on 10 percent
of the samples to determine test comparability.  Because the
results showed no significant differences in detection or quanti-
fication levels, ICAPES data were used for the seven toxic
metals.

                     Metals Analyzed by ICAP

                    Calcium        Iron
                    Magnesium      Manganese
                    Sodium         Molybdenum
                    Aluminum      *Nickel
                    Boron         *Lead
                    Barium         Tin
                   *Berylliura      Titanium
                   *Cadmium        Vanadium
                    Cobalt         Yttrium
                   ^Chromium      *Zinc
                   ^Copper

                      Metals Analyzed by AA

                          *Antimony
                          *Arsenic
                          *Selenium
                          ^Thallium
                          *Mercury
                          ^Silver

*Toxic metals.

Analyses for the organic toxic pollutants were performed by
Arthur D.  Little, ERGO, IT, S-Cubed, and West Coast Technical
Service.  Analyses for the toxic metal pollutants were performed
by CENTEC,  Radian, Versar,  and NUS.  Radian, ARO, and NUS per-
formed analyses for cyanide, conventional and nonconventional
pollutants.
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EPA did not expect to find any asbestos  in nonferrous metals
forming wastewaters because this category only includes metals
that have already been refined from ores that might  contain
asbestos.  Therefore, analysis for asbestos fibers was not per-
formed.

Pesticide priority pollutants were also  not expected to be sig-
nificant in the nonferrous metals forming industry.  Samples from
one facility were analyzed for pesticide priority pollutants by
electron capture-gas chromatography by the method specified in 44
FR 69464, December 3, 1979.  Pesticides were not detected in
these samples, so no other samples were analyzed for these
pollutants.

Analyses for the remaining organic priority pollutants (volatile
fraction, base/neutral, and acid compounds) were conducted using
an isotope dilution method which is a modification of the analyt-
ical techniques specified in 44 FR 69464, December 3, 1979.  The
isotope dilution method has been recently developed  to improve
the accuracy and reliability of the analysis.  A copy of the
method is in the record of rulemaking for this proposed regula-
tion.   However, no standard was used in the analysis of 2,3,7,8-
tetrachlorodibenzo-p-dioxin (TCDD, pollutant 129).   Instead,
screening for this compound was performed by comparing analytical
results to EPA's gas chromatography/mass spectroscopy (GC/MS)
computer file.

Analysis for cyanide used methods specified in 40 CFR Part 136
and described in "Methods for Chemical Analysis for Water and
Wastes," EPA-600/4-79-020 (March 1979).

Past studies by EPA and others have identified many nontoxic
pollutant parameters useful in characterizing industrial waste-
waters and in evaluating treatment process removal efficiencies.
Some of these pollutants may also be selected as reliable indi-
cators of the presence of specific toxic pollutants.  For these
reasons, a number of nontoxic pollutants were studied for the
nonferrous metals forming category.  These pollutants may be
divided into two general groups as shown in Table V-3.  Analyses
for these pollutants were performed by the methods specified in
40 CFR Part 136 and described in EPA-600/4-79-020.

The analytical quantification levels used in evaluation of the
sampling data reflect the accuracy of the analytical methods
employed.  Below these concentrations, the identification of the
individual compounds is possible, but quantification is diffi-
cult.   Pesticides and PCB ' s can be analytically quantified at
concentrations above 0.005 mg/1, and other organic toxic levels
above 0.010 mg/1.  Levels associated with toxic metals are as
follows:  0.010 mg/1 for antimony; 0.010 mg/1 for arsenic; 1 x
                               399

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107  fibers/1  for  asbestos; 0.005 mg/1  for beryllium;  0.020  mg/1
for  cadmium;  0.020 mg/1  for chromium;  0.050 mg/1  for  copper;  0.02
mg/1  for cyanide; 0.050  mg/1  for lead; 0.0002  mg/1  for  mercury;
0.050 mg/1  for nickel; 0.010  mg/1  for  selenium; 0.010 mg/1  for
silver; 0.010 mg/1 for thallium; and 0.020 mg/1 for zinc..

The  detection limits used were  reported with the  analytical data
and hence are the appropriate limits to apply  to  the  data.
Detection limit variation can occur as a result of  a  number of
laboratory-specific, equipment-specific, daily operator-specific,
and pollutant-specific factors.  These factors can  include
day-to-day  differences in machine  calibration  and variation in
stock solutions,  operators, and pollution sample  matrices  (i.e.,
presence of some  chemicals will alter  the detection of  particular
pollutants).

Quality Control.  Quality control  measures used in  performing all
analysesconducted for this program complied with the guidelines
given in "Handbook for Analytical  Quality Control in  Water  and
Wastewater Laboratories" (published by EPA Environmental Monitor-
ing and Support Laboratory, Cincinnati, Ohio, 1976).  As part of
the daily quality control program, blanks (including  sealed
samples of blank water carried  to  each sampling site  and returned
unopened,  as well as samples  of blank water used  in the field),
standards,  and spiked samples were routinely analyzed with  actual
samples.  As part of the overall program, all analytical instru-
ments (such as balances, spectrophotometers, and  recorders) were
routinely maintained and calibrated.

Historical Data

A useful source of long-term or historical data available for
nonferrous metals forming plants are the Discharge  Monitoring
Reports (DMR's) completed as a part of the National Pollutant
Discharge Elimination System  (NPDES) and/or State Pollutant
Discharge Elimination System  (SPDES).  DMR's were obtained
through the EPA regional offices and state regulatory agencies
for the years 1981 through the most recent date available.  The
DMR's present a summary  of the  analytical results from  a series
of samples taken during  a given month for the pollutants desig-
nated in the plant's permit.  In general, minimum,  maximum,  and
average values, in mg/1  or Ibs/day, are presented for such  pollu-
tants as total suspended solids, oil and grease,  pH,  chromium,
and zinc.   The samples were collected from the plant  outfall(s),
which represents the discharge(s)  from the plant.   For  facilities
with wastewater treatment,  the DMR's provide a measure  of the
performance of the treatment  system.  In theory,  these  data could
serve as a basis for characterizing treated wastewater  from non-
ferrous metals forming plants.  However, there is no  information
on concentration of pollutants in  wastewater prior  to treatment
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and too little information on the performance of  the plant at  the
time the samples were collected to use these data in evaluating
the performance of various levels of treatment.  The data
reported in DMR's could be used to compare the treatment perfor-
mance of actual plants to the treatment effectiveness concentra-
tions presented in Section VII.  However, it was not possible  to
perform this comparison in the limited time available between
receipt of the DMR's and the Court Ordered deadline for proposal
of this regulation.

The DMR data for uranium forming plants included  the toxic metals
cadmium, copper, and nickel.  The data were used to select the
pollutants proposed for regulation in the uranium forming
subcategory.

WATER USE AND WASTEWATER CHARACTERISTICS

Water use, wastewater discharge, and analytical sampling data  for
each subcategory are presented in the administrative record which
accompanies this rulemaking package.  These data  (listed by waste
stream) were collected from the dcp's and during field sampling.
They include source water concentrations and current recycle
practices.

Analytical sampling data are summarized in Tables V-4 through
V-14.  These tables  present the concentration range of regulated
pollutants detected in the waste streams sampled in each subcate-
gory.  Selection of regulated pollutants is discussed in Section
VI.

As indicated in Table V-l, not every waste stream generated by
nonferrous metals forming operations was sampled during the
screen sampling program.  However, in order to evaluate the
applicability of the various treatment technologies to non-
sampled waste streams, the physical and chemical characteristics
of these streams were extrapolated from similar sampled streams.
This extrapolation was also necessary to estimate the costs of
the various treatment technologies, as discussed in Section VIII.
Extrapolation of sampling data from sampled to non-sampled waste
streams was not used to select pollutants for regulation in this
category (see Section VI).

Waste streams generated by similar physical processes using
similar process chemicals will have very similar physical and
chemical characteristics.  For example, water used to cool extru-
sions will have low concentrations of all pollutants.   This is
demonstrated by the results of the chemical analyses of lead and
nickel extrusion press and solution heat treatment contact cool-
ing water (Table V-15).  The major difference between these two
waste streams is that the concentration of lead is higher in the
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 lead cooling water  (0.13 mg/1 vs. not  detected)  and  the  concen-
 tration of nickel is higher in the nickel cooling water  (0.14
 mg/1 vs. 0.007 mg/1).  This pattern will be repeated whenever
 water, without additives, is used to cool hot metal.

 In contrast, spent rolling emulsions have high concentrations  of
 several pollutants.  The results of chemical analyses  of  lead,
 nickel, and precious metals rolling spent emulsions  are presented
 in Table V-16.  All three waste streams have high concentrations
 of oil and grease, total suspended and dissolved solids,  and
 several metals.  The lead rolling spent emulsion has a high con-
 centration of lead  (29.0 mg/1), the nickel rolling spent  emulsion
 has high concentrations of nickel and  chrome (8.95 mg/1  and 1.27
 mg/1, respectively), and the precious  metals rolling spent emul-
 sion has high concentrations of copper, silver,  and  zinc  (25.0
 mg/1, 0.13 m^/1, and 6.00 mg/1, respectively).   It is  not sur-
 prising to find chromium in nickel rolling spent emulsions and
 copper and zinc in precious metals rolling spent emulsions
 because chromium is a common alloy of  nickel and copper  and zinc
 are common alloys of precious metals.  Thus, the major difference
 between the three waste streams is the presence  of the metals
 formed in the operation generating the waste stream.

 From the discussion above, it follows  that refractory  metals,
 zirconijum, and uranium extrusion press and solution  heat  treat-
 ment contact cooling water will have chemical characteristics
 similar to lead and nickel extrusion press and solution heat
 treatment contact cooling water.  The  major difference between
 the waste streams will be the concentration of the metal  cooled.
 Similarly, zinc and refractory metals  rolling spent  emulsions
 will have chemical characteristics similar to lead,  nickel and
 precious metals rolling spent emulsions, except  for  the concen-
 tration of the metal rolled.  However, because zinc  and  lead are
 rolled at lower temperatures than nickel and refractory metals,
 zinc rolling spent emulsions may be more like lead rolling spent
 emulsions and refractory metals rolling spent emulsions may be
 more like nickel rolling spent emulsions.

Arguments analogous to those presented above were used to esti-
 mate the physical and chemical characteristics of all  non-sampled
 waste streams.  These estimations, and summaries of  sampling
 data, are presented below.

 Lead/Tin/Bismuth Forming Subcategory

Rolling Spent Emulsions.  As discussed in Section III, oil-in-
 water emulsionsare used as coolants and lubricants.   Rolling
 emulsions are typically recycled using in-line filtration and
 periodically batch discharged when spent.
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One sample of rolling  spent  emulsions  was  collected at one plant.
Elevated concentrations  of lead  (29  mg/1),  zinc (1.4 mg/1),  oil
and grease (270 mg/1),  and TSS  (480  mg/1)  v/ere detected in the
sample.

Rolling Spent _Soajp__Solutions_.  As  discussed in Section III,  soap
solutions can be used  as  lubricants  and coolants in rolling.   Of
the plants surveyed, only one plant  reported the use of soap
solutions in rolling.

No samples of rolling  spent  soap  solutions  were collected during
the sceen sampling program.  However,  the  Agency believes that
this stream will have  wastewater  characteristics similar to
alkaline cleaning rinsewater in  this subcategory.   Spent soap
solutions contain the  same process  chemicals as alkaline cleaning
baths, at mass loadings  (rag/kkg)  similar to the concentrations
found  in alkaline cleaning rinses.   Therefore, the pollutants
present and the mass loadings of  pollutants present, in rolling
spent  soap solutions and  alkaline  cleaning rinses  are expected to
be similar.

Drawing Spent Neat: OJ_l_s_.  As discussed in  Section III, oil-based
lubricants may be used in drawing  operations to ensure uniform
drawing temperatures and avoid excessive wear on dies and man-
drels.  Drawing oils are usually  recycled  until their lubricant
properties are exhausted and are  then  contract hauled.

Since none of the plants surveyed  reported  discharging the draw-
ing spent neat oils, no  samples were collected.

Drawing Spent Emulsions.  As discussed in  Section 111, oil-in-
water emulsions can~Hb~e used  as drawing lubricants.   The drawing
emulsions are frequently recycled  and  batch discharged periodi-
cally after their lubricating properties are exhausted.

No samples of drawing  spent  emulsions  were  collected during  the
screen sampling program.  However,  the Agency believes that  this
stream will have wastewater  characteristics similar to rolling
spent emulsions in this  subcategory.   These two waste streams are
generated from similar physical processes  which use similar pro-
cess chemicals.  Therefore,  the pollutants  present in each waste
stream and the mass loading  (mg/kkg  product) at which they are
present should be similar.

Drawing Spent jSoajj_ SoJ.irti.ons.  As  discussed in Section ill,  soap
solutions can be used  as drawing  lubricants.   The  drawing soap
solutions are frequently recycled  and  batch discharged periodi-
cally after their lubricating properties are exhausted.
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No samples of drawing spent soap solutions were collected during
the screen sampling program.  However, the Agency believes that
this stream will have wastewater characteristics similar to alka-
line cleaning rinsewater in this subcategory.  Spent soap solu-
tions contain the same process chemicals as  alkaline cleaning
baths, at concentrations similar to the concentrations found in
alkaline cleaning rinses.  Therefore, the pollutants present and
the mass loadings at which they are present  in drawing spent soap
solutions and alkaline cleaning rinses are expected to be
similar.

Extrusion Press and Solution Heat Treatment  Contact Cooling
Water.  As discussed in Section III, heat treatment of lead/tin/
bismuth products frequently involves the use of a water quench in
order to achieve desired metallic properties.  Eleven plants
reported 16 extrusion press and solution heat treatment processes
that involve water quenching either by spraying water onto the
metal as it emerges from the die or press or by direct quenching
into a contact water bath.

One sample of extrusion press and solution heat treatment contact
cooling water was collected at one plant.  Elevated concentra-
tions of chromium (4.6 mg/1) were detected in the sample.

Extrusion Press Hydraulic Fluid Leakage.  As discussed in Section
III,due to thelargeforce applied by a hydraulic extrusion
press, hydraulic fluid leakage is unavoidable.

No samples of extrusion press hydraulic fluid leakage were col-
lected during the screen sampling program.   However, the Agency
believes that this stream will have wastewater characteristics
similar to press hydraulic fluid leakage in  the nickel/cobalt
subcategory.  The pollutants present in these two waste streams
are attributable to the hydraulic fluid used, not the metal
formed.  Therefore, the pollutants present and the concentration
(mg/1) at which they are present should be similar.

Continuous Strip Casting Contact Cooling Water.  As discussed in
Section III, in continuous casting, no restrictions are placed on
the length of the casting and it is not necessary to interrupt
production to remove the cast product.  Although the use of con-
tinuous casting techniques has been found to significantly reduce
or eliminate the use of contact cooling water and oil lubricants,
five plants reported the use of continuous strip contact cooling
water.

One sample of continuous strip casting contact cooling water was
collected at one plant.  Elevated concentrations of lead (1.2
mg/1) and zinc (3.1 mg/1) were detected in the sample.
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Semi-Continuous Ingot Casting Contact Cooling Water.  As dis-
cussed in Section III,semi-continuous ingot casting may require
the use of contact cooling water in order to achieve the desired
physical properties of the metal.

Two samples of semi-continuous ingot casting contact cooling
water were collected  from one stream at one plant.  Elevated con-
centrations of lead (1.10 mg/1) and TSS (80 mg/1) were detected
in the samples.

Shot Casting Contact Cooling Water.  As discussed in Section III,
contact cooling water is required to cool the cast lead shot so
that it will not reconsolidate as well as to achieve the desired
metallic properties.

Three samples of shot casting contact cooling water were col-
lected from one stream at one plant.  Elevated concentrations of
lead (52.2 mg/1), antimony (3.30 mg/1), tin (10.5 rag/1), oil and
grease (22 mg/1), and TSS (420 mg/1) were detected in the
samples.

Shot-Forming Wet Air Pollution Controj. Blowdown.  As discussed in
Section III, shot-forming may require wet air pollution control
in order to meet air quality standards.  Of the plants surveyed,
only one reported the use of wet air pollution control on a
shot-forming operation.

No samples of shot-forming wet air pollution control blowdown
were collected during the screen sampling program.  However, the
Agency believes that this stream will have wastewater character-
istics similar to shot casting contact cooling water in this
subcategory.  The pollutants in each of these waste streams
derive from contact of the water with particles of metal, so the
pollutants present are expected to be similar.  However, because
the air pollution control device is designed to capture small
particles (dust), the mass loading of total suspended solids is
expected to be higher in shot-forming wet air pollution control
blowdown than in shot casting contact cooling water.

Swaging Spent Emulsions.  As discussed in Section III, oil-in-
water emulsions can be used as swaging lubricants.  The swaging
emulsions are frequently recycled and batch discharged periodi-
cally after their lubricating properties are exhausted.

No samples of swaging spent emulsions were collected during the
screen sampling program.  However, the Agency believes that this
stream will have wastewater characteristics similar to rolling
spent emulsions in this subcategory.  These two waste streams are
generated from operations using similar process chemicals (oil-
in-water emulsions) for similar purposes (lubrication).  There-
fore, the pollutants present in each waste stream and the mass
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loading (mg/kkg product) at which they are present should be
similar.

Alkaline Cleaning Spent Baths.  As discussed in Section III,
alkaline cleaning iscommonly used to clean lead/tin/bismuth sur-
faces.  Products can be cleaned with an alkaline solution either
by immersion or spray.

One sample of an alkaline cleaning spent bath was collected at
one plant.  Elevated concentrations of lead (183 mg/1), antimony
(7.30 mg/1), oil and grease (600 mg/1), and TSS (560 mg/1) were
detected in the sample.

Alkaline Cleaning Rinsewater.   As discussed in Section III, rins-
ing, usually with warm water,  should follow the alkaline cleaning
process to prevent the solution from drying on the product.

Four samples of alkaline cleaning rinsewater were collected from
two streams at one plant.  Elevated concentrations of lead  (40.8
mg/1), antimony (1.10 mg/1), and TSS (260 mg/1) were detected in
the samples.

Degreasing Spent Solvents.  As described in Section III, solvent
cleaners are used to remove lubricants (oils and greases) applied
to the surface of nonferrous metals during mechanical forming
operations.  Basic solvent cleaning methods include straight
vapor degreasing, immersion-vapor degrasing, spray-vapor degreas-
ing, ultrasonic vapor degreasing, emulsified solvent degreasing,
and cold cleaning.

Solvents most commonly used for all types of vapor degreasing are
trichloroethylene, 1,1,1-trichloroethane, methylene chloride,
perchloroethylene, and various chlorofluorocarbons.  Solvent
selection depends on the required process temperature (solvent
boiling point), product dimension, and metal characteristics.
Contaminated vapor degreasing solvents are frequently recovered
by distillation.  The sludge residue generated is toxic and may
be flammable, requiring appropriate handling and disposal pro-
cedures .

Since none of the plants surveyed reported discharging the vapor
degreasing spent solvents, no samples were collected.

Miscellaneous Nondescript Wastewater Sources.   Several low volume
sourcesof wastewater were reported on the dcp's and observed
during the site and sampling visits.  These sources are mainte-
nance and cleanup, autoclave contact cooling water, final product
lubrication, and product degreasing rinsewater.  Because they
generally represent low volume periodic discharges applicable to
most plants, the Agency is including an allowance for all of
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these streams under the miscellaneous nondescript wastewater
sources waste stream.

Operations Which Do Not Use Process Water.  The Agency proposes a
discharge allowance of zero for operations which do not generate
process wastewater.  The following operations generate no process
wastewater either because they are dry or because they use
noncontact cooling water only:

     Continuous Wheel Casting
     Continuous Sheet Casting
     Stationary Casting
     Shot Pressing
     Forging
     Stamping
     Pointing
     Punching
     Shot Blasting
     Slug Forming
     Powder Metallurgy Operations (Pressing, Sintering, Sizing)
     Powder Tumbling
     Melting
     Solder Cream Making
     Annealing
     Tumble Cleaning
     Slitting
     Sawing
     Coiling, Spooling
     Trimming

Nickel/Cobalt Forming Subcategory

Rolling Spent Neat Oils.  As described in Section III, the
rolling of nickel/cobalt products typically requires the use of
mineral oil lubricants.  The oils are usually recycled with
in-line filtration and periodically disposed of by sale to an oil
reclaimer or by incineration.   Because discharge of this stream
is not practiced, limited flow data were available for analysis.

Since none of the plants surveyed reported discharging the roll-
ing spent neat oils, no samples of this waste stream were
collected.

Rolling Spent Emulsions.  As discussed in Section III, oil-in-
water emulsions are used in rolling operations as coolants and
lubricants.   Rolling emulsions are typically recycled using
in-line filtration with periodic batch discharge of the spent
emulsion.
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Twelve samples of rolling spent emulsions were collected  from  six
streams at two plants.  Elevated concentrations of nickel  (34.2
mg/1), zinc (6.70 mg/1), oil and grease  (7,600 mg/1), and TSS
(6,800 mg/1) were detected in the samples.

Rolling Contact Lubricant-Coolant Watery.  As discussed in Section
III, it is necessary to use a lubricants-coolant during rolling to
prevent excessive wear on the rolls, to prevent adhesion of metal
to the rolls, and to maintain a suitable and uniform rolling tem-
perature.  Water is one type of lubricant-coolant which may be
used.

One sample of rolling contact lubricant-coolant water was col-
lected at one plant.  Elevated concentrations of copper (1.3
mg/1), fluoride (2,000 mg/1), oil and grease (22 mg/1), and TSS
(63 mg/1) were detected in the sample.

Rolling Solution Heat Treatment Contact Cooling Water.  As dis-
cussed in Section III, solution heat treatment can be used after
most forming operations in order to improve mechanical properties
by maximizing the concentration of hardening contaminants in the
solid metal solution.  Solution heat treatment typically involves
significant quantities of contact cooling water.

No samples of rolling solution heat treatment contact cooling
water were collected during the screen sampling program.  How-
ever', the Agency believes that this stream will nave wastewater
characteristics similar to extrusion press and solution heat
treatment contact cooling water in this subcategory.  These two
waste streams are generated from operations using water for an
identical purpose:  to cool hot metal.  In addition, no process
chemicals are added to either type of cooling water.  Therefore,
both the pollutants present and the mass loadings of pollutants
present in these two waste streams are expected to be similar.

Tube Reducing Spent Lubricants.  As discussed in Section III,
tube reducing, much like rolling, may require a lubricating com-
pound in order to prevent excessive wear of the tube reducing
rolls, prevent adhesion of metal to the rolls, and to maintain a
suitable and uniform tube reducing temperature.

One sample of tube reducing spent lubricants was collected from
one stream at one plant.  Elevated concentrations of nickel (58.0
mg/1), copper (43.5 mg/1), lead (47.6 mg/1), zinc (63.1 mg/1),
and oil and grease  (200,000 mg/1) were detected in the sample.
In addition, the sample had elevated concentrations of the toxic
organics 1,1,1-trichloroethane (33 mg/1) and N-nitrosodiphenyl-
amine (28.2 mg/1).

Drawing Spent Neat Oils.  As discussed^in Section III, oil-based
lubricants may be required in draws which have a high reduction
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in diameter.  Drawing oils are usually recycled, with  in-line
filtration, until their lubricating properties are exhausted.

Since none of the plants surveyed reported discharging the draw-
ing spent neat oils, no samples were collected.

Drawing Spent Emulsions.  As discussed in Section III, oil-in-
water emulsions are often used as coolants and lubricants in
drawing.  The drawing emulsions are frequently recycled and batch
discharged periodically after their lubricating properties are
exhausted.

No samples of drawing spent emulsions were collected during the
screen sampling program.  However, the Agency believes that this
stream will have wastewater characteristics similar to rolling
spent emulsions in this subcategory.  These two waste streams are
generated from operations using similar process chemicals (oil-
in-water emulsions) for similar purposes (lubrication).  There-
fore, the pollutants present and the mass loadings of pollutants
present in these two waste streams are expected to be similar.

Extrusion Spent Lubricants.  As discussed in Section III, the
extrusion process requires the use of a lubricant to prevent
adhesion of the metal to the die and ingot container walls.

Since none of the plants surveyed reported wastewater discharge
values for extrusion spent lubricants, no samples of this waste
stream were collected.

Extrusion Press and Solution Heat Treatment Contact Cooling
Water.Asdiscussed in Section III,heat treatmentisfrequently
used after extrusion to attain the desired mechanical properties
in the extruded metal.  Contact cooling of the extrusion, some-
times called press heat treatment, can be accomplished with a
water spray near the die or by immersion in a water tank adjacent
to the runout table.

One sample of extrusion press heat treatment contact cooling
water was collected at one plant.  Elevated concentrations of
chromium (0.130 mg/1) were detected in the sample.

Forging, Extrusion, and Isostatic Press Hydraulic Fluid Leakage.
As discussed in Section III, due to the large force applied by a
hydraulic press, hydraulic fluid leakage is unavoidable.

Three samples of extrusion press hydraulic fluid leakage were
collected at one plant and one sample of forging press hydraulic
fluid leakage was collected at another plant.  Elevated concen-
trations of nickel  (1.30 mg/1), oil and grease (420 mg/1), and
TSS (500 mg/1) were detected in the samples.
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Forging Equipment Cleaning Wastewater.  Forging equipment  may  be
periodically cleaned in order to prevent the excessive build-up
of oil and grease on the forging die.

No samples of forging equipment cleaning wastewater were col-
lected during the screen sampling program.  However, the Agency
believes that this stream will have wastewater characteristics
similar to forging die contact cooling water in this subcategory.
These two waste streams are generated from similar physical
processes (flushing a forging die with water), so the pollutants
present are expected to be similar.  However, the water is used
for different purposes, in one case to cool a hot die, in  the
other, to remove built-up contaminants.  Therefore, the mass
loadings of oil and grease are expected to be higher in forging
equipment cleaning wastewater than in forging die contact  cooling
water.

Forging Die Contact Cooling Water.  As discussed in Section III,
forging dies may require cooling to maintain the proper die tem-
perature between forgings, or to cool the dies prior to removal
from the forge hammer.

One sample of forging die contact cooling water was collected  at
one plant.   Elevated concentrations of nickel (16 mg/1), copper
(3.4 mg/1)  and TSS (1,800 mg/1) were detected in the sample.

Forging and Swaging Spent Neat Oils.  As described in Section
IIl7 an oil medium can be usedfor proper lubrication of forging
and swaging dies.  Of the plants surveyed reporting the use of
forging and swaging neat oils, all recycle the oils until  their
lubricating properties are exhausted, at which time the oils are
contract hauled.

Since none  of the plants surveyed reported discharging the forg-
ing and swaging spent neat oils, no samples of this waste  stream
were collected.

Stationary and Direct Chill Casting Contact Cooling Water.  As
discussed in Section III, contact cooling water is a necessary
part of direct chill casting and is sometimes used in stationary
casting.  The cooling water may be contaminated by lubricants
applied to  the mold before and during the casting process  and by
the cast metal itself.

No samples  of stationary and direct chill casting contact  cooling
water were  collected during the screen sampling program.   How-
ever, the Agency believes that this stream will have wastewater
characteristics similar to rolling contact lubricant-coolant
water in this subcategory.  These two waste streams are generated
from operations using water for similar purposes (to cool  hot
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metal).  In addition, no process  chemicals  are  added  to  either
type of cooling water.  Therefore, both the pollutants present
and the mass loadings of pollutants present in  the  two streams
are expected to be similar.

Vacuum Melting Steam Condensate.  As discussed  in Section III,
nickel/cobalt may be melted by  an operation known as  vacuum  melt-
ing.  The high pressure steam used to create the vacuum  condenses
to an extent as it produces the vacuum.  Although this water does
not come in contact with the metal product, it  may  potentially be
contaminated with metal fines or  components of  lubricant com-
pounds volatilized in the furnace if scrap  is being melted.

One sample of vacuum melting steam condensate was collected  at
one plant.  No pollutants were  detected in  the  sample at elevated
concentrations.

Metal Powder Production Atomization Wastewater.  As discussed in
Section III,metal powder iscommonly produced  through wet atomi-
zation of a molten metal.  Of the plants surveyed,  three reported
the use of water in atomization of molten nickel.

One sample of metal powder production atomization wastewater was
collected at one plant.  Elevated concentrations of chromium (1.0
mg/1), cobalt (5.2 mg/1), TSS (63 mg/1), and oil and  grease  (22
mg/1; were detected in the sample.

Annealing Solution Heat Treatment Contact Cooling Water.  As
discussed in Section III, solution heat treatment is  implemented
after annealing operations to improve mechanical properties  by
maximizing the concentration of hardening contaminants in the
solid metal solution.  Solution heat treatment  typically involves
significant quantities of contact cooling water.

Two samples of solution heat treatment contact  cooling water were
collected from two streams at two plants.  Elevated concentra-
tions of nickel (6.80 mg/1), copper (2.92 mg/1), oil  and grease
(40 mg/1), and TSS (78 mg/1) were detected in the samples.

Vet Air Pollution Control Slowdown.  As discussed in  Section III,
wet air pollution control devices^are required  to control air
pollution from some operations.   Scrubbers are  frequently neces.-
sary over pickling operations to  control fumes  and  over  shot
blasting operations to control  particulates.

Two samples of wet air pollution  control blowdown were collected.
Slowdown from a scrubber on a pickling operation was  sampled at
one plant and on a shot blasting  operation at another plant.
Elevated concentrations of nickel (20.0 mg/1),  copper (2.85
mg/1), chromium (1.75 mg/1), and TSS (130 mg/1) were  detected in
the samples.
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Surface Treatment Spent Baths.  As  discussed  in Section  III,  a
number of chemical surface treatments may be  applied  after  the
forming of nickel/cobalt products.  Although  spent  surface  treat-
ment baths are often discharged, two out of 22 plants reporting
surface treatment baths have the spent baths  contract hauled.

Samples of five spent surface treatment baths were  collected  at
two plants.  Very high concentrations of nickel (193,000 mg/1),
copper (4,800 mg/1), cobalt (4,000  mg/1), chromium  (3,600 mg/1),
fluoride (94,000 mg/1), and TSS (5,800 mg/1) were detected  in  the
samples.

Sjurface Treatment Rinsewater.  As discussed in Section III, rins-
ing follows the surface treatment process to prevent the surface
treatment solution from affecting the surface of the  metal  beyond
the desired amount.

Twenty-three samples of surface treatment rinsewater were col-
lected from eight streams at three  plants.  Elevated  concentra-
tions of nickel (364 mg/1), copper  (87.4 mg/1), chromium (18.8
mg/1), cobalt (4.0 mg/1), zinc (2.36 mg/1), oil and grease  (130
mg/1), and TSS (760 mg/1) were detected in the samples.

Alkaline Cleaning Spent Baths.  As  discussed in Section  III,
alkaline cleaners are formulations  of alkaline salts, water,  and
surfactants.  Spent solutions are discharged from alkaline  clean-
ing processes.

Three samples of alkaline cleaning  spent baths were collected
from three streams at two plants.    Elevated concentrations  of
nickel (122 mg/1), copper (39.2 mg/1), zinc (3.9 mg/1),  chromium
(3.59 mg/1), oil and grease (49 mg/1), and TSS (4,000 mg/1) were
detected in the samples.

Alkaline Cleaning Rinsewater.  As discussed in Section III, metal
parts are usually rinsed following  alkaline cleaning to  remove
the cleaning solution and any solubilized contaminants.

Four samples of alkaline cleaning rinsewater were collected from
three streams at two plants.   Elevated concentrations of nickel
(5.58 mg/1), mg/1), oil and grease  (26 mg/1), and TSS (190  mg/1)
were detected in the samples.

Molten Salt Spent Baths.  As discussed in Section III, molten
salt baths are used to descale nickel and cobalt alloys.  Formed
parts to be descaled are immersed in the bath for up to  15
minutes, removed, and water-quenched.

When removed from the heated bath container, the molten  salt bath
solution solidifies and is no longer a liquid waste stream.  The
solidified spent salt bath is usually discarded as  a hazardous


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waste because it contains high concentrations of hexavalent  chro-
mium.  Therefore, no samples of molten salt baths were collected.

Molten Salt Rinsewater.  As discussed in Section III, when molten
salt baths are used to descale nickel and cobalt alloys,  they are
generally followed by a water quench/rinse step.

Seven samples of molten salt rinsewater were collected from  three
streams at three plants.  Elevated concentrations of nickel  (14
mg/1), copper (8.05 mg/1), cobalt (2.8 mg/1), chromium (1,100.
mg/1), and TSS (4,200 mg/1) were detected in the samples.

Ammonia Rinse Wastewater.  As discussed in Section III, an
ammonia rinse may be used after acid pickling of nickel/cobalt
products to neutralize the acid prior to further rinsing.  The
ammonia rinse is periodically batch discharged when spent.

One sample of ammonia rinse wastewater was collected at one
plant.  Elevated concentrations of nickel (456 mg/1), copper
(54.0 mg/1). chromium (108 mg/1), zinc (32.0 mg/1), and TSS
(9,000 mg/1) were detected in the sample.

Sawing/Grinding Spent Lubricants.  As discussed in Section III,
sawing/grinding operations generally require a lubricant  in  order
to minimize friction and act as a coolant.

Ten samples of sawing/grinding spent lubricants were collected
from 10 streams at two plants.  Elevated concentrations of nickel
(116 mg/1), copper (16.5 mg/1), cobalt (3.3 mg/1), chromium  (24.0
mg/1), oil and grease (16,000 mg/1), and TSS (2,440 mg/1) were
detected in the samples.

Steam Cleaning Condensate.  As discussed in Section III,  steam
cleaning may be used to remove oil and grease from the surface of
metal.  Steam is condensed as it hits the surface of the  rela-
tively cooler metal and is then discharged.

No samples of steam cleaning condensate were collected during the
screen sampling program.  However, the Agency believes that  this
stream will have wastewater characteristics similar to rolling
contact lubricant-coolant water in this subcategory.  These  two
waste streams are generated in processes in which water, without
any added process chemicals, contacts metal.  In the case of
contact lubricant-coolant water,  the metal is hot and the water
(relatively) cool.   In the case of steam cleaning condensate,
the water/steam is  hot and the metal (relatively) cool.  However,
the pollutants present and the mass loadings of pollutants
present in the two streams are expected to be similar.
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Hydrostatic Tube Testing Wastewajber.  As discussed  in Section
III, hydrostatic testing operations are used to check nonferrous
metals parts for surface defects or subsurface imperfections.
Hydrostatic testing operations are sources of wastewater because
the spent water bath or test media must be periodically discarded
due to the transfer into the testing media of oil and grease,
solids, and suspended and dissolved metals from each product
tested.

No samples of hydrostatic tube testing wastewater were collected
during the screen sampling program.  However, the Agency believes
that this stream will have wastewater characteristics similar  to
rolling contact lubricant-coolant water in this subcategory.
These two waste streams are generated in processes  in which
water, without any added process chemicals, contacts metal.
Therefore, the pollutants present in each waste stream and the
mass loading (mg/kkg) at which they are present should be
similar.

Degreasing Spent Solvents.  As described in Section III, solvent
cleaners are used to remove lubricants (oils and greases) applied
to the surface of nonferrous metals during mechanical forming
operations.  Basic solvent cleaning methods include straight
vapor degreasing, immersion-vapor degreasing, spray-vapor
degreasing, ultrasonic vapor degreasing, emulsified solvent
degreasing, and cold cleaning.

Solvents most commonly used for all types of vapor  degreasing  are
trichloroethylene, 1,1,1-trichloroethane, methylene chloride,
perchloroethylene, and various chlorofluorocarbons.  Solvent
selection depends on the required process temperature (solvent
boiling point), product dimension, and metal characteristics.
Contaminated vapor degreasing solvents are frequently recovered
by distillation.  The sludge residue generated is toxic and may
be flammable, requiring appropriate handling and disposal pro-
cedures .

Since none of the plants surveyed reported discharging the vapor
degreasing spent solvents, no samples were collected.

Miscellaneous Nondescript Wastewater Sources.  Several low volume
sources oTT wastewater" were report eT~on~ the Hep and  observed dur-
ing the site and sampling visits.  These sources are maintenance
and cleanup,  final product Uibrication, and product degreasing
rinsewater.  Because they generally represent low volume periodic
discharges applicable to most plants, the Agency is including  an
allowance for all of these streams under the miscellaneous
nondescript wastewater soitrc.es wast*3 stream.

Operations Which Do Not_l)eo Process 'water.  Ihe Agency proposes a
dischargr allowance or zn-.. lor ope-'af Ions vuvLch do not generate
                               4.U

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process wastewater.  The following operations generate no process
wastewater, either because they are dry or because they use
noncontact cooling water only:

     Powder Metallurgy Operations (Compacting, Sintering, Sizing)
     Powder Blending
     Powder Ball Milling
     Powder Attrition
     Powder Extrusion
     Hot Isostatic Pressing
     Grit, Sand, Shot Blasting
     Welding
     Plasma Torch Cutting
     Gas Cleaning
     Coil Buildup, Coiling
     Straightening
     Electroflux Remelting

Zinc Forming Subcategory

Rolling Spent Neat Oils.  As described in Section III, mineral
oil or kerosene-based lubricants can be used in the rolling of
zinc products.  The oils are usually recycled with in-line fil-
tration and periodically disposed of by sale to an oil reclaimer
or by incineration.

Since none of the plants surveyed reported discharging the roll-
ing spent neat oils, no samples were collected.

Rolling Spent Emulsions.  As discussed in Section III, oil-in-
water emulsions are used in rolling operations as coolants and
lubricants.  Rolling emulsions are typically recycled using
in-line filtration treatment, with periodic batch discharge of
the recycled emulsion.

No samples of rolling spent emulsions were collected during the
screen sampling program.  However, the Agency believes that this
stream will have wastewater characteristics similar to rolling
spent emulsions in the lead/tin/bismuth subcategory.  These two
waste streams are generated by identical physical processes which
use similar process chemicals.  The only difference should be the
identity of metals present.  The mass loading (mg/kkg) of zinc in
zinc rolling spent emulsions should be similar to the mass load-
ing of lead in lead rolling spent emulsions, and vice versa.   The
other pollutants present in each waste stream and the mass load-
ing at which they are present should be similar.

Rolling Contact Lubricant-Coolant Water.   As discussed in Section
III,it is necessary to use a lubricant-coolant during rolling to
prevent excessive wear on the rolls,  to prevent adhesion of metal
                               415

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 to  the  rolls,  and  to  maintain  a  suitable  and uniform rolling  tem-
 perature.  Water is one  type of  lubricant-coolant which  may be
 used.

 No  samples of  rolling contact  lubricant-coolant water were col-
 lected  during  the  screen sampling program.  However,  the Agency
 believes  that  this  stream will have wastewater characteristics
 similar to casting  contact cooling water  in the lead/tin/bismuth
 subcategory.   These two  waste  streams  are generated  by using
 water, without additives, to cool hot  metal.  The only difference
 between the wastewater characteristics of the two streams should
 be  the metals  present.   The mass loading  (mg/kkg) of  zinc in  zinc
 rolling contact lubricant-coolant water should be similar to  the
 mass loading of lead  in  lead casting contact cooling  water, and
 vice versa.  The other pollutants present in each waste  stream
 and the mass loading  at  which they are present should be
 similar.

 Drawing Spent  Emulsions.  As discussed in Section III, oil-in-
 water emulsions are used for many drawing applications in order
 to  ensure uniform  drawing temperatures and avoid excessive wear
 on  the dies and mandrels used.  The drawing emulsions are fre-
 quently recycled and  batch discharged periodically after their
 lubricating properties are exhausted.

 No  samples of  drawing  spent emulsions were collected  during the
 screen sampling program.  However, the Agency believes that this
 stream will have wastewater characteristics similar  to rolling
 spent emulsions in the lead/tin/bismuth subcategory.  These waste
 streams are generated  from operations using similar process chem-
 icals (oil-in-water emulsions) for similar purposes  (lubrica-
 tion).  The only difference should be the  metals present.  The
 mass loading (mg/kkg)  of zinc in zinc drawing spent  emulsions
 should be similar to  the mass loading of  lead in lead rolling
 spent emulsions, and  vice versa.  The other pollutants present in
 each waste stream and  the mass loading at which they  are present
 should be similar.

 Direct Chill Casting  Contact Cooling Water.  As discxissed in Sec-
 tion III, contact cooling water is a necessary part of direct
 chill casting.   The cooling water may be  contaminated by lubri-
 cants applied  to the  mold before and during the casting  process.
 The cooling water may  be recycled.

No  samples of  direct  chill casting contact cooling water were
 collected during the  screen sampling program.  However,  the
 Agency believes that  this stream will have wastewater character-
 istics similar to semicontinuous ingot casting contact cooling
 water in the lead/tin/bismuth subcategory.  These two waste
 streams are generated by using water, without additives,  to cool
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cast metal.  Since lubricants may be applied to the casting molds
in both processes, both streams may be contaminated by these
lubricants.  The only difference between the waste streams should
be the metals present.  The mass loading (mg/kkg) of zinc in zinc
direct chill casting contact cooling water should be similar to
the mass loading of lead in lead semicontinuous ingot casting
contact cooling water, and vice versa.  The other pollutants
present and the mass loading at which they are present should be
similar.

Stationary Casting Contact Cooling Water.  As discussed  in Sec-
tion III, lubricants and cooling water are usually not required
in stationary casting.  Since molten metal is poured into the
molds, if contact cooling water is used, it is frequently lost
due to evaporation.

Since none of the plants surveyed reported discharging the
stationary casting contact cooling water, no samples were
collected.

Solution Heat Treatment Contact Cooling Water.  As discussed in
Section III, solution heat treatment is implemented after most
forming operations to improve mechanical properties by maximizing
the concentration of hardening contaminants in solid solution.
Solution heat treatment typically involves significant quantities
of contact cooling water.

No samples of solution heat treatment contact cooling water were
collected during the screen sampling program.  However,  the
Agency believes that this stream will have wastewater character-
istics similar to continuous sheet casting contact cooling water
in the lead/tin/bismuth subcategory.  These two waste streams
derive from the use of water, without additives, to cool hot
metal.  The only difference should be the metals present.  The
mass loading (mg/kkg) of zinc in zinc solution heat treatment
contact cooling water should be similar to the mass loading of
lead in lead continuous sheet casting contact cooling water, and
vice versa.  The other pollutants present in each waste  stream
and the mass loading at which they are present should be
similar.

Surface Treatment Rinsewater.  As discussed in Section III, rins-
ing follows the surtace treatment process to prevent the solution
from affecting the surface of the metal beyond the desired
amount.

One sample of surface treatment rinsewater was collected at one
plant.  Elevated concentrations of zinc (42.3 mg/1), chromium
(0.160 mg/1), nickel (8.10 mg/1), and TSS (20 mg/1) were detected
in the sample.
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Alkaline Cleaning Spent Baths.  As  discussed  in Section  III,
alkaline cleaners are formulations  of alkaline salts, water,  and
surfactants.  Spent solutions are discharged  from alkaline  clean-
ing processes after their properties are exhausted.

No samples of alkaline cleaning spent baths were collected  during
the screen sampling program.  However, the Agency believes  that
this stream will have wastewater characteristics similar  to alka-
line cleaning rinsewater in this subcategory.  As a zinc  piece  is
removed from an alkaline cleaning bath, it carries a small  volume
of the bath with it.  The rinsewater used to  remove the  carried-
over bath solution from the formed  piece will contain the same
pollutants as the bath, only diluted.  Therefore, the pollutants
present in zinc alkaline cleaning baths are expected to be  iden-
tical to the pollutants present in  zinc alkaline cleaning rinse-
water, except that the mass loadings of oil and grease and  dis-
solved metals are expected to be higher in the spent baths  than
in the rinsewater while the mass loading of total suspended
solids is expected to be much higher in the baths than in the
rinsewater.

Alkaline Cleaning Rinsewater.  As discussed in Section III, fol-
lowing alkaline treating, metal parts are rinsed.  Rinses are
discharged from alkaline cleaning processes.

One sample of alkaline cleaning rinsewater was collected  at one
plant.  Elevated concentrations of  zinc (1.12 mg/1), cyanide  (1.3
mg/1), oil and grease (23 mg/1), and TSS (90 mg/1) were detected
in the sample.

Sawing/Grinding Spent Lubricants.   As discussed in Section  III,
sawing/grinding operations generally require a lubricant:  in order
to minimize friction and act as a coolant.

No samples of sawing/grinding spent lubricants were collected
during the screen sampling program.   However, the Agency believes
that this stream will have wastewater characteristics similar to
sawing/grinding spent lubricants in the nickel/cobalt subcate-
gory.   These two waste streams are  generated by identical physi-
cal processes which use similar process chemicals.  The only  dif-
ference should be the metals present.  The mass loading  (mg/kkg)
of zinc in zinc sawing/grinding spent lubricants should be  simi-
lar to the mass loading of nickel in nickel sawing/grinding spent
lubricants, and vice versa.  The mass loading of chromium in  zinc
sawing/grinding spent lubricants should be insignificant, since
chromium is often alloyed with nickel but not with zinc,,  The
other pollutants present in each waste stream and the mass
loading at which they are present should be similar.
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Degrees ing Spent Solvents.  As  described  in Section III,  solvent
cleaners are used to remove lubricants  (oils and greases) applied
to the surface of nonferrous metals during mechanical  forming
operations.  Basic solvent cleaning methods include straight
vapor degreasing, immersion-vapor degreasing, spray-vapor
degreasing, ultrasonic vapor degreasing,  emulsified solvent
degreasing, and cold cleaning.

Solvents most commonly used for all types of vapor degreasing are
trichloroethylene, 1,1,1-trichloroethane, methylene chloride,
perchloroethylene, and various  chlorofluorocarbons.  Solvent
selection depends on the required process temperature  (solvent
boiling point), product dimension, and  metal characteristics.
Contaminated vapor degreasing solvents  are frequently  recovered
by distillation.  The sludge residue generated is toxic and may
be flammable, requiring appropriate handling and disposal pro-
cedures .

Since none of the plants surveyed reported discharging the vapor
degreasing spent solvents, no samples were collected.

Operations Which Do Not Use Process Water.  The Agency proposes a
discharge allowance of zero for operations which do not generate
process wastewater.  The following operations generate no process
wastewater, either because they are dry operations or  because
they use only noncontact cooling water:

     Continuous Casting
     Melting
     Slitting
     Stamping
     Sawing
     Homogenizing
     Printing
     Coating
     Drying
     Metal Powder Production

Beryllium Forming Subcategory

Area Cleaning Wastewater.  Due to the toxicity of beryllium, it
is necessary to keepforming areas reasonably clean.   After the
operations of a shift, areas need to be hosed down.

No samples of area cleaning wastewater were collected  during the
screen sampling program.  However, the Agency believes that this
stream will have wastewater characteristics similar to billet
washing wastewater in this subcategory.  These two waste streams
are generated in washing/cleaning operations.  Therefore, the
pollutants present in beryllium area cleaning wastewater are
                               419

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expected to be identical to the pollutants present in beryllium
billet washing wastewater, except that mass loadings of oil and
grease and total suspended solids are expected to be higher in
the area cleaning wastewater.

Billet Washing Wastewater.  Beryllium billets are washed after
vacuum casting and sintering to remove an oxide layer on the
billet formed at the elevated casting and sintering temperatures.
Billets are washed using a high pressure spray nozzle to blast
off the oxide layer.  In the plant surveyed, the wastewater is
not recirculated.

Two samples of billet washing wastewater were collected from two
streams at one plant.  Elevated concentrations of beryllium (82
mg/1), copper (0.75 mg/1), and TSS (160 mg/1) were detected in
the samples.

Surface Treatment Spent Baths.  As discussed in Section III, a
number of chemical treatments may be applied after the forming of
nonferrous metals products.  Beryllium products are commonly
etched with a nitric acid-hydrofluoric acid solution.  The acid
bath is used until its etching properties have been diminished
and fresh chemicals are needed.

One sample of a surface treatment spent bath was collected at one
plant.  Elevated concentrations of beryllium (15,000 mg/1),
chromium, (3.0 mg/1), zinc (2.0 mg/1), nickel (2.4 mg/1), fluoride
(79,000 mg/1), and TSS (240 mg/1; were detected in the sample.

Surface Treatment Rinsewater.  As discussed in Section III, after
a surface treatment bath,tHe nonferrous metal product must be
rinsed in order to stop the surface reaction from proceeding
beyond the desired amount.  An overflow rinse tank is used after
the beryllium etching bath in the plant surveyed.

Two samples of surface treatment rinsewater were collected from
one stream at one plant.  Elevated concentrations of beryllium
(35 mg/1), copper (6.1 mg/1), and TSS (18 mg/1) were detected in
the samples.

Sawing/Grinding Spent Lubricants.  As discussed in Section III,
sawing/grinding operations generally require a lubricant in order
to minimize friction and act as a coolant.

One sample of sawing/grinding spent lubricants was collected at
one plant.  Elevated concentrations of beryllium (17 mg/1), zinc
(0.86 mg/1),  copper (1.5 mg/1), cyanide (1.1 mg/1), oil and
grease (21,000 mg/1), and TSS (19 mg/1) were detected in the
sample.
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Inspection/Testing Wastewater.  As discussed in Section III,
product testing operations are used to check nonferrous metals
parts for surface defects, subsurface imperfections, and product
density.  Product testing operations are usually sources of
wastewater because the spent water bath or test media must be
periodically discarded due to the transfer into the testing media
of oil and grease, solids, and suspended and dissolved metals
from each product tested.  Toxic organics may also be present,
originating in the lubricants used in preceding forming opera-
tions.  Beryllium products are washed before undergoing density
testing, therefore, no pollutants are expected in this waste
stream.  The testing water is used indefinitely at the plant
surveyed.

One sample of inspection/testing wastewater was collected at one
plant.  No pollutants were detected at elevated concentrations in
the sample.

Degreasing Spent Solvents.  As described in Section III, solvent
•cleaners are used to remove lubricants (oils and greases) applied
to the surface of nonferrous metals during mechanical forming
operations.  Basic solvent cleaning methods include straight
vapor degreasing, immersion-vapor degreasing, spray-vapor
degreasing, ultrasonic vapor degreasing, emulsified solvent
degreasing, and cold cleaning.

Solvents most commonly used for all types of vapor degreasing are
trichloroethylene, 1,1,1-trichloroethane, methylene chloride,
perchloroethylene, and various chlorofluorocarbons.  Solvent
selection depends on the required process temperature (solvent
boiling point), product dimension, and metal characteristics.
Contaminated vapor degreasing solvents are frequently recovered
by distillation.  The sludge residue generated is toxic and may
be flammable, requiring appropriate handling and disposal pro-
cedures.

Since none of the plants surveyed reported discharging the vapor
degreasing spent solvents, no samples were collected.

Operations Which Do Not Use Process Water.  The Agency proposes a
discharge allowance of zero for operations which do not generate
process wastewater.  The following operations generate no process
wastewater, either because they are dry or because they use only
noncontact cooling water:

     Billet Chipping
     Powder Metallurgy Operations (Pressing, Sintering)
                               421

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Precious Metals Forming Subcategory

Rolling Spent Emulsions.  As discussed in Section III, oil-in-
water emulsions are used in rolling operations as coolants and
lubricants.  Rolling emulsions are typically recycled using
in-line filtration with periodic batch discharge of the recycled
emulsion as it loses its lubricating properties.

One sample of rolling spent emulsions was collected at one plant.
Elevated concentrations of silver (0.130 mg/1), copper (25.0
mg/1), lead (1.00 mg/1), nickel  (1.00 mg/1), oil and grease
(1,500 mg/1),  and TSS (500 mg/1) were detected in the sample.

Rolling Solution Heat Treatment Contact Cooling Water.  As dis-
cussed in Section III,solution heat treatment can be used after
most forming operations in order to improve mechanical properties
by maximizing the concentration of hardening contaminants in
solid solution.  Solution heat treatment typically involves
significant quantities of contact cooling water.

No samples of rolling solution heat treatment contact cooling
water were collected during the screen sampling program.  How-
ever, the Agency believes that this stream will have wastewater
characteristics similar to semi-continuous and continuous casting
contact cooling water in this subcategory.  These two waste
streams are generated by the use of water, without additives, to
cool hot metal.  Therefore, the pollutants present in each waste
stream and the mass loading at which they are present, should be
similar.

Drawing Spent Neat Oils.  As discussed in Section III, oil-based
lubricantsmay be required in draws which have a high reduction
in diameter.  Drawing oils are usually recycled until their
lubricating properties are exhausted.

Since none of the plants surveyed reported discharging the draw-
ing spent neat oils, no samples were collected.

Drawing Spent Emulsions.  As discussed in Section III, oil-in-
water emulsions may be used as coolants and lubricants in draw-
ing.  The drawing emulsions are frequently recycled and batch
discharged periodically after their lubricating properties are
exhausted.

One sample of drawing spent emulsions was collected at one plant.
Elevated concentrations of copper (46.4 mg/1), zinc (5.18 mg/1),
lead (1.05 mg/1), and oil and grease (33,000 mg/1) were detected
in the sample.
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Drawing Spent Soap Solutions.  As discussed in Section III, soap
solutions can be used as drawing lubricants.  The drawing soap
solutions may be recycled and batch discharged periodically after
their lubricating properties are exhausted.

No samples of drawing spent soap solutions were collected during
the screen sampling program.  However, the Agency believes that
this stream will have wastewater characteristics similar to roll-
ing spent emulsions in this subcategory.  These two waste streams
are generated from operations using similar process chemicals for
similar purposes (lubrication).  Therefore, the pollutants pres-
ent and the mass loading at which they are present should be
similar.

Extrusion Solution Heat Treatment Contact Cooling Water.  As dis-
cussed in Section III, solution heat treatment can be used after
most forming operations in order to improve mechanical properties
by maximizing the concentration of hardening contaminants in
solid solution.  Solution heat treatment typically involves
significant quantities of contact cooling water.

No samples of extrusion solution heat treatment contact cooling
water were collected during the screen sampling program.  How-
ever, the Agency believes that this stream will have wastewater
characteristics similar to semi-continuous and continuous contact
cooling water in this subcategory.   These two waste streams are
generated by using water, without additives, to cool hot metal.
Therefore, the pollutants present in each waste stream and the
mass loading at which they are present should be similar.

Semi-Continuous and Continuous Casting Contact Cooling Water.  As
discussed in Section III,a number of different continuouscast-
ing processes are currently being used in industry.  The use of
continuous casting techniques has been found to significantly
reduce or eliminate the use of contact cooling water and oil
lubricants.

One sample of semi-continuous and continuous casting contact
cooling water was collected at one plant.  Elevated concentra-
tions of cyanide (0.50 mg/1) and TSS (43 mg/1) were detected in
the sample.

Stationary Casting Contact Cooling Water.  As discussed in Sec-
tion III, stationary casting of metal ingots is practiced at many
nonferrous metals forming plants.  Lubricants and cooling water
are usually not required, however,  two of the plants surveyed re-
ported the use and discharge of stationary casting contact cool-
ing water.
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No samples of stationary casting contact cooling water were  col-
lected during the screen sampling program.  However, the Agency
believes that this stream will have wastewater characteristics
similar to semi-continuous and continuous casting contact cooling
water in this subcategory.  These two waste streams are; generated
by using water, without additives, to cool hot metal.  Therefore,
the pollutants present in each waste stream and the mass loading
at which they are present should be similar.

Direct Chill Casting Contact Cooling Water.  As discussed in Sec-
tion III, contact cooling water is a necessary part of direct
chill casting.  The cooling water may be contaminated by lubri-
cants applied to the mold before and during the casting process.

No samples of direct chill casting contact cooling water were
collected during the screen sampling program.  However, the
Agency believes that this stream will have wastewater character-
istics similar^to semi-continuous and continuous casting contact
cooling water in this subcategory.  These two waste streams are
generated by using water, without additives, to cool hot metal.
Therefore, the pollutants present in each waste stream and the
mass loading at which they are present should be similar.

Shot Casting Contact Cooling Water.   As discussed in Section III,
during shot casting,a tank of contact cooling water, either
stagnant or circulating,  is necessary for quick quenching of cast
shot.

Two samples of shot casting contact cooling water were collected
from one stream at one plant.   Elevated concentrations of cadmium
(9.88 mg/1), copper (0.600 mg/1), zinc (5.66 mg/1), and oil and
grease (54 mg/1) were detected in the samples.

Casting Wet Air Pollution Control Blowdown.  As discussed in Sec-
tion III, casting may require wet air pollution control in order
to meet air quality standards.  Of the plants surveyed, two
reported the use of wet air pollution control on a casting
operation.

No samples of casting wet air pollution control blowdown were
collected during the screen sampling program.  However, the
Agency believes that this stream will have wastewater character-
istics similar to shot casting contact cooling water in this sub-
category.  The pollutants in each of these waste streams derive
from the contact of the water with particles of metal, so the
pollutants present are expected to be similar.  However, because
the air pollution control device is designed to capture small
particles and gases (dust and fumes) generated during the casting
process, the mass loadings of total suspended solids and total
dissolved solids are expected to be higher in casting wet air
                               424

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pollution control blowdown than  in shot casting contact  cooling
water.

Metal Powder Production Atomization Wastewater.  As discussed in
Section III, metal powder is commonly produced through wet atomi-
zation of a molten metal.  Water is removed after the atomization
step, commonly by settling, then discharged.

No samples of metal powder production atomization wastewater were
collected during the screen sampling program.  However,  the
Agency believes that this stream will have wastewater character-
istics similar to shot casting contact cooling water in  this
subcategory.  These two waste streams are generated by using
water to cool molten metal.  Therefore, the pollutants present in
each waste stream and the mass loading (mg/kkg) at which they are
present should be similar.

Metal Powder Production Ball Milling Wastewater.  As discussed in
Section III,metal powderscan be produced by milling with water,
most commonly wet ball milling.  After the wet milling operation,
excess water is extracted from the metal powder, commonly by set-
tling, and then discharged.

No samples of metal powder production ball milling wastewater
were collected during the screen sampling program.  However, the
Agency believes that this stream will have wastewater character-
istics similar to tumbling wastewater in this subcategory.  These
two waste streams are generated from similar physical processes
using water for similar purposes, so the pollutants present are
expected to be similar.  However, because process chemicals (rust
inhibitors, detergents) are sometimes added to tumbling  water,
the mass of loadings of total dissolved solids are expected to be
higher in tumbling wastewater than in metal powder production
ball milling wastewater.

Pressure Bonding Contact Cooling Water.  As discussed in Section
III,metalscan be bonded together through the use of pressure
applied onto the desired forms.  Cooling water may be applied
after the bonding operation to facilitate handling of the bonded
product.

One sample of pressure bonding contact cooling water was col-
lected at one plant.  Elevated concentrations of zinc (3.42 mg/1)
and copper (7.85 mg/1) were detected in the sample.

Annealing Contact Cooling Water.   As discussed in Section III,
annealing is used by plants in the nonferrous metals forming
category to remove the effects of strain hardening or solution
heat treatment.  Once removed from the annealing furnace, it is
essential that the heat-treatable alloys be cooled at a  control-
led rate.  Contact cooling water may be used for this purpose.
                               425

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No samples of annealing contact cooling water were collected  dur-
ing the screen sampling program.  However, the Agency believes
that this stream will have wastewater characteristics similar to
semi-continuous and continuous casting contact cooling water  in
this subcategory.  These two waste streams are generated by using
water, without additives, to cool hot metal.  Therefore, the
pollutants present in each waste stream and the mass loading  at
which they are present should be similar.

Surface Treatment Spent Baths.  As discussed in Section III,  a
number of chemical treatments may be applied after the forming of
precious metals products.  The surface treatment baths must be
periodically discharged after their properties are exhausted.

No samples of surface treatment spent baths were collected during
the screen sampling program.  However, the Agency believes that
this stream will have wastewater characteristics similar to sur-
face treatment rinsewater in this subcategory.  As a precious
metal piece is removed from a surface treatment bath, it carries
with it a small volume of the bath.  The rinsewater used to
remove the carried-over bath solution from the formed piece will
contain the same pollutants as the bath, only at lower concentra-
tion.  Therefore, the pollutants present in precious metals
surface treatment baths are expected to be identical to the
pollutants in precious metals surface treatment rinsewater,
except that the mass loadings of dissolved metals and total
suspended solids are expected to be higher in surface treatment
spent baths than in surface treatment rinsewater.

Surface Treatment Rinsewater.  As discussed in Section III, rins-
ing followsthe surface treatment process to prevent the solution
from affecting the surface of the metal beyond the desired
amount.

Four samples of surface treatment rinsewater were collected from
two streams at two plants.  Elevated concentrations of silver
(6.70 mg/1), zinc (4.66 mg/1), cadmium  (11.1 mg/1), copper (60.6
mg/1), and TSS (3,000 mg/1) were detected in the samples.

Alkaline Cleaning Spent Baths.  As discussed in Section III,
alkaline cleaners are formulations of alkaline salts, water,  and
surfactants.  Spent solutions are discharged from alkaline clean-
ing processes after their properties are exhausted.

No samples of alkaline cleaning spent baths were collected during
the screen sampling program.  However, the Agency believes that
this stream will have wastewater characteristics similar to alka-
line cleaning spent baths in the nickel/cobalt subcategory.
These two waste streams are generated by identical physical pro-
cesses which use similar process chemicals.  The only difference
                               426

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should be the metals present.  The mass  loading of precious
metals in precious metals alkaline cleaning spent baths should be
similar to the mass loading of nickel in nickel alkaline  cleaning
baths, and vice versa.  Also, chromium should not be present in
significant amounts.  The other pollutants present in each waste
stream, and the mass loading at which they are present, should be
similar.

Alkaline Cleaning Rinsewater.  As discussed in Section III,  fol-
1owing alkaline treating, metal parts are rinsed.  Rinses are
discharged from alkaline cleaning processes.

No samples of alkaline cleaning rinsewater were collected during
the screen sampling program.  However, the Agency believes that
this stream will have wastewater characteristics similar  to  alka-
line cleaning rinsewater in the nickel/cobalt subcategory.  These
two waste streams are generated by identical physical processes
which use similar process chemicals.  The only difference should
be the metals present.  The mass loading of precious metals  in
precious metals alkaline cleaning rinsewater should be similar to
the mass loading of nickel in nickel alkaline cleaning rinse-
water, and vice versa.  Also, chromium should not be present in
significant amounts.  The other pollutants present in each waste
stream, and the mass loading at which they are present, should be
similar.

Prebonding Cleaning Wastewater.  As discussed in Section III,
prior to bonding, metal surfaces must be cleaned in order to
obtain a good bond.  The main source of  process water in  metal
cladding operations is in cleaning the metal surfaces prior to
bonding.  Acid, caustic, or detergent cleaning can be performed
depending on the metal type.  For small  batch operations, the
cleaning steps can involve dipping the metal into small cleaning
bath tanks and hand rinsing the metal in a sink.  For larger con-
tinuous operations, the metal may be cleaned in a power scrubline
In a typical scrubline, the strip passes through a detergent
bath, spray rinse, acid bath, spray rinse, rotating abrasive
scrub brushes, and a final rinse.  The metal may then pass
through a heated drying chamber or may air dry.

Eight samples of prebonding cleaning wastewater were collected
from three streams at two plants.  Elevated concentrations of
silver (0.100 mg/1), zinc (2.32 mg/1), copper (5.95 mg/1),
cyanide (0.28 mg/1), nickel (3.60 mg/1), oil and grease (16
mg/1), and TSS (400 mg/1) were detected  in the samples.

Tumbling Wastewater.  As discussed in Section III, tumbling is a
controlled method of processing parts to remove burrs, scale,
flash, and oxides as well as to improve  surface finish of formed
metal parts.  Water is commonly added to the tumbling container
and later discharged.
                              427

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Four samples of tumbling wastewater were collected from two
streams at two plants.  Elevated concentrations of silver  (0.220
mg/1), lead (1.85 mg/1), zinc (3.16 mg/1), iron (7,850 mg/1),
copper (142 mg/1), nickel (3.25 mg/1), chromium (3.18 mg/1), oil
and grease (40 mg/1), and TSS (110 mg/1) were detected in  the
samples.

Burnishing Wastewater.  As discussed in Section III, burnishing
is the process of finish sizing or smooth finishing a workpiece
(previously machined or ground) by displacement, rather than
removals of minute surface irregularities.  Water is commonly
used to aid in this operation.

No samples of burnishing wastewater were collected during  the
screen sampling program.  However, the Agency believes that this
stream will have wastewater characteristics similar to tumbling
wastewater in this subcategory.  These two waste streams are
generated from similar physical processes which use water  for
similar purposes.  Therefore, the pollutants present in each
waste stream and the mass loading (mg/kkg) at which they are
present should be similar.

Sawing/Grinding Spent Emulsions.  As discussed in Section  III,
the rolls used in rolling operations obtain surface abrasions
after repeated use.  The rolls must be surface ground in order to
obtain a smooth rolling surface.  The rolled product will  not be
formed properly if the rolls are not adequately smooth.  Roll
grinding and other sawing and grinding operations generally
require a lubricant to minimize friction and act as a coolant.
Oil-in-water emulsions are commonly used for this purpose.  The
emulsions are typically recycled using in-line filtration  and
batch discharged periodically after their lubricating properties
are exhausted.

A sample of roll grinding spent emulsions was collected at one
plant.  Elevated concentrations of zinc (0.920 mg/1), chromium
(0.240 mg/1), and oil and grease (500 mg/1) were detected  in the
sample.

Degreasing Spent Solvents.  As described in Section III, solvent
cleaners are used to remove lubricants (oils and greases)  applied
to the surface of nonferrous metals during mechanical forming
operations.  Basic solvent cleaning methods include straight
vapor degreasing, immersion-vapor degreasing, spray-vapor
degreasing, ultrasonic vapor degreasing, emulsified solvent
degreasing, and cold cleaning.

Solvents most commonly used for all types of vapor degreasing are
trichloroethylene, 1,1,1-trichloroethane, methylene chloride,
perchloroethylene, and various chlorofluorocarbons.  Solvent
                               428

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selection depends on the required process temperature (solvent
boiling point), product dimension, and metal characteristics.
Contaminated vapor degreasing solvents are frequently recovered
by distillation.  The sludge residue generated is toxic and may
be flammable, requiring appropriate handling and disposal pro-
cedures.

Since none of the plants surveyed reported discharging the vapor
degreasing spent solvents, no samples were collected.

Operations Which Do Not Use Process Water.  The Agency proposes a
discharge allowance of zero for operations which do not generate
process wastewater.  The following operations generate no process
wastewater, either because they use only noncontact cooling water
or because they use no water at all:

     Forging, Swaging
     Punching, Stamping
     Welding
     Soldering
     Melting, Screening
     Sawing
     Slitting
     Metal Powder Production

Metal Powder Production and Powder Metallurgy Iron, Copper, and
Aluminum Subcategory

Metal Powder Production Atomization Wastewater.  As discussed in
Section III, wet atomization is a method of producing metal
powder in which a stream of water impinges upon a molten metal
stream, breaking it into droplets which solidify as powder par-
ticles.  Water atomization is used to produce irregularly shaped
particles, required for powder metallurgy applications in which a
powder is cold pressed into a compact.  Because cooling times
play an important role in determining particle configuration, the
atomized metal droplets are sometimes rapidly cooled by falling
into a water bath.   Atomization and quench water are separated
from the metal powder by gravity settling or filtration and
discharged.

No samples of iron, copper or aluminum atomization wastewater
were collected during the screen sampling program.  However, the
Agency believes that this stream will have wastewater character-
istics similar to tumbling, burnishing, and cleaning wastewater
in this subcategory.   These two waste streams are generated from
operations using water, usually without added process chemicals,
in contact with finely divided metal.  The pollutants present in
each waste stream and the mass loading at which they are present
should be similar,  except for total suspended solids and oil and
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grease.  Oil and grease, present in high concentrations  in  clean-
ing wastewater, is not expected to be present in significant
concentrations in metal powder production atomization wastewater.
Because metal powders are more finely divided than the parts
tumbled and in higher concentration than the metal fines produced
during tumbling, the mass loading of total suspended solids is
expected to be higher in metal powder production atomization
wastewater than in tumbling, burnishing, and cleaning wastewater.

Metal Powder Production Milling Wastewater.  As discussed in Sec-
tion III, metal powders are also produced by mechanical  reduc-
tion.  The most common pieces of mechanical reduction equipment
are ball mills, vortex mills, hammer mills, disc mills,  and roll
mills.

Water or other liquids may be used to aid in the milling opera-
tion or to facilitate handling after powder is milled.

No samples of metal powder production milling wastewater were
collected during the screen sampling program.  However,  the
Agency believes that this stream will have wastewater character-
istics similar to tumbling, burnishing, and cleaning wastewater
in this subcategory.  These two waste streams are generated from
operations using water, usually without added process chemicals,
in contact with finely divided metal.  The pollutants present in
each waste stream and the mass loading at which they are present,
should be similar, except for total suspended solids and oil and
grease.  Oil and grease, present in high concentrations  in clean-
ing wastewater, is not expected to be present in significant
concentrations in metal powder production milling wastewater.
Metal powders are more finely divided than tumbled parts.
Powders are also present in higher concentration than the metal
fines produced during tumbling.  Therefore, the mass loading of
total suspended solids is expected to be higher in metal powder
production milling wastewater than in tumbling, burnishing, and
cleaning wastewater.

Metal Powder Production Wet Air Pollution Control Slowdown.  As
discussed in Section III, during the production of metal powders,
particulates may become airborne.   The use of wet air pollution
control may be necessary in order to meet particulate air quality
standards.

No samples of metal powder production wet air pollution  control
blowdown were collected during the screen sampling program.  How-
ever, the Agency believes that this stream will have wastewater
characteristics similar to blowdown from air pollution control
scrubbers used to control particulate emissions in the nickel/
cobalt subcategory.  The only difference between the wastewater
characteristics of the two streams should be the metals  present.
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The mass loading (mg/kkg) of iron, copper and/or aluminum in
iron, copper and aluminum metal powder production wet air pol-
lution control scrubber blowdown should be similar to the nickel
mass loading in nickel air pollution control scrubber blowdown,
and vice versa.  The other pollutants present in each waste
stream and the mass loading at which they are present, should be
similar.

Sizing/Repressing Spent Lubricants.  As discussed in Section III,
powder metallurgy parts may be sized or repressed after sintering
to increase the density of the part and/or to bring the part
closer to required tolerances.  Lubricants, such as turbine oil,
may be used to prevent the adhesion of the part to the sizing
die.  Since none of the plants surveyed reported discharging
sizing spent lubricants (they are completely consumed in the
process), no samples were collected.

Oil-Resin Impregnation wastewater.  As discussed in Section III,
porous parts pressed from metalpowders may be impregnated with
oils or resins.  Following impregnation, the parts may be rinsed
with water to remove excess oil or resin and the rinsewater may
be discharged.

No samples of oil-resin impregnation wastewater were collected
during the screen sampling program.  However, the Agency believes
that this stream will have wastewater characteristics similar to
tumbling, burnishing, and cleaning wastewater in this subcate-
gory.  These two waste streams are generated from similar physi-
cal processes in which water is used to clean formed parts.
Therefore, the pollutants present in each waste stream and the
mass loading (mg/kkg) at which they are present should be
similar.

Steam Treatment Wet Air Pollution Control Blowdown.  As discussed
in Section III, steam treatment operations may require the use of
wet air pollution control devices in order to meet air quality
standards.

Three samples of steam treatment wet air pollution control blow-
down were collected from one stream at one plant.  Elevated
concentrations of oil and grease (42 mg/1) and TSS (200 mg/1)
were detected in the samples.

Tumbling, Burnishing, and Cleaning Wastewater.  As discussed in
Section III,tumblingisan operation in parts pressed from metal
powder are rotated in a barrel with ceramic or metal slugs or
abrasives to remove scale, fins, or burrs.  It may be done dry or
with an aqueous solution.  Burnishing is a surface finishing pro-
cess in which minute surface irregularities are displaced rather
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than removed.  It also can be done by dry or  in an  aqueous  solu-
tion.  Pressed parts can also be cleaned in hot soapy water to
remove excess oil from oil quenching operations.

Six samples of tumbling wastewater were collected from  three
streams at one plant.  Four samples of cleaning wastewater were
collected from one stream at one plant.  Elevated concentrations
of iron (211 mg/1), copper (253 mg/1), aluminum (34.3 mg/1),
cyanide (1.8 mg/1), lead (45.1 mg/1), nickel  (3.00  mg/1), zinc
(9.56 mg/1), boron (440 mg/1), tin (15.8 mg/1), titanium  (2.50
mg/1), oil and grease (2,100 mg/1), and TSS (3,000  mg/1) were
detected in the samples.

Sawing/Grinding Spent Lubricants.  As discussed in  Section III,
sawing/grinding operationsgenerally require  a lubricant  in order
to minimize friction and act as a coolant.

Two samples of sawing/grinding lubricants were collected  from two
streams at one plant.  Elevated concentrations of iron  (176
mg/1), copper (1.55 mg/1), aluminum (7.00 mg/1), zinc (3.26
mg/1), boron (166 mg/1), cyanide (2.5 mg/1),  oil and grease (720
mg/1), and TSS (120 mg/1) were detected in the samples.

Degreasing Spent Solvents.  As described in Section III,  solvent
cleaners are used to remove lubricants (oils  and greases) applied
to the surface of metals during powder metallurgy operations.
Basic solvent cleaning methods include straight vapor degreasing,
immersion-vapor degreasing, spray-vapor degreasing, ultrasonic
vapor degreasing, emulsified solvent degreasing, and cold
cleaning.

Solvents most commonly used for all types of  vapor  degreasing are
trichloroethylene, 1,1,1-trichloroethane, methylene chloride,
perchloroethylene, and various chlorofluorocarbons.  Solvent
selection depends on the required process temperature (solvent
boiling point),  product dimension,  and metal  characteristics.
Contaminated vapor degreasing solvents are frequently recovered
by distillation.   The sludge residue generated is toxic and may
be flammable, requiring appropriate handling  and disposal pro-
cedures .

Since none of the plants surveyed reported discharging  the vapor
degreasing spent solvents, no samples were collected.

Operations Which Do Not Use Process Water.  The Agency  proposes a
discharge allowance of zero for operations which do not generate
process wastewater.  The following operations generate  no process
wastewater because they use only noncontact cooling water or
because they use no water at all:
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     Powder Metallurgy Operations  (Compacting, Sintering)
     Sanding
     Rolling
     Machining
     Screening
     Blending
     Briquetting
     Crushing, Pulverizing

Titanium Forming Subcategory

Cold Rolling Spent Lubricants.  As discussed in Section III,
mineral oil or kerosene-based lubricants are typically used in
cold rolling.  However, water soluble lubricants are also used in
titanium cold rolling.

No samples of cold rolling spent lubricants were collected  during
the screen sampling program.  However, the Agency believes  that
this stream will have wastewater characteristics similar to roll-
ing spent emulsions in the nickel/cobalt subcategory.  These two
waste streams are generated by identical physical processes which
use similar process chemicals.  The only difference should be the
metals present.  The mass loading  (mg/kkg) of titanium in tita-
nium cold rolling spent lubricants should be similar to the mass
loading of nickel in nickel rolling spent emulsions, and vice
versa.  Also, the mass loading of chromium should be insignifi-
cant because titanium is seldom alloyed with chromium.  The other
pollutants present in each waste stream and the mass loading at
which they are present should be similar.

Hot Rolling Contact Lubricant-Coolant Water.  As discussed  in
Section III, it is necessary to use a lubricant-coolant during
rolling to prevent excessive wear on the rolls, to prevent  adhe-
sion of metal to the rolls, and to maintain a suitable and uni-
form rolling temperature.  Water is one type of lubricant-coolant
which may be used.

No samples of hot rolling contact lubricant-coolant water were
collected during the screen sampling program.  However, the
Agency believes that this stream will have wastewater character-
istics similar to rolling contact lubricant-coolant water in the
nickel/cobalt subcategory.  These two waste streams are generated
by using water, without additives, to cool and lubricate metal
during the rolling process.  The only difference between the
wastewater characteristics of the two streams should be the
metals present.  The mass loading (mg/kkg) of titanium in
titanium hot rooling contact lubricant-coolant water should be
similar to the mass loading of nickel in nickel rolling contact
lubricant-coolant water, and vice versa.  The other pollutants
present in each waste stream and the mass loading at which they
are present should be similar.
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Extrusion Spent Lubricants.  As discussed in Section III,  the
extrusion process requires the use of a lubricant to prevent
adhesion of the metal to the die and ingot container walls.

No samples of extrusion spent lubricants were collected during
the screen sampling program.  However, the Agency believes that
discharged titanium extrusion lubricants will have wastewater
characteristics similar to rolling spent emulsions in the  nickel/
cobalt subcategory.  These two waste streams are generated from
operations which use similar process chemicals for similar pur-
poses (lubrication).  The only difference between the wastewater
characteristics of the two streams should be the metals present.
The mass loading (mg/kkg) of titanium in titanium extrusion spent
lubricants should be similar to the mass loading of nickel in
nickel rolling spent emulsions, and vice versa.  Also, the mass
loading of chromium should be insignificant because titanium is
seldom alloyed with chromium.  The other pollutants in each waste
stream, and the mass loading at which they are present, should be
similar.

Forging Spent Lubricants.  As discussed in Section III, either a
water or oil medium can be sprayed onto forging dies for proper
lubrication.

Since none of the plants surveyed reported wastewater discharge
values for forging spent lubricants, no samples were collected.

Forging Die Contact Cooling Water.  As discussed in Section III,
forging dies may require cooling to maintain the proper die tem-
perature between forgings.

No samples of forging contact cooling water were collected during
the screen sampling program.  However, the Agency believes that
this stream will have wastewater characteristics similar to forg-
ing die contact cooling water in the nickel/cobalt subcategory.
These two waste streams are generated by using water, without
additives, to cool forging dies.  The only difference between the
wastewater characteristics of the two streams should be the
metals present.  The mass loading (mg/kkg) of titanium in  tita-
nium forging die contact cooling water should be similar to the
mass loading of nickel in nickel forging die contact cooling
water, and vice versa.  Also, the mass loading of chromium should
be insignificant because titanium is seldom alloyed with chro-
mium.  The other pollutants in each waste stream, and the  mass
loading at which they are present, should be similar.

Forging Wet Air Pollution Control Blowdown.  As discussed  in Sec-
tion III, wet air pollution control devices are needed to  control
air pollution from some operations.  For instance, scrubbers may
be needed over forging operations where partial combustion of
oil-based lubricants may generate particulates and smoke.
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No samples of forging wet air pollution  control  blowdown were
collected during the screen sampling program.  However, the
Agency believes that this stream will have wastewater  character-
istics similar to surface treatment wet  air pollxition  control
blowdown in this subcategory.  These two waste streams  are
generated by devices designed to control emission of airborne
pollutants.  However, because airborne particulates are generated
at higher concentration  from forging operations  than surface
treatment operations, the mass loading of total  suspended solids
is expected to be higher in forging wet  air pollution  control
blowdown than in surface treatment wet air pollution control
blowdown.  The other pollutants present  in each  waste  stream, and
the concentration at which they are present,  are expected to be
similar.

Heat Treatment Contact Cooling Water.  As discussed in  Section
III, heat treatment  is used by plants in the  nonferrous metals
forming category to give the metal the desired mechanical prop-
erties.  After heat  treatment, the metals must be cooled at a
controlled rate.  Contact cooling water  may be used for this
purpose.

No samples of heat treatment contact cooling water were collected
during the screen sampling program.  However, the Agency believes
that this stream will have wastewater characteristics  similar to
annealing contact cooling water in the nickel/cobalt subcategory.
These two waste streams  are generated by using water, without
additives,  to cool hot metal.  The only  difference between the
wastewater characteristics of the two streams should be the
metals present.   The mass loading (mg/kkg) of titanium  in tita-
nium heat treatment contact cooling water should be similar to
the mass loading of nickel in nickel annealing contact  cooling
water, and vice versa.  Also, the mass loading of chromium should
be insignificant because titanium is seldom alloyed with chro-
mium.  The other pollutants in each waste stream, and  the mass
loading at which they are present, should be similar.

Surface Treatment Spent Baths.   As discussed in  Section III, a
number of chemical treatments may be applied after the  forming of
titanium products.   The surface treatment baths  must be period-
ically discharged after  their properties are exhausted.

Two samples of surface treatment spent baths were collected from
two streams at one plant.  Elevated concentrations of titanium
(44,100 mg/1), aluminum  (4,170 mg/1), iron (17,020 mg/1),
fluoride (86,000 mg/1), and TSS (1,920 mg/1) were detected in the
samples.
                               435

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Surface Treatment Rinsewater.  As discussed in Section III, rins-
ing follows the surface treatment process to prevent the solution
from affecting the surface of the metal beyond the desired
amount.

Seven samples of surface treatment rinsewater were collected from
three streams at one plant.  Elevated concentrations of titanium
(55.3 mg/1), iron (124 mg/1), fluoride (85.0 mg/1), and TSS (40
mg/1) were detected in the samples.

Surface Treatment Wet Air Pollution Control Blowdown.  As dis-
cussed in Section III, wet air pollution control devices must
accompany some operations in order to meet air quality standards.

One sample of surface treatment wet air pollution control blow-
down was collected.   Elevated concentrations of titanium (2.750
mg/1), iron (1.800 mg/1), fluoride (33 mg/1), and TSS (40 mg/1)
were detected in the samples.

Alkaline^ Cleaning Spent Baths.  As discussed in Section III ,
alkalineT cleaning Is commonly used to clean formed metal parts.
Products can be cleaned with an alkaline solution either by
immersion or spray.

No samples of alkaline cleaning spent baths were collected  during
the screen sampling program.   However, the Agency believes  that
this stream will have wastewater characteristics similar to
alkaline cleaning spent baths in the nickel/cobalt subcategory.
These two waste streams are generated from operations using simi-
lar process chemicals to clean formed metal products.  The  only
difference between the wastewater characteristics of the two
streams should be the metals present.  The mass loading (mg/kkg)
of titanium in titanium alkaline cleaning spent baths should be
similar to the mass  loading of nickel in nickel alkaline cleaning
spent baths, and vice versa.  Also, the mass loading of chromium
should be insignificant because titanium is seldom alloyed  with
chromium.  The other pollutants in each waste stream, and the
mass loading at which they are present, should be similar.

Alkaline Cleaning Rinsewater.  As discussed in Section III, rins-
ing followsthe alkaline cleaning process to prevent the solution
from drying on the product.

No samples of alkaline cleaning rinsewater were collected during
the screen sampling program.  However, the Agency believes  that
this stream will have wastewater characteristics similar to
alkaline cleaning rinsewater in the nickel/cobalt subcategory.
These two waste streams are generated from using water to remove
alkaline cleaning solutions from cleaned metal.  The only differ-
ence between the wastewater characteristics of the two streams
                               436

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should be the metals present.  The mass  loading  (mg/kkg) of  tita-
nium in titanium alkaline cleaning rinsewater should be similar
to the mass loading of nickel in nickel  alkaline  cleaning rinse-
water, and vice versa.  Also, the mass loading of chromium should
be insignificant because titanium is seldom alloyed with chro-
mium.  The other pollutants in each waste stream, and the mass
loading at which they are present, should be similar.

Tumbling Wastewater.  As described in Section III, tumbling  is an
operation in which forgings are rotated  in a barrel with ceramic
or metal slugs or abrasives to remove scale, fins, oxides, or
burrs.  It may be done dry, with water,  or an aqueous solution
containing cleaning compounds, rust inhibitors or other
additives.

One sample of tumbling wastewater was collected.  Elevated
concentrations of titanium  (156 mg/1), iron (111  mg/1), aluminum
(182 mg/1), boron (116 mg/1), fluoride (110 mg/1), ammonia (34
mg/1), cyanide (4.0 mg/1), oil and grease (17 mg/1), and TSS
(6,800 mg/1) were detected in the sample.

Sawing/Grinding Spent Lubricants.  As discussed in Section III,
sawing/grinding operationsgenerally require a lubricant in  order
to minimize friction and act as a coolant.

One sample of sawing/grinding spent lubricant was collected.
Elevated concentrations of titanium (6.00 mg/1),  iron (17.5
mg/1), aluminum (33.0 mg/1), fluoride (110 mg/1), cyanide (3.8
mg/1), oil and grease (34 mg/1), and TSS (244 mg/1) were detected
in the sample.

Degreasing Spent Solvents.  As described in Section III, solvent
cleaners are used to remove lubricants (oils and  greases) applied
to the surface of nonferrous metals during mechanical forming
operations.  Basic solvent cleaning methods include straight
vapor degreasing, immersion-vapor degreasing, spray-vapor
degreasing, ultrasonic vapor degreasing, emulsified solvent
degreasing, and cold cleaning.

Solvents most commonly used for all types of vapor degreasing are
trichloroethylene, 1,1,1-trichloroethane, methylene chloride,
perchloroethylene, and various chlorofluorocarbons.  Solvent
selection depends on the required process temperature (solvent
boiling point), product dimension, and metal characteristics.
Contaminated vapor degreasing solvents are frequently recovered
by distillation.   The sludge residue generated is toxic and  may
be flammable, requiring appropriate handling and  disposal pro-
cedures.

Since none of the plants surveyed reported discharging the vapor
degreasing spent solvents, no samples were collected.
                               437

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Operations Which Do Not Use Process Water.  The Agency proposes a
discharge allowance of zero for operations which do not generate
process wastewater.  The following operations generate no process
wastewater, because they use only noncontact cooling water or
because they use no water at all:

     Casting
     Shot Blasting
     Grit Blasting
     Machining
     Torching
     Deoxidizing
     Straightening
     Trimming
     Piercing
     Shearing

Refractory Metals Forming Subcategory

Rolling Spent Neat Oils.  As discussed in Section III, the roll-
ing of refractory metal products typically requires the use of
mineral oil lubricants.  The oils are usually recycled with
in-line filtration and periodically disposed of by sale to an oil
reclaimer or by incineration.  Because discharge of this stream
is not practiced, flow data were not available for analysis.
Only one plant surveyed reported using neat oil rolling lubri-
cants, but this plant did not report the quantity of lubricant
used.

Since none of the plants surveyed reported discharging the roll-
ing spent neat oils, no samples were collected.

Rolling Spent Emulsions.  As discussed in Section III, oil-in-
water emulsions are used in rolling operations as coolants and
lubricants.  Rolling emulsions are typically recycled using
in-line filtration treatment and batch discharged periodically
when the lubricating properties of the emulsions are exhausted.

No samples of rolling spent emulsions were collected during the
screen sampling program.  However, the Agency believes that this
stream will have wastewater characteristics similar to nickel/
cobalt rolling spent emulsions.  These two waste streams are
generated by identical physical processes which use similar
process chemicals.  The only difference between the wastewater
characteristics of the two streams should be the metals present.
The mass loading (mg/kkg) of refractory metals rolling spent
emulsions should be similar to the mass loading of nickel in
nickel rolling spent emulsions, and vice versa.  In addition, the
mass loading of chromium in refractory metals rolling spent emul-
sions should be insignificant because refractory metals are
seldom alloyed with chromium.  The other pollutants in each waste
stream, and the mass loading at which they are present, should be
similar.
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Drawing Spent Lubricants.  As discussed in Section III, a wide
variety of drawinglubricants are used in order to ensure uniform
drawing temperatures and avoid excessive wear on the dies and
mandrels.  Drawing lubricants are usually recycled until no
longer effective.

Since none of the plants surveyed reported discharging the draw-
ing spent lubricants, no samples were collected.

Extrusion Press and Solution Heat Treatment Contact Cooling
Water.As discussed in Section III, heat treatment isfrequently
used after extrusion to attain the desired mechanical properties.
Heat treated products are primarily cooled by contact with water.

No samples of extrusion heat treatment contact cooling water were
collected during the screen sampling program.  However, the
Agency believes that this stream will have wastewater character-
istics similar to nickel/cobalt press and solution heat treatment
contact cooling water.  These two waste streams are generated by
using water, without additives, to cool hot metal.  The only dif-
ference between the wastewater characteristics of the two streams
should be the metals present.  The mass loading (mg/kkg) of
refractory metals in refractory metals extrusion press and solu-
tion heat treatment contact cooling water should be similar to
the mass loading of nickel in nickel extrusion press and solution
heat treatment contact cooling water, and vice versa.  In addi-
tion, the mass loading of chromium in refractory metals extrusion
press and solution heat treatment contact cooling water should be
insignificant because refractory metals are seldom alloyed with
chromium.  The other pollutants in each waste stream, and the
mass loading at which they are present, should be similar.

Extrusion Press Hydraulic Fluid Leakage.  As discussed in Section
III, due to the large force applied by a hydraulic press,
hydraulic fluid leakage is unavoidable.

One sample of extrusion press hydraulic fluid leakage was col-
lected during the screen sampling program.  Elevated concentra-
tions of copper (21 mg/1), molybdenum (20 mg/1), oil and grease
(44,000 mg/l), and total suspended solids (19,000 mg/1) were
detected in the sample.

Forging Spent Lubricants.  As discussed in Section III, proper
lubrication of the dies is essential in forging refractory
metals.  Of the plants surveyed reporting the use of forging
lubricants, both reported total consumption due to evaporation
and drag-out.

Since none of the plants surveyed reported discharging the forg-
ing spent lubricants, no samples were collected.
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Forging Solution Heat Treatment Contact Cooling Water.  As  dis-
cussed in Section III, heat treatment isfrequently used after
forging to attain the desired mechanical properties in  the  forged
metal.  Contact cooling water may be used to cool the alloy at a
controlled rate after heat treatment.

No samples of forging solution heat treatment contact cooling
water were collected during the screen sampling program.  How-
ever, the Agency believes that this stream will have wastewater
characteristics similar to nickel/cobalt extrusion press and
solution heat treatment contact cooling water.  These two waste
streams are generated by using water, without additives, to cool
hot metal.  The only difference between the wastewater  character-
istics of the two streams should be the metals present.  The mass
loading (mg/kkg) of refractory metals in refractory metals
forging solution heat treatment contact cooling water should be
similar to the mass loading of nickel in nickel extrusion press
and solution heat treatment contact cooling water, and  vice
versa.  Also, the mass loading of chromium should be insignifi-
cant because refractory metals are seldom alloyed with  chromium.
The other pollutants in each waste stream, and the mass loading
at which they are present, should be similar.

Extrusion and Forging Equipment Cleaning Wastewater.  As dis-
cussed in Section III,extrusion and forging equipment  should be
periodically cleaned in order to prevent the excessive  build-up
of oil and grease on the dies.

No samples of extrusion and forging equipment cleaning  wastewater
were collected during the screen sampling program.  However, the
Agency believes that this stream will have wastewater character-
istics similar to nickel forging die contact cooling water.
These two waste streams are generated from similar physical
processes (flushing a forging die with water) so the pollutants
present are expected to be similar.  However, the water is  used
for different purposes, in one case to cool a hot die,  in the
other, to remove built-up contaminants.  Therefore, the mass
loadings of oil and grease are expected to be higher in forging
equipment cleaning wastewater than in forging die contact cooling
water.  In addition, the metals present in the two waste streams
are expected to differ.  The only difference between the waste-
water characteristics of the two streams should be the  metals
present.  The mass loading (mg/kkg) of refractory metals in
refractory metals extrusion and forging equipment cleaning waste-
water should be similar to the mass loading of nickel in nickel
forging die contact cooling water, and vice versa.  Also, the
mass loading of chromium should be insignificant because refrac-
tory metals are seldom alloyed with chromium.  The other pollu-
tants in each waste stream, and the mass loading at which they
are present, should be similar.
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Met:al Powder Production Wastewater.  As discussed  in Section III,
refractory metal powders are frequently produced by mechanical
reduction.  The most common pieces of mechanical reduction  equip-
ment are ball mills, vortex mills, hammer mills, disc mills, and
roll mills.  Water or other liquids may be used to aid  in the
milling operation or to facilitate handling after powder is
milled.  One plant reported discharging wastewater from a ball
milling operation.

No samples of metal powder production milling wastewater were
collected during the screen sampling program.  However, the
Agency believes that this stream will have wastewater character-
istics similar to tumbling/burnishing wastewater in this subcate-
gory.  These two waste streams are generated from operations
using water, often without added process chemicals, in  contact
with finely divided metal.  The pollutants present in each waste
stream and the mass loading at which they are present,  should be
similar, except for total suspended solids.  Metal powders are
more finely divided than tumbled parts.  Powders are also present
in higher concentration than the metal fines produced during
tumbling.  Therefore, the mass loading of total suspended solids
is expected to be higher in metal powder production milling
wastewater than in tumbling/burnishing wastewater.

Metal Powder Production Wet Air Pollution Control Slowdown.  As
discussed in Section III,particulates may become airborne during
the production of metal powders.  Wet air pollution control
equipment may be necessary to capture these particles in order to
meet particulate air quality standards.

No samples of metal powder production wet air pollution control
blowdown were collected during the screen sampling program.  How-
ever, the Agency believes that this stream will have wastewater
characteristics similar to blowdown from air pollution  control
scrubbers used to control particulates in the nickel/cobalt
subcategory.  These two waste streams are generated by  air
pollution devices used to remove particulate contaminants from
air.   The only difference between the wastewater characteristics
of the two streams should be the metals present.  The mass load-
ing (mg/kkg) of refractory metals in refractory metals  powder
production wet air pollution control scrubber blowdown  should be
similar to the nickel mass loading in nickel shot blaster scrub-
ber blowdown, and vice versa.  In addition, the mass loading of
chromium should be insignificant because refractory metals are
seldom alloyed with chromium.  The other pollutants present in
each waste stream and the mass loading at which they are present
should be similar.

Metal Powder Pressing Spent Lubricants.  As discussed in Section
III,lubricants may be needed in the fabrication step in which
                               441

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metal powders are compacted in a closed die to produce a  final
shape.  Since none of the plants surveyed reported discharging
metal powder pressing spent lubricants, no samples were
collected.

Casting Contact Cooling Water.  As discussed in Section III,
casting may require the use of contact cooling water in order to
achieve the desired physical properties of the metal.  Since the
one plant reporting the use of casting contact cooling water
reported complete evaporation, no samples were collected.

Post-Casting Billet Washwater.  Refractory metals billets may be
washed after casting to remove an oxide layer on the billet
formed at the elevated casting temperatures.  The one surveyed
plant reporting the use of post-casting washwater did not
recirculate the water.

No samples of post-casting washwater were collected during the
screen sampling program.  However, the Agency believes that this
stream will have wastewater characteristics  similar to beryllium
billet washing wastewater.  These two waste streams are generated
by using water, without additives, to clean a cast billet.  The
only difference between the wastewater characteristics of the two
streams should be the metals present.  The mass loading (mg/kkg)
of refractory metals in refractory metals post-casting billet
washwater should be similar to the mass loading of beryllium in
beryllium billet washing wastewater, and vice versa.  The other
pollutants in each waste stream,  and the mass loading at which
they are present, should be similar.

Surface Treatment Spent Baths.  As discussed in Section IH? a
number of chemical treatments may be applied after the forming of
refractory metal products.  The surface treatment baths must be
periodically discharged after their properties are exhausted.

One sample of surface treatment spent baths was collected.  Ele-
vated concentrations of nickel (12.4 mg/1), copper (6.3 mg/1),
silver (6.1 mg/1), and TSS (140 mg/1) were detected in the sam-
ple.

Surface Treatment Rinsewater.  As discussed in Section III, rins-
ing follows the surface treatment process to prevent the solu-
tion from affecting the surface of the metal beyond the desired
amount.

Four samples of surface treatment rinsewater were collected from
four streams at three plants.  Elevated concentrations of alumi-
num (6.8 mg/1), fluoride (1,018 mg/1), and TSS (80 mg/1) were
detected in the samples.
                               442

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Surface Treatment Wet Air Pollution Control Slowdown.  As  dis-
cussed in Section 111, wet air pollution control devices are
needed to accompany some operations in order to meet quality
standards.

One sample of surface treatment wet air pollution control  blow-
down was collected.  Elevated concentrations of fluoride (130
mg/1) and TSS (150 mg/1) were detected in the sample.

Surface Coating Wet Air Pollution Control Slowdown.  As discussed
in Section IIl7 wet air pollution control devices are needed to
control air pollution from some operations.

No samples of coating wet air pollution control blowdown were
collected during the screen sampling program.  However, the
Agency believes that this stream will have wastewater character-
istics similar to surface treatment wet air pollution control
blowdown in this subcategory.  These two waste streams derive
from air pollution control operations used to collect and  concen-
trate airborne contaminants.  The contaminants generated by
surface coating are expected to be similar to the contaminants
generated by other surface treatments.  Therefore, the pollutants
present in each waste stream, and the mass loading at which they
are present, should be similar.

Alkaline Cleaning Spent Baths.  As discussed in Section III,
alkaline cleaners are formulations of alkaline salts, water, and
surfactants.  Spent solutions are discharged from alkaline clean-
ing processes.

No samples of alkaline cleaning spent baths were collected during
the screen sampling program.  However, the Agency believes that
this stream will have wastewater characteristics similar to
alkaline cleaning spent baths in the nickel/cobalt subcategory.
These two waste streams are generated by identical physical pro-
cesses which use similar process chemicals.  The only difference
between the wastewater characteristics of the two streams  should
be the metals present.  The mass loading (mg/kkg) of refractory
metals in refractory metals alkaline cleaning spent baths  should
be similar to the mass loading of nickel in nickel alkaline
cleaning spent baths, and vice versa.  Also, the mass loading of
chromium should be insignificant because refractory metals are
seldom alloyed with chromium.  The other pollutants in each waste
stream, and the mass loading at which they are present, should i e
similar.

Alkaline Cleaning Rinsewater.  As discussed in Section III, fol-
lowing alkaline treating, metal parts are rinsed.  Rinses  are
discharged from alkaline cleaning processes.
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No samples of alkaline cleaning rinsewater were collected  during
the screen sampling program.  However, the Agency believes that
this stream will have wastewater characteristics similar to
alkaline cleaning rinsewater in the nickel/cobalt subcategory.
These two waste streams are generated by using water to remove
alkaline cleaning solutions from cleaned metal.  The only  differ-
ence between the wastewater characteristics of the two streams
should be the metals present.  The mass loading (mg/kkg) of
refractory metals in refractory metals alkaline cleaning rinse-
water should be similar to the mass loading of nickel in nickel
alkaline cleaning rinsewater, and vice versa.  Also, the mass
loading of chromium should be insignificant because refractory
metals are seldom alloyed with chromium.  The other  pollutants
in each waste stream, and the mass loading at which they are
present, should be similar.

Molten Salt Spent Baths.  As discussed in Section III, molten
salt baths are used to descale refractory metal alloys.  Formed
parts to be descaled are immersed in the bath for up to 15
minutes, removed, and water-quenched.  Since none of the plants
surveyed reported discharging the molten salt spent baths, no
samples were collected.

Molten Salt Rinsewater.  As discussed in Section III, when molten
salt baths are used to descale refractory metal alloys, they are
generally followed by a water quench/rinse step.

Four samples of molten salt rinsewater were collected from two
streams at one plant.  Elevated concentrations of boron (7.0
mg/1),  and TSS (285 mg/1) were detected in the samples.

Tumbling/Burnishing Wastewater.  As discussed in Section III,
tumbling is a controlled method of processing parts to remove
burrs,  scale, flash, and oxides as well as to improve surface
finish.  Burnishing is the process of finish sizing or smooth
finishing a workpiece (previously machined or ground) by dis-
placement, rather than removal, of minute surface irregularities.
Water is used to facilitate tumbling and burnishing.

Five samples of tumbling/burnishing wastewater were collected
from three streams at one plant.  Elevated concentrations  of
nickel (35.9 mg/1), copper (4.16 mg/1), aluminum (13.1 mg/1), and
TSS (1,860 mg/1) were detected in the samples.

Sawing/Grinding Spent Neat Oils.  As discussed in Section III,
sawing/grinding operations may use mineral-based oils or heavy
grease as the lubricant required to minimize friction and  act as
a coolant.  Normally, saw oils are not discharged as a wastewater
stream.  Since none of the plants surveyed reported discharging
the sawing spent neat oils, no samples were collected.
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Saving/Grinding Spent Emulsions.  As discussed in Section III,
sawing/grinding operations generally require a lubricant in order
to minimize friction and act as a coolant.  Oil-in-water emul-
sions are frequently used to lubricate sawing and grinding
operations.  The emulsions are usually recycled with in-line
filtration to remove swarf and batch discharged periodically as
their lubricating properties are exhausted.

No samples of sawing/grinding spent emulsions were collected
during the screen sampling program.  However, the Agency believes
that this stream will have wastewater characteristics similar to
nickel/cobalt sawing/grinding spent lubricants in this subcate-
gory.  These two waste streams are generated by identical physi-
cal processes which use similar process chemicals.  The only
difference between the wastewater characteristics of the two
streams should be the metals present.  The mass loading (mg/kkg)
of refractory metals in refractory metals sawing/grinding spent
emulsions should be similar to the mass loading of nickel and
cobalt in nickel/cobalt sawing/grinding spent emulsions, and vice
versa.  Also, the mass loading of chromium in this waste stream
should be insignificant because refractory metals are seldom
alloyed with chromium.  The other pollutants in each waste
stream, and the mass loading at which they are present, should be
similar.

Sawing/Grinding Contact Lubricant-Coolant Water.  As discussed in
Section III,a lubricant-coolant is frequently needed during
sawing/grinding.  Water is one type of lubricant-coolant which
may be used.

Two samples of sawing/grinding contact lubricant-coolant water
were collected from two streams at two plants.  Elevated concen-
trations of molybdenum (5,470 mg/1), iron (13.0 mg/1), and TSS
(310 mg/1) were detected in the samples.

Sawing/Grinding Wet Air Pollution Control Blowdown.  As discussed
in Section III, wet air pollution control devices are needed to
accompany some operations in order to meet quality standards.

No samples of sawing/grinding wet air pollution control blowdown
were collected during the screen sampling program.  However, the
Agency believes that this stream will have wastewater character-
istics similar to surface treatment wet air pollution control
blowdown in this subcategory.  These two waste streams derive
from air pollution control operations used to collect and con-
centrate airborne contaminants.  Since sawing/grinding operations
are expected to generate more airborne particulates than surface
treatment, the mass loading of total suspended solids is expected
to be higher in sawing/grinding wet air pollution control blow-
down than in surface treatment wet air pollution control blow-
down.  The other pollutants in each waste stream, and the mass
loading at which they are present, should be similar.
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F o s t - Sawing/Grinding Rinsewater.  As  discussed  in  Section III,
the formed metals may be rinsed  following  sawing/grinding to
remove  the lubricants and  saw  chips for  reprocessing.

No samples of post-sawing/grinding rinsewater were collected
during  the screen sampling program.   However, the  Agency  believes
that this stream will have wastewater characteristics  similar  to
sawing/grinding contact lubricant-coolant  water  in this subcate-
gory.   Since the pollutants  in each of these waste streams  are
generated from sawing and grinding operations, the pollutants
present in each waste stream and the  mass  loading  at which  they
are present should be similar.

Product Testing Wastewater.  As  described  in Section III, testing
operations are used to check nonferrous  metals parts for  surface
defects or subsurface imperfections.  Testing operations  are
sources of wastewater because  the spent  water bath or  test  media
must be^periodically discarded due to the  transfer into the test-
ing media of oil and grease, solids,  and suspended and dissolved
metals  from each product tested.

One sample of product testing wastewater was collected during the
screen  sampling program.  Elevated concentrations  of nickel  U.6
mg/1), oil and grease (72 mg/1), and  total suspended solids  (22
mg/1) were detected in the sample.

Degreasing Spent Solvents.   As described in Section III,  solvent
cleaners are used to remove  lubricants (oils and greases) applied
to the  surface of nonferrous metals during mechanical  forming
operations.   Basic solvent cleaning methods include straight
vapor degreasing, immersion-vapor degreasing, spray-vapor
degreasing,  ultrasonic vapor degreasing, emulsified solvent
degreasing,  and cold cleaning.

Solvents most commonly used  for  all types  of vapor degreasing are
trichloroethylene, 1,1,1-trichloroethane,  methylene chloride,
perchloroethylene, and various chlorofluorocarbons.  Solvent
selection depends on the required process temperature  (solvent
boiling point),  product dimension, and metal characteristics.
Contaminated vapor degreasing  solvents are frequently  recovered
by distillation.  The sludge residue  generated is  toxic and may
be flammable,  requiring appropriate handling and disposal pro-
cedures .

Since none of the plants surveyed reported discharging the vapor
degreasing spent solvents, no samples were collected.

Operations Which J3^_Not__Use  Process Water_.   The Agency proposes a
discharge alTowance o~F zero "Tor "operations which do not generate
process wastewater.   The following operations generate no process
                               446

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wastewater, because they use only  noncontact  cooling water  or
because they use no water at all:

     Powder Metallurgy Operations  (Pressing,  Sintering)
     Annealing
     Soldering
     Welding
     Screening
     Blending
     Straightening
     Blasting

Zirconium/Hafnium Forming Subcategory

Drawing Spent Lubricants.  As discussed  in Section III, a suita-
blelubricantis required to ensure uniform drawing temperatures
and avoid excessive wear on the  dies and mandrels used.  A  wide
variety of lubricants can be used.

Since none of the plants surveyed  reported discharging the  draw-
ing spent lubricants, no samples were collected.

Extrusion Spent Emulsions.  As discussed in Section III, the
extrusion process requires the use of a  lubricant to prevent
adhesion of the metal to the die and ingot container walls.

No samples of extrusion spent emulsions were  collected during the
screen sampling program.  However, the Agency believes that this
stream will have wastewater characteristics similar to nickel/
cobalt rolling spent emulsions.  These two waste streams are
generated from operations which use similar process chemicals for
similar purposes (lubrication).  The only difference between the
wastewater characteristics of the  two streams should be the
metals present.  The mass loading  (mg/kkg) of zirconium/hafnium
in zirconium/hafnium extrusion spent emulsions should be similar
to the mass loading of nickel/cobalt in nickel/cobalt rolling
spent emulsions, and vice versa.   The other pollutants in each
waste stream, and the mass loading at'which they are present,
should be similar.

Extrusion Press Hydraulic Fluid Leakage.  As  discussed in Section
lYI", due to the large force applied by a hydraulic press,
hydraulic fluid leakage is unavoidable.

No samples of extrusion press hydraulic  fluid leakage were  col-
lected during the screen sampling  program.  However, the Agency
believes that this stream will have wastewater characteristics
similar to nickel/cobalt forging,  extrusion,  and isostatic  press
hydraulic fluid leakage.  The pollutants present in these two
waste streams are attributable to  the hydraulic fluid used, not
                               447

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the metal formed.  Therefore, the pollutants present,  and  the
concentration  (mg/1) at which they are present, should be
similar.

Extrusion Heat Treatment Contact Cooling Water.  As  discussed  in
Section III, heat treatment is frequently used after extrusion to
attain the desired mechanical properties in the extruded metal.
Contact cooling water may be sprayed onto the metal  as it  emerges
from the die or press, or be contained in a bath for direct
quenching.

No samples of extrusion heat treatment contact cooling water were
collected during the screen sampling program.  However, the
Agency believes that this stream will have wastewater  character-
istics similar to nickel/cobalt extrusion press and  solution heat
treatment contact cooling water.   These two waste streams  are
generated by using water, without additives, to cool hot metal.
The only difference between the wastewater characteristics of the
two streams should be the metals present.  The mass  loading
(mg/kkg) of zirconium/hafnium in zirconium/hafnium extrusion
press and solution heat treatment contact cooling water should be
similar to the mass loading of nickel/cobalt in nickel/cobalt
extrusion press and solution heat treatment contact  cooling
water, and vice versa.  The other pollutants in each waste
stream, and the mass loading at which they are present, should be
similar.

Tube Reducing Spent Lubricants.   As discussed in Section III,
tube reducing,much like rolling, may require a lubricating com-
pound in order to prevent excessive wear of the tube reducing
equipment, prevent adhesion of metal to the tube reducing  equip-
ment,  and maintain a suitable and uniform tube reducing tempera-
ture.

No samples of tube reducing spent lubricants were collected dur-
ing the screen sampling program.   However,  the Agency believes
that this stream will have wastewater characteristics  similar to
nickel/cobalt tube reducing spent lubricants.   These two waste
streams are generated by identical physical processes which use
similar process chemicals.  The only difference between the
wastewater characteristics of the two streams should be the
metals present.  The mass loading (mg/kkg)  of zirconium/hafnium
in zirconium/hafnium tube reducing spent lubricants  should be
simlar to the mass loading of nickel/cobalt in nickel/cobalt tube
reducing spent lubricants, and vice versa.   The other pollutants
in each waste stream,  and the mass loading at which they are
present, should be similar.

Forging Solution Heat Treatment Contact Cooling Water.  As dis-
cussed in Section III,forging diesmay require cooling such that
the proper die temperature is maintained between forg;ings.
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No  samples  of  forging  solution heat  treatment  contact  cooling
water were  collected during the screen sampling program.  How-
ever, the Agency believes  that this  stream will have wastewater
characteristics similar to nickel/cobalt extrusion press and
solution heat  treatment contact cooling water.  These  two waste
streams are generated  by using water, without  additives, to cool
hot metal.  The only difference between the wastewater character-
istics of the  two streams  should be  the metals present.  The mass
loading (mg/kkg) of zirconium/hafnium in zirconium/hafnium
forging solution heat  treatment contact cooling water  should be
similar to  the mass loading of nickel/cobalt in nickel/cobalt
extrusion press and solution heat treatment contact cooling
water, and  vice versa.  The other pollutants in each waste
stream, and the mass loading at which they are present, should be
similar.

Surface Treatment Spent Baths.  As discussed in Section III, a
number of chemical treatments may be applied after the  forming of
zirconium/hafnium products including pickling  and coating.  The
surface treatment baths must be periodically discharged after
their properties are exhausted.

Two samples of forging surface treatment spent baths were col-
lected from two streams at one plant.  Elevated concentrations of
antimony (5.5  mg/1), cyanide (0.273 mg/1), chromium (18 mg/1),
fluoride (11,800 mg/1), and ammonia  (392.5 mg/1) were  detected in
the samples.

Surface Treatment Rinsewater.  As discussed in Section  III, rins-
ingfollowsthe surface treatment process to prevent the solution
from affecting the surface of the metal beyond the desired
amount.

No samples  of  surface  treatment rinsewater were collected during
the screen  sampling program.  However, the Agency believes that
this stream will have wastewater characteristics similar to sur-
face treatment spent baths in this subcategory.  As a  zirconium
or hafnium piece is removed from a surface treatment bath, it
carries a small volume of  the bath with it.  The rinsewater used
to remove the  carried over bath solution from the formed metal
piece will  contain the same pollutants as the bath, only in lower
concentration.  Therefore, the pollutants present in zirconium/
hafnium surface treatment  rinsewater are expected to be identical
to the pollutants present  in zirconium/hafnium surface  treatment
baths, except  that the mass loadings of the pollutants  are
expected to be lower.

Alkaline Cleaning Spent Baths.   As discussed in Section III,
alkaline cleaners are  formulations of alkaline salts,  water, and
surfactants.   Spent solutions are discharged from the alkaline
cleaning processes.
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No samples of alkaline cleaning spent baths were collected  during
the screen sampling program.  However, the Agency believes  that
this stream will have wastewater characteristics similar to
nickel/cobalt alkaline cleaning spent baths.  These two waste
streams are generated by identical physical processes which use
similar process chemicals.  The only difference between the
wastewater characteristics of the two streams should be the
metals present.  The mass loading (mg/kkg) of zirconium/hafnium
in zirconium/hafnium alkaline cleaning spent baths should be
similar to the mass loading of nickel/cobalt in nickel/cobalt
alkaline cleaning spent baths, and vice versa.  The other pollu-
tants in each waste stream, and the mass loading at which they
are present, should be similar.

Alkaline Cleaning Rinsewater.  As discussed in Section III,
following alkaline cleaning, metal parts are rinsed.  Rinses are
discharged from alkaline cleaning processes.

No samples of alkaline cleaning rinsewater were collected during
the screen sampling program.  However, the Agency believes that
this stream will have wastewater characteristics similar to
nickel/cobalt alkaline cleaning rinsewater.  These two waste
streams are generated by identical physical processes which use
similar process chemicals.  The only difference between the
wastewater characteristics of the two streams should be the
metals present.  The mass loading (mg/kkg) of zirconium/hafnium
in zirconium/hafnium alkaline cleaning rinsewater should be
similar to the mass loading of nickel/cobalt in nickel/cobalt
alkaline cleaning rinsewater, and vice versa.  The other pollu-
tants in each waste stream, and the mass loading at which they
are present, should be similar.

Sawing/Grinding Spent Lubricants.  As discussed in Section III,
sawing/grinding operations generally require a lubricant in order
to minimize friction and act as a coolant.

No samples of sawing/grinding spent lubricants were collected
during the screen sampling program.   However, the Agency believes
that this stream will have wastewater characteristics similar to
nickel/cobalt sawing/grinding spent lubricants.  These two waste
streams are generated by identical physical processes which use
similar process chemicals.  The only difference between the
wastewater characteristics of the two streams should be the
metals present.  The mass loading (mg/kkg) of zirconium/hafnium
in zirconium/hafnium sawing/grinding spent lubricants should be
similar to the mass loading of nickel/cobalt in nickel/cobalt
sawing/grinding spent lubricants, and vice versa.  The other
pollutants in each waste stream, and the mass loading at which
they are present, should be similar.
                               450

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Sawing/Grinding Wet Air Pollution Control Slowdown.  As  discussed
in Section 11J-7 wet air pollution control devices are needed  to
control air pollution  from  some  operations.  Scrubbers are
frequently necessary over sawing/grinding operations where
particulates are a problem.

Since none of the plants surveyed reported discharging the
sawing/grinding wet air pollution control blowdown, no samples
were collected.

Degreasing Spent Baths.  As  discussed  in Section III, immersion-
vapor degreasing is used to  clean metal parts coated with large
quantities of oil, grease,  or hard-to-remove soil.  Solvents  used
are the same as those used  in straight vapor degreasing.  Solu-
tions of organic solvent in  water are  also used for degreasing.

Since none of the plants surveyed reported discharging the
degreasing spent baths, no  samples were collected.

Degreasing Rinsewater.  As  discussed in Section III, it  is some-
times necessary to rinse degreased parts with water to meet cer-
tain product specifications.

No samples of degreasing rinsewater were collected during the
screen sampling program.  However, the Agency believes that this
stream will have wastewater  characteristics similar to nickel/
cobalt alkaline cleaning rinsewater.  These two waste streams are
generated from rinsing formed parts which have been cleaned or
degreased.  Each rinsewater  will contain the same process chemi-
cals as the bath which it follows, plus contaminants introduced
into the bath by the cleaned or  degreased metal piece.   Degreas-
ing rinsewater may contain organic pollutants at low mass load-
ing; nickel/cobalt alkaline  cleaning rinsewater will not.  In
addition,  the two waste streams will differ in metals present.
The mass loading (mg/kkg) of zirconium/hafnium in zirconium/haf-
nium degreasing rinesewater  should be similar to the mass loading
of nickel/cobalt in nickel/cobalt alkaline cleaning rinsewater,
and vice versa.   The other pollutants in each waste stream, and
the mass loading at which they are present, should be similar.

Operations Which Do Not Use  Process Water.  The Agency proposes a
discharge allowance of zero  for operations which do not  generate
process wastewater.  The following operations generate no process
wastewater, because they use only noncontact cooling water or
because they use no water at all:

     Rolling
     Casting
     Annealing
     Shot Blasting
                               451

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     Grit Blasting
     Bead Blasting
     Polishing
     Straightening
     Cutting, Trimming
     Debarring, Sanding

Magnesium Forming Subcategory

Rolling Spent Emulsions.  As discussed in Section III, oil-in-
water emulsions are used in rolling operations as coolants and
lubricants.  Rolling emulsions are typically recycled using
in-line filtration treatment.

Since none of the plants surveyed reported wastewater discharge
values for rolling spent em Isions, no samples were collected.

Forging Spent Lubricants.  As discussed in Section III, either
water, oil,or granulated carbon can be applied to forging dies
for proper lubrication.  Since none of the plants surveyed
reported wastewater discharge values for forging spent
lubricants, no samples were collected.

Forging Solution Heat Treatment Contact Cooling Vater.  As dis-
cussed in Section III, solution heat treatment is implemented
after forging to improve mechanical properties by maximizing the
concentration of hardening contaminants in solid solution.  Solu-
tion heat treatment typically involves significant quantities of
contact cooling water.

No samples of forging solution heat treatment contact cooling
water were collected during the screen sampling program.  How-
ever, the Agency believes that this stream will have wastewater
characteristics similar to extrusion press and solution heat
treatment contact cooling water in the lead/tin/bismuth subcate-
gory.  These two waste streams are generated by using water,
without additives, to cool hot metal.  The only difference
between the wastewater characteristics of the two streams should
be the metals present.  The mass loading (mg/kkg) of magnesium in
magnesium forging solution heat treatment contact cooling water
should be similar to the mass loading of lead in lead/tin/bismuth
extrusion press and solution heat treatment contact cooling
water, and vice versa.  Also, there should be no significant mass
loading of antimony in magnesium forging solution heat treatment
contact cooling water because magnesium is not commonly alloyed
with antimony.  The other pollutants in each waste stream, and
the mass loading at which they are present, should be similar.

Forging Wet Air Pollution Control Blowdown.  As discussed in
Section III, wet air pollution control devices are needed to
                               452

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control air pollution from some operations.  For  instance,  scrub-
bers may be necessary when particulates and smoke are generated
from the partial combustion of oil-based  lubricants  as  they
contact the hot forging dies.

No samples of forging wet air pollution control blowdown were
collected during the screen sampling program.  However, the
Agency believes that this stream will have wastewater character-
istics similar to wet air pollution control blowdown in the
nickel/cobalt forming subcategory.  These two waste streams
derive from air pollution control devices used to collect and
concentrate airborne contaminants, both gaseous and particulate.
The only difference between the wastewater characteristics  of the
two streams should be the metals present.  The mass loading
(mg/kkg) of magnesium in magnesium forging wet air pollution
control blowdown should be similar to the mass loading of nickel
in nickel wet air pollution control blowdown, and vice versa.
The other pollutants in each waste stream, and the mass loading
at which they are present, should be similar.

Forging Equipment Cleaning Wastewater.  As discussed in Section
III, forging equipment should be periodically cleaned in order to
prevent the excessive buildup of oil, grease, and caked-on  solid
lubricants on the forging die.

No samples of forging equipment cleaning wastewater were col-
lected during the screen sampling program.  However, the Agency
believes that this stream will have wastewater characteristics
similar to alkaline cleaning rinsewater in the lead/tin/bismuth
subcategory.  These two waste streams are generated by cleaning
operations which use similar process chemicals.  Since granulated
coal and graphite suspensions are frequently used to lubricate
magnesium forging operations, magnesium forging equipment clean-
ing wastewater may contain higher mass loadings of total sus-
pended solids.  In addition, the metals present in the two waste
streams should differ.  The mass loading  (mg/kkg) of magnesium in
magnesium forging equipment cleaning wastewater should be similar
to the mass loading of lead in lead/tin/bismuth alkaline cleaning
rinsewater, and vice versa.  Also, there  should be no significant
concentration of antimony in magnesium forging equipment cleaning
wastewater because magnesium is not commonly alloyed with anti-
mony.   The other pollutants in each waste stream, and the mass
loading at which they are present, should be similar.

Direct Chill Casting Contact Cooling Water.  As discussed in Sec-
tion III,  contact cooling water is a necessary part of direct
chill casting.  The cooling water may be  contaminated by lubri-
cants  applied to the mold before and during the casting process.
The one plant reporting the use of direct chill casting contact
cooling water discharges no water, therefore no samples of this
waste stream were collected.
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Surface Treatment Spent Bathjg.  As discussed  in Section III,  a
number of chemical treatments may be applied  after the forming of
magnesium products.  The surface treatment baths must be period-
ically discharged after their properties are  exhausted,,

Three samples of surface treatment spent baths were collected
from three streams at one plant.  Elevated concentrations  of  mag-
nesium (9,150 mg/1), chromium (28,000 mg/1),  zinc (89.0 mg/1),
aluminum (64 mg/1), ammonia  (97 mg/1), oil and grease (47,000
mg/1), and TSS (160 mg/1) were detected in the samples.,

Surface Treatment Rinsewater.  As discussed in Section III, rins-
ing follows the surface treatment process to  prevent the solution
from affecting the surface of the metal beyond the desired
amount.

Twelve samples of surface treatment rinsewater were collected
from eight streams at one plant.  Elevated concentrations of  mag-
nesium (148 mg/1), zinc (2.1 mg/1), chromium  (516 mg/1), ammonia
(81 mg/1), oil and grease (16 mg/1),  and TSS  (97 mg/1) were
detected in the samples.

Sawing/Grinding Spent Lubricants.  As discussed in Section III,
sawing/grinding operationsgenerally require  a lubricant in order
to minimize friction and act as a coolant.  Since none of the
plants surveyed reported wastewater discharge values for
sawing/grinding spent lubricants, no samples  of this waste stream
were collected.

Sanding and Repairing Wet Air Pollution Control Slowdown.  As
discussed in Section III, wet air pollution control devices are
needed to control air pollution from some operations.  For
instance, scrubbers are frequently necessary  over sanding and
repairing operations where particulates are a problem.

No samples of sanding and repairing wet air pollution control
blowdown were collected during the screen sampling program.
However,  the Agency believes that this stream will have waste-
water characteristics similar to shot blaster wet air pollution
control blowdown in the nickel/cobalt subcategory.  These two
waste streams derive from air pollution control devices used  to
collect and concentrate airborne particulates.  The only differ-
ence between the wastewater characteristics of the two streams
should be the metals present.  The mass loading (mg/kkg) of
magnesium in mangesium sanding and repairing wet air pollution
control blowdown should be similar to the mass loading of nickel
in nickel shot blaster wet air pollution control blowdown, and
vice versa.   The other pollutants in each waste stream,  and the
mass loading at which they are present, should be similar.
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Degreasing Spent Solvents.  As  described  in Section III,  solvent
cleaners are used to remove lubricants  (oils and greases)  applied
to the surface of nonferrous metals  during mechanical  forming
operations.  Basic solvent cleaning  methods include straight
vapor degreasing, immersion-vapor  degreasing,  spray-vapor
degreasing, ultrasonic vapor degreasing,  emulsified solvent
degreasing, and cold cleaning.

Solvents most commonly used for all  types of vapor degreasing  are
trichloroethylene, 1,1,1-trichloroethane, methylene chloride,
perchloroethylene, and various  chlorofluorocarbons.  Solvent
selection depends on the required  process temperature  (solvent
boiling point), product dimension, and  metal characteristics.
Contaminated vapor degreasing solvents  are frequently recovered
by distillation.  The  sludge residue generated  is toxic and may
be flammable, requiring appropriate handling and disposal  pro-
cedures .

Since none of the plants surveyed  reported discharging the vapor
degreasing spent solvents, no samples were collected.

Operations Which Do Not Use Process Water.  The Agency proposes a
discharge allowance of zero for operations which do not generate
process wastewater.  The following operations generate no  process
wastewater, because they use only  noncontact cooling water or
because they use no water at all:

     Extrusion
     Shot Blasting
     Powder Atomization
     Screening
     Turning

Uranium Forming Subcategory

Extrusion Spent Lubricants.  As discussed in Section III,  the
extrusion process requires the use of a lubricant to prevent
adhesion of the metal to the die and ingot container walls.

Since none of the plants surveyed reported wastewater discharge
values for extrusion spent lubricants,  no samples were collected.

Extrusion Tool Contact Cooling Water.   As discussed in Section
III,following an extrusion,the dummy  block drops from the press
and is cooled before being used again.  Water is sometimes used
to quench the extrusion tools.

No samples of extrusion tool contact cooling water were collected
during the screen sampling program.  However, the Agency believes
that  this stream will have wastewater characteristics similar to
                               455

-------
forging die contact cooling water in the nickel/cobalt  subcate-
gory.  These two waste streams are generated by using water,
without added process chemicals, to cool metal forming  equipment.
The only difference between the wastewater characteristics of the
two streams should be the metals present.  The mass loading
(mg/kkg) of uranium in uranium extrusion tool contact cooling
water should be similar to the mass loading of nickel in nickel/
cobalt forging die contact cooling water, and vice versa.  Also,
there should be no significant mass loading of chromium in ura-
nium extrusion tool contact cooling water because uranium is not
commonly alloyed with chromium.  The other pollutants in each
waste stream, and the mass loading at which they are present,
should be similar.

Extrusion Press and Solution Heat Treatment Contact Cooling
Water.As discussed in Section III, heat treatment is  frequently
used after extrusion to attain the desired mechanical properties
in the extruded metal.  Contact cooling of the extrusion can be
accomplished in one of three ways:  with a water spray  near the
die, by immersion in a water tank adjacent to the runout table,
or by passing the metal through a water mill.

No samples of extrusion solution heat treatment contact cooling
water were collected during the screen sampling program.  How-
ever, -the Agency believes that this stream will have wastewater
characteristics similar to extrusion press and solution heat
treatment contact cooling water in the nickel/cobalt subcategory.
These two waste streams are generated by using water, without
additives, to cool hot metal.  The only difference between the
wastewater characteristics of the two streams should be the
metals present.  The mass loading (mg/kkg) of uranium in uranium
extrusion press and solution heat treatment contact cooling water
should be similar to the mass loading of nickel in nickel extru-
sion press and solution heat treatment contact cooling  water, and
vice versa.  Also, there should be no significant mass  loading of
chromium in uranium extrusion press and solution heat treatment
contact cooling water because uranium is not commonly alloyed
with chromium.  The other pollutants in each waste stream, and
the mass loading at which they are present, should be similar.

Forging Spent Lubricants.  As discussed in Section III, proper
lubrication of the dies is essential in forging nonferrous
metals.  A colloidal graphite lubricant is commonly sprayed onto
the dies for this purpose.

Since none of the plants surveyed reported wastewater discharge
values for forging spent lubricants, no samples were collected.

Forging Solution Heat Treatment Contact Cooling Water.  As dis-
cussed in Section III, forging dies may require cooling to main-
tain the proper die temperature between forgings.
                               456

-------
No samples of forging solution heat treatment contact cooling
water were collected during the screen sampling program.  How-
ever, the Agency believes that this stream will have wastewater
characteristics similar to extrusion press and solution heat
treatment contact cooling water in the nickel/cobalt subcategory.
These two waste streams are generated by using water, without
additives, to cool hot metal.  The only difference between the
wastewater characteristics of the two streams should be the
metals present.  The mass loading (mg/kkg) of uranium in uranium
extrusion press and solution heat treatment contact cooling water
should be similar to the mass loading of nickel in nickel extru-
sion press and solution heat treatment contact cooling water, and
vice versa.  Also, the mass loading of chromium in uranium
forging solution heat treatment contact cooling water should be
insignificant because uranium is not commonly alloyed with
chromium.  The other pollutants in each waste stream, and the
mass loading at which they are present, should be similar.

Surface Treatment Spent Baths.  As discussed in Section III, a
number of chemical treatments may be applied after forming ura-
nium products.  The surface treatment baths must be periodically
discharged after their properties are exhausted.

No samples of surface treatment spent baths were collected during
the screen sampling program.  However, one plant supplied a par-
tial analysis of its spent surface treatment baths on its dcp.
Elevated concentrations of uranium (266,162 mg/1), titanium
(3,353 mg/1), magnesium (246 mg/1),  fluoride (231 mg/1), and
barium (1,272 mg/1) were reported.

Surface Treatment Rinsewater.  As discussed in Section III, rins-
ing shouldfollow the surface treatment process to prevent the
solution from affecting the surface of the metal beyond the
desired amount.

No samples of surface treatment rinsewater were collected during
the screen sampling program.  However, one plant supplied a par-
tial analysis of surface treatment rinsewater on its dcp.  Ele-
vated concentrations of uranium (1,250 mg/1), titanium  (18 mg/1),
and barium (41 mg/1) were reported.

Surface Treatment Wet Air Pollution Control Slowdown.  As dis-
cussed in Section III, wet air pollution control devices are
needed to control air emissions from some operations in order to
meet air quality standards.  Scrubbers are frequently needed to
control acid fumes from surface treatment operations.

No samples of surface treatment wet air pollution control blow-
down were collected during the screen sampling program.  However,
                               457

-------
the Agency believes that this stream will have wastewater  char-
acteristics similar to surface treatment wet air pollution con-
trol blowdown in the titanium forming subcategory.  These  two
waste streams derive from air pollution control devices used to
collect and concentrate acid fumes.  The only difference between
the wastewater characteristics of the two streams should be the
metals present.  The mass loading  (mg/kkg) of uranium in uranium
surface treatment wet air pollution control blowdown should be
similar to the mass loading of titanium in titanium surface
treatment wet air pollution control scrubber blowdown, and vice
versa.  The other pollutants in each waste stream, and the mass
loading at which they are present, should be similar.

Sawing/Grinding Spent Emulsions.  As discussed in Section III,
sawing/grinding operations generally require a lubricant in order
to minimize friction and act as a coolant.  The emulsions are
typically recirculated, with in-line filtration to remove  swarf,
and periodically batch discharged as the lubricating properties
are exhausted.

No samples of sawing/grinding spent emulsions were collected dur-
ing the screen sampling program.  However, the Agency believes
that this stream will have wastewater characteristics similar to
sawing/grinding spent lubricants in the nickel/cobalt subcate-
gory.  These two waste streams are generated by identical physi-
cal processes which use similar process chemicals.  The only
difference between the wastewater characteristics of the two
streams should be the metals present.  The mass loading (mg/kkg)
of uranium in uranium sawing/grinding spent emulsions should be
similar to the mass loading of nickel in nickel sawing/grinding
spent emulsions, and vice versa.  Also, the mass loading of
chromium in uranium sawing/grinding spent emulsions should be
insignificant because uranium is not commonly alloyed with
chromium.  The other pollutants in each waste stream, and the
mass loading at which they are present, should be similar.

Post-Sawing/Grinding Rinsewater.  As discussed in Section III,
following the sawing/grinding operations, the lubricant and par-
ticulates occasionally need to be rinsed off the formed metal.

No samples of post-sawing/grinding rinsewater were collected dur-
ing the screen sampling program.  However, the Agency believes
that this stream will have wastewater characteristics similar to
sawing/grinding contact lubricant-coolant water in the refractory
metals subcategory.  These waste streams are both derived  from
sawing/grinding operations,  so the only difference between the
wastewater characteristics of the two streams should be the
metals present.  The mass loading (mg/kkg) of uranium in uranium
post-sawing/grinding rinsewater should be similar to the mass
loading of refractory metals in refractory metals sawing/grinding
                               458

-------
contact lubricant-coolant water, and vice versa.  The other pol-
lutants in each waste stream, and the mass loading at which they
are present, should be similar.

Degreasing Spent Solvents.  As described in Section III, solvent
cleaners are used to remove lubricants (oils and greases) applied
to the surface of nonferrous metals during mechanical forming
operations.  Basic solvent cleaning methods include straight
vapor degreasing, immersion-vapor degreasing, spray-vapor
degreasing, ultrasonic vapor degreasing, emulsified solvent
degreasing, and cold cleaning.

Solvents most commonly used for all types of vapor degreasing are
trichloroethylene, 1,1,1-trichloroethane, methylene chloride,
perchloroethylene, and various chlorofluorocarbons.  Solvent
selection depends on the required process temperature (solvent
boiling point), product dimension, and metal characteristics.
Contaminated vapor degreasing solvents are frequently recovered
by distillation.  The sludge residue generated  is toxic and may
be flammable, requiring appropriate handling and disposal pro-
cedures .

Since none of the plants surveyed reported discharging the vapor
degreasing spent solvents, no samples were collected.

Operations Which Do Not Use Process Water.  The Agency proposes a
discharge allowance of zero for operations which do not generate
process wastewater.   The following operations generate no process
wastewater, because they use only noncontact cooling water or
because they use no water at all:

     Stationary Casting
     Direct Chill Casting
     Salt Solution Heat Treatment
                               459

-------
                     Table V-l
NUMBER OF SAMPLES PER WASTE STREAM, BY SUBCATEGORY
Waste Stream / / / /
Rolling spent nea t oils
Rolling spent emulsions
Rol 1 ing contact 1 ubr icant-e oo lant water
Rol 1 ing spent soap sol ut ions
Rolling solution nedt treatment contat t cooling water
Drawing spent neat oils
Drawing spent emul s ions
Drawing spent lubricants
Drawing spent soap solutions
Extrusion spent emul sions
Extrusion spent lubricants
Extrusion press and solution heat treatment contact
cooling water
Extrusion and forging press hydraulic fluid leakage
Extrusion tool contact cooling water
Forging, swaging spent neat oils
Forging, swaging spent emu 1 s ions
Forging spent lubricants
Forging solution heat treatment contat t cooling water
Forging die contact cooling water
Forging wet air pol lution control blowdoun
Forging equipment L 1 ean ing wastewater
Press ing spent lubricants
Tube reducing spent lubricants
Metal powder produc t ion wet atomiza t ion wastewa ter
Metal powder production milling wastewate r
Metal powder production wet air pol lution control
blowdown
Metal powder produc t ion wabtewater
Continuous strip casting contact cooling water
Semi-continuous ingot casting contact cool ing water
Direct chill casting contact cooling water
Shot casting contact cooling water
Casting contact cooling water

1

A

A
A

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1

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0
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0
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0
0

0
1
2
0
5
0
                        460

-------
               Table V-l (Continued)
NUMBER OF SAMPLES PER WASTE STREAM, BY SUBGATEGORY
Wa^te SL red m
Pobt-casting bilteL wa.-.hwater
Stationary and diret t chill i,a.-.i ing contac t t ool ing
water
Semi- c on t inuous and eont inuous cast ing con L act
cool ing water
Casting vacuum melting steam eondensate
Cast ing we t air pollut ion control b lowdown
Post-casting washwater
So In t ion heat treatment cont'/









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1
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0
1
                        461

-------
                             Table V-l  (Continued)
           NUMBER OF SAMPLES  PER WASTE STREAM,  BY  SUBCATEGORY
WdbLe Stream
Sizing »penL lubricants
Steam treatment wet air pollution cont rol blowdown
Oil-resin impregnation wastewater
Miscellaneous nondescript wastewater
Wet air pollution control blowdown

/



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 *This waste stream was reported in dcp responses for plants in this subcategory, but no raw wastewater samples
 were analyzed.

**Number of samples of this waste stream analyzed.
                                           462

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         Table V-3

    NONTOXIC POLLUTANTS


        Conventional

total suspended solids (TSS)
oil and grease
PH


      Nonconventional

acidity
alkalinity
aluminum
ammonia nitrogen
barium
boron
calcium
chemical oxygen demand (COD)
chloride
cobalt
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iron
magnesium
manganese
molybdenum
phenolics
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sodium
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tin
titanium
total dissolved solids (TDS)
total organic carbon (TOG)
total solids (TS)
vanadium
yttrium
            464

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                                  Table V-15

                    RESULTS OF CHEMICAL ANALYSES OF SAMPLED
          LEAD AND NICKEL EXTRUSION PRESS AND SOLUTION HEAT TREATMENT
                             CONTACT COOLING WATER
        Parameter

  Oil and grease
  TSS
  PH
  Antimony
  Arsenic
  Beryllium
  Cadmium
  Chromium
  Copper
  Lead
  Nickel
  Silver
  Zinc
  Cyanide
  Acidity
  Alkalinity
  Aluminum
  Ammonia
  Fluoride
  Iron
  Magnesium
  Sulfate
  Titanium
  Total dissolved solids
  Lead
 (mg/1)

  3
  5
  7.6
   —**

  0.001
  0.005

  0.024
  0.13
  0.007
  0.08

170

  0.08
  0.22
  0.023


  0.084
Nickel
(mg/D

 7
 3
 7.4
 0.05

 0.14

 0.07
55

 0.13
 0.83
   Treatment
 Effectiveness
LS&F Technology
    (mg/1)*

     10
      2.6

      0.47
      0.34
      0.20
      0.049
      0.07
      0.39
      0.08
      0.22
      0.07
      0.23
      0.047
      1.49
     32.2
      9.67
      0.28
 *From Table VI1-9.

**—Not detected or not detected above concentration detected in source water.
                                     477

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                                  Table V-16

                    RESULTS OF CHEMICAL ANALYSES OF SAMPLED
           LEAD, NICKEL, AND PRECIOUS METALS ROLLING SPENT EMULSIONS
      Parameter

Oil and grease
TSS
pH
Antimony
Arsenic
Beryllium
Cadmium
Chromium
Copper
Lead
Nickel
Silver
Zinc
Cyanide
Acidity
Alkalinity
Aluminum
Ammonia
Fluoride
Iron
Magnesium
Sulfate
Total dissolved solids
Chemical oxygen demand
Total organic carbon
   Lead
  (mg/1)

   270
   480
     7.92
    —**
     0.25
    29.0
     0.003

     1.4
   310
     0.35
     0.15
     0.82
     7.3
    59
 1,020
15,000
 1,700
  Nickel
  (mg/D

 1,095
   191
     6.77

     0.006

     0.02
     1.27
     1.17
     1.06
     8.95
     0.002
     1.95
     0.83
     2.70
    20.86
 2,040
17,584
 1.203
Precious
 Metals
 (mg/D

 1,500
   500
     8.7
                                 0.2
    25.0
     1.00
     1.00
     0.13
     6.00
                  20
               2,100
     0.4
     0.29
    26.5
 8,500
32,000
   900
    43
Treatment
Effective-
ness LS&F
Technology
  (mg/D*

  10
   2.6

   0.47
   0.34
   0.20
   0.049
   0.07
   0.39
   0.08
   0.22
   0.07
   0.23
   0.047
   1.49
  32.2
   9.67
   0.28
 *From Table VII-9.

**—Not detected or not detected above concentration detected in source water.
                                    478

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                           Section VI

                SELECTION OF POLLUTANT PARAMETERS
The Agency has studied nonferrous metals forming wastewaters to
determine the presence or absence of toxic, conventional, and
selected nonconventional pollutants.  The toxic and nonconven-
tional pollutants are subject to BPT and BAT effluent limita-
tions, as well as NSPS, PSES, and PSNS.   The conventional
pollutants are subject to BPT and BCT effluent limitations, as
well as NSPS.

One hundred and twenty-nine toxic pollutants (known as the 129
priority pollutants) were studied pursuant to the requirements of
the Clean Water Act of 1977 (CWA).   These pollutant parameters,
which are listed in Table VI-1, are members of the 65 pollutants
and classes of toxic pollutants referred to as Table 1 in Section
307(a)(1) of the CWA.

From the original list of 129 pollutants, three pollutants have
been deleted in two separate amendments  to 40 CFR Subchapter N,
Part 401.  Dichlorodifluoromethane and trichlorofluoromethane
were deleted first (46 FR 2266, January 8, 1981) followed by the
deletion of bis-(chloromethyl) ether (46 FR 10723, February 4,
1981).

Past studies by EPA and others have identified many nontoxic,
nonconventional pollutant parameters useful in characterizing
industrial wastewaters and in evaluating treatment process
removal efficiencies.  Certain of these and other parameters may
also be selected as reliable indicators  of the presence of
specific toxic pollutants.  For these reasons, a number of non-
toxic pollutants were also studied for the nonferrous metals
forming category.

The conventional pollutants considered (total suspended solids,
oil and grease, and pH) traditionally have been studied to char-
acterize industrial wastewaters.  These parameters are especially
useful in evaluating the effectiveness of wastewater treatment
processes.

Several nonconventional pollutants were considered.  As discussed
in Section V, raw wastewater samples were analyzed for the fol-
lowing:   acidity, alkalinity, aluminum,  ammonia nitrogen, barium,
boron, calcium, chemical oxygen demand (COD), chloride, cobalt,
fluoride, iron, magnesium, manganese, molybdenum, total phenols,
phosphate, sodium, sulfate, tin, titanium, total dissolved solids
(TDS), total organic carbon (TOC),  total solids (TS), vanadium,
                               479

-------
and yttrium.  Several other nonconventional pollutants were also
considered for limitation in particular subcategories where they
would be expected to be found at significant concentrations,
although no raw waste data were available for them prior to
proposal.  These pollutants include columbium, hafnium, radium,
tantalum, tungsten, uranium, and zirconium.

RATIONALE FOR SELECTION OF POLLUTANT PARAMETERS

Exclusion of Toxic Pollutants

The Settlement Agreement in Natural Resources Defense Council,
Inc. vs. Train, 8 ERG 2120 (D.D.C. 1976), modified 12 ERG 1833
(D.D.C. 1979), modified by orders of October 26, 1982, August 2,
1983, and January 6,T98A, which preceded the Clean Water Act,
contains provisions authorizing the exclusion from regulation in
certain instances of particular pollutants, categories, and
subcategories.

Paragraph 8(a)(iii) of the Settlement Agreement allows the Admin-
istrator to exclude from regulation toxic pollutants not detecta-
ble by Section 304(h) analytical methods or other state-of-the-
art methods.  Pollutants that were never detected, or that were
never found above their analytical quantification level, are pro-
posed for exclusion.  The analytical quantification level for a
pollutant is the minimum concentration at which that pollutant
can be reliably measured.  For the toxic pollutants in this
study, the analytical quantification levels are:  0.005 mg/1 for
pesticides, PCB's, and beryllium; 0.010 mg/1 for antimony,
arsenic, selenium, silver, thallium, and the remaining organic
toxic pollutants; 0.020 mg/1 for cadmium, chromium, cyanide, and
zinc; 0.050 mg/1 for copper, lead, and nickel; and 0.0002 mg/1
for mercury.

Since there was no reason to expect TCDD (2 ,3 ,7,8-tetrachlorodi-
benzo-p-dioxin) in nonferrous metals forming process water, EPA
decided that maintenance of a TCDD standard in analytical labora-
tories was too hazardous.  Consequently, TCDD. was analyzed by
GC/MS screening, and compared to EPA's GC/MS computer file.
Samples collected by the Agency's contractor were not analyzed
for asbestos.  Asbestos is not expected to be a part of nonfer-
rous metals forming wastewater since the category only includes
metals that have already been refined from any ores that might
contain asbestos.  In addition, asbestos is not known to be
present in any process chemicals used in any forming operations.

Paragraph 8(a)(iii) also allows the Administrator to exclude from
regulation toxic pollutants detected in amounts too small to be
effectively reduced by technologies known to the Administrator.
Pollutants which were detected below levels considered to be
                               480

-------
achievable by specific available treatment methods are proposed
for exclusion.  For the toxic metals, the chemical precipitation,
sedimentation, and filtration technology treatment effectiveness
values, which are presented in Section VII were used.  For the
toxic organic pollutants detected above their analytical quanti-
fication level, treatment effectiveness values for activated
carbon technology were used.  These treatment effectiveness
values represent the most stringent treatment options considered
for pollutant removal.  This allows for the most conservative
exclusion for pollutants detected below treatable levels.

In addition to the provisions outlined above, Paragraph 8(a)(iii)
of the Settlement Agreement (1) allows the Administrator to
exclude from regulation toxic pollutants detectable in the
effluent from only a small number of sources within the subcate-
gory because they are uniquely related to those sources, and
(2) allows the Administrator to exclude from regulation toxic
pollutants which will be effectively controlled by the technolo-
gies upon which are based other effluent limitations and guide-
lines, or by pretreatment standards.  Such compounds are proposed
for exclusion.

The toxic pollutants proposed for regulation are those found at
the highest concentration in untreated wastewater in each sub-
category.  The lime and settle and lime, settle, filter technol-
ogies were selected as the bases for BPT and BAT because they
control these pollutants.  Because the lime and settle and lime,
settle, filter technologies will also control toxic pollutants
found at lower concentrations, those pollutants are not specifi-
cally regulated.  The description of the pollutant selection for
each subcategory, below, lists the toxic metals found at highest
cocentrations and which are, thus, regulated.  The toxic metals
found at lower concentrations are also listed.  These toxic
metals were not regulated because adequate control of the regu-
lated pollutants will also control the toxic metals found in
lower concentrations.

Waste streams in the nonferrous metals forming category have been
grouped together by the subcategorization scheme described in
Section IV.  The pollutant exclusion procedure was applied for
each of the following subcategories:

      (1)  Lead/Tin/Bismuth Forming

      (2)  Nickel/Cobalt Forming

      (3)  Zinc Forming

      (4)  Beryllium Forming

      (5)  Precious Metals Forming
                              481

-------
       (6)  Iron and Steel/Copper/Aluminum Metal Powder Production
           and Powder Metallurgy

       (7)  Titanium Forming

       (8)  Refractory Metals Forming

       (9)  Zirconium/Hafnium Forming

     (10)  Magnesium Forming

Toxic pollutants remaining after the application of the above
exclusion process were selected for specific regulation.

Paragraph 8 criteria were not used in the selection of pollutant
parameters in the uranium forming subcategory.  No analyses were
made of wastewater generated by operations in this subcategory
prior to proposal of these guidelines and standards.

Regulation of Nonconventional Pollutants

In each subcategory, the metal present at highest concentration
is the metal being subjected to the forming operations.  In
several subcategories the metal present in the greatest amount is
a toxic metal (nickel in the nickel forming subcategory, for
example).  In other subcategories the metal present in the
greatest amount is a nonconventional pollutant (titanium in the
titanium forming subcategory, for example).  In these cases, the
nonconventional metal was selected for regulation to ensure that
all the toxic metals are adequately removed from the wastewater
by the treatment system.  Regulation of only two or three toxic
metals in these subcategories would not ensure adequate control
of all toxic metals because the toxic metals are present at
relatively low concentrations.  The Agency believes that control
of the nonconventional metals formed in the magnesium, refractory
metals, titanium, uranium, and zirconium/hafnium forming subcate-
gories is necessary to ensure adequate removal of all toxic
metals, both toxic and nonconventional.

Radium has been selected for regulation in the uranium forming
subcategory, in addition to toxic metals and uranium, because
radium is a contaminant of uranium and would be expected to be
present in uranium forming process wastewater.

In addition, the nonconventional pollutants ammonia and fluoride
were selected for regulation in subcategories where these pollu-
tants are found at treatable levels.
                              482

-------
DESCRIPTION OF POLLUTANT PARAMETERS

A description of the pollutant parameters detected above their
analytical quantification level in any sample of nonferrous
metals forming wastewater is included in the administrative
record which accompanies this rulemaking package.  The descrip-
tion of each pollutant provides the following information:  the
source of the pollutant; whether it is a naturally occurring
element, processed metal, or 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 a POTW at concentrations that might be expected from
industrial discharges.

POLLUTANT SELECTION BY SUBCATEGORY

Section V of this development document presented a summary of
data collected during nonferrous metals forming plant sampling
visits and subsequent chemical analyses.  This section examines
that data and discusses the selection or exclusion of pollutants
for limitation.

Pollutant Selection for Lead/Tin/Bismuth Forming

Conventional and Nonconventional Pollutant Parameters

This study analyzed samples from the lead/tin/bismuth forming
subcategory for three conventional pollutant parameters and 26
nonconventional pollutant parameters.

Conventional and Nonconventional Pollutant Parameters Selected
for Limitation.  The conventional pollutants and pollutant
parameters selected for limitation in this subcategory are:

     total suspended solids (TSS)
     oil and grease
     PH

No nonconventional pollutants or pollutant parameters are
selected for limitation in this subcategory.  Although these
pollutants are not selected in establishing nationwide limita-
tions, it may be appropriate, on a case-by-case basis, for  the
local permitter to specify effluent limitations for bismuth and
tin.

Toxic Pollutants

The frequency of occurrence of the toxic pollutants in the  waste-
water samples taken is presented in Table VI-2.  These data pro-
vide the basis for the categorization of specific pollutants, as
discussed below.  Table VI-2 is based on the raw wastewater
sampling data.


                              483

-------
Toxic Pollutants Never Detected.   Paragraph 8(a)(ill)  of the
Revised Settlement Agreement allows the Administrator  to exclude
from regulation those toxic pollutants 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 subcategory; therefore,  they are not selected
for limitation:
 1.  acenaphthene                  49.
 2.  acrolein                      50.
 3.  acrylonitrile                 51.
 5.  benzidene                     52.
 7.  chlorobenzene                 53.
 8.  1,2,4-trichlorobenzene        54.
 9.  hexachlorobenzene             55.
10.  1,2-dichloroethane            56.
12.  hexachlorethane               57.
13.  1,1-dichloroethane            58.
14.  1,1,2-trichloroethane         59.
16.  chloroethane                  60.
17.  bis (chloromethyl) ether      61.
18.  bis (2-chloroethyl) ether     62.
19.  2-chloroethyl vinyl ether     63.
20.  2-chloronaphthalene           64.
21.  2,4,6-trichlorophenol         67.
24.  2-chlorophenol                68.
25.  1,2-dichlorobenzene           69.
26.  1,3-dichlorobenzene           70.
27.  1,4-dichlorobenzene           71.
28.  3,3'-dichlorobenzidine        72.
29.  1,1-dichloroethylene          73.
30.  1,2-trans-dlchloroethylene    74.
31.  2,4-dichlorophenol            75.
32.  1,2-dichloropropane           76.
33.  1,2-dichloropropylene         77.
34.  2,4-dimethylphenol            78.
35.  2,4-dinitrotoluene            79.
36.  2,6-dinitrotoluene            80.
37.  1,2-diphenylhydrazine         82.
39.  fluoranthene                  83.
40.  4-chlorophenyl phenyl ether   84.
41.  4-bromophenyl phenyl ether    85.
42.  bis(2-chloroisopropyl) ether  86.
43.  bis(2-choroethoxy) methane    87.
44.  methylene chloride            88.
45.  methyl chloride               89.
46.  methyl bromide                90.
47.  bromoform                     91.
48.  dichlorobromomethane          92.
trichlorofluoromethane
dichlorodifluoromethane
chlorodibromomethane
hexachlorobutadiene
hexachlorocyclopentadiene
isophorone
naphthalene
nitrobenzene
2-nitrophenol
4-nitrophenol
2,4-dinitrophenol
4,6-dinitro-o-cresol
M-nitrosodimethylamine
N-nitrosodiphenylamine
N-nitrosodi-n-propylamine
pentachlorophenol
butyl benzyl phthalate
di-n-butyl phthalate
di-n-octyl phthalate
diethyl phthalate
dimethyl phthalate
benzo(a)anthracene
benzo(a)pyrene
benzo(b)fluoranthene
benzo(b)fluoranthene
chrysene
acenaphthylene
anthracene
benzo(ghi)perylene
fluorene
dibenzo(a,h)anthracene
ideno(l,2,3-cd)pyrene
pyrene
tetrachloroethylene
toluene
trichloroethylene
vinyl chloride
aldrin
dieldrin
chlordane
4,4'-DDT
                              484

-------
 93.  4,4'-DDE
 94.  4,4'-ODD
 95.  alpha-endosulfan
 96.  beta-endosulfan
 97.  endosulfan sulfate
 98.  endrin
 99.  endrin aldehyde
100.  heptachlor
101.  heptachlor epoxide
102.  alpha-BHC
103.  beta-BHC
104.  gamma-BHC
105.  delta-BHC
106.  PCB-1242
107.  PCB-1254
108.  PCB-1221
109.  PCB-1232
110.  PCB-1248
111.  PCB-1260
112.  PCB-1016
113.  toxaphene
116.  asbestos
129.  2,3,7,8-tetra chlorodi-
      benzo-p-dioxin (TCDD)
Toxic Pollutants Never Found Above Their Analytical Quantifica-
tion Level .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 quantification concentration in any wastewater samples
from this subcategory; therefore, they are not selected for
limitation:

       4.  benzene
       6.  carbon tetrachloride
      11.  1,1,1-trichloroethane
     125.  selenium
     126.  silver
     127.  thallium

Toxic Pollutants Present Below Concentrations Achievable by
Treatment.Paragraph 8(a)(iii) 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 limitation because they were
not found in any wastewater samples from this subcategory above
concentrations considered achievable by existing or available
treatment technologies:

      15.  1,1,2,2-tetrachloroethane
      22.  parachlorometa cresol
      23.  chloroform
      38.  ethylbenzene
     115.  arsenic
     117.  beryllium
     118.  cadmium
     123.  mercury
     124.  nickel
                               485

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Toxic Pollutants Detected in a Small Number of Sources.  Para-
graph 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 are not selected for
limitation on this basis:

      65.  phenol
      66.  bis(2-ethylhexyl) phthalate
      81.  phenanthrene
     119.  chromium
     120.  copper
     121.  cyanide

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

Toxic Pollutants Effectively Controlled by Technologies Which
Other Effluent Limitations and Guidelines Are Based Upon. As
discussed above,paragraph 8(a)(iii)allowsfor the exclusion of
a toxic pollutant which will be effectively controlled by the
technologies upon which are based other effluent limitations and
guidelines, or pretreatment standards.  The following pollutant
is not selected for limitation on this basis:

     128.  zinc

Toxic Pollutants Selected for Limitation.  The toxic pollutants
listed below are selected for limitation for this subcategory
because they were detected at treatable concentrations in
untreated wastewater:

     114.  antimony
     122.  lead

Pollutant Selection for Nickel/Cobalt Forming

Conventional and Nonconventional Pollutant Parameters

This study considered samples from the nickel/cobalt forming sub-
category for three conventional pollutant parameters and 26
nonconventional pollutant parameters.
                              486

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Conventional and Nonconventipnal Pollutant Parameters Selected
for Limitation^The conventional and nonconventional pollutants
and pollutant parameters selected for limitation in this subcate-
gory are:

     total suspended solids (TSS)
     oil and grease
     PH
     fluoride

Although no other nonconventional pollutants are selected in
establishing nationwide limitations, it may be appropriate,  on a
case-by-case basis, for the local permitter to specify effluent
limitations for cobalt and iron.

Toxic Pollutants

The frequency of occurrence of the toxic pollutants in the waste-
water samples taken is presented in Table VI-3.  These data pro-
vide the basis for the categorization of specific pollutants, as
discussed below.  Table VI-3 is based on the raw wastewater
sampling data.

Toxic Pollutants Never Detected.  Paragraph 8(a)(iii) of the
Revised Settlement Agreement allows the Administrator to exclude
from regulation those toxic pollutants 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 subcategory; therefore, they are not selected
for limitation:
 2.  acrolein                    26.
 3.  acrylonitrile               27.
 6.  carbon tetrachloride        30.
 7.  chlorobenzene               31.
 8.  1,2,4-trichlorobenzene      32.
 9.  hexachlorobenzene           33.
10.  1,2-dichloroethane          35.
14.  1,1,2-trichloroethane       38.
15.  1,1,2 ,2-tetrachloroethane   40.
16.  chloroethane                41.
17.  bis (chloromethyl) ether    42.
18.  bis (2-chloroethyl) ether   45.
19.  2-chloroethyl vinyl ether   46.
20.  2-chloronaphthalene         47.
21.  2,4,6-trichlorophenol       48.
24.  2-chlorophenol              49.
25.  1,2-dichlorobenzene         50.
1,3-dichlorobenzene
1,4-dichlorobenzene
1,2 -trans-dichloroethylene
2,4-dichlorophenol
1,2-dichloropropane
1,2-dichloropropylene
2,4-dinitrotoluene
ethylbenzene
4-chlorophenyl phenyl ether
4-bromophenyl phenyl ether
bis(2-chloroisopropyl)ether
methyl chloride
methyl bromide
bromoform
dichlorobromomethane
trichlorofluoromethane
dichlorodifluoromethane
                              487

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51.  chlorodibromomethane         98.
52.  hexachlorobutadiene          99.
53.  hexachlorocyclopentadiene   100.
54.  isophorone                  101.
56.  nitrobenzene                102.
59.  2,4-dinltrophenol           103.
74.  benzo(b)fluoranthene        104.
79.  benzo(ghi)perylene          105.
82.  dibenzo (a,h)anthracene     106.
85.  tetrachloroethylene         107.
87.  trichloroethylene           108.
88.  vinyl chloride              109.
89.  aldrin                      110.
90.  dieldrin                    111.
91.  chlordane                   112.
92.  4,4'-DDT                    113.
93.  4,4'-DDE                    116.
94.  4,4'-DDD                    129.
95.  alpha-endosulfan
96.  beta-endosulfan
97.  endosulfan sulfate
    endrin
    endrin aldehyde
    heptachlor
    heptachlor epoxide
    alpha-BHC
    beta-BHC
    gamma-BHC
    delta-BHC
    PCB-1242
    PCB-1254
    PCB-1221
    PCB-1232
    PCB-1248
    PCB-1260
    PCB-1016
    toxaphene
    asbestos
    2,3,7,8-tetra chlorodi-
    benzo-p-dioxin (TCDD)
Toxic Pollutants Never Found Above Their Analytical Quantifica-
tion Level.The provision of Paragraph 8(a)(iii) of the Revised
Settlement Agreement excluding from regulation those toxic pollu-
tants 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 ana-
lytical quantification concentration in any wastewater samples
from this subcategory; therefore, they are not selected for limi-
tation:
37.  1,2-diphenylhydrazine
43.  bis(2-ethylhexyl)
     phthalate
61.  N-nitrosodimethylamine
69.  di-n-octyl phthalate
70.  diethyl phthalate
71.  dimethyl phthalate
72.  benzo(a)anthracene
75.  benzo(k)fluoranthene
76.  chrysene
77.  acenaphthylene
78.  anthracene
83.  indeno(l,2,3-cd)pyrene
Toxic Pollutants Present Below Concentrations Achievable by
Treatment.Paragraph 8(a)(iii) 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 limitation because they were
not found in any wastewater samples from this subcategory above
concentrations considered achievable by existing or available
treatment technologies:
                              488

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       4.  benzene
      12.  hexachloroethane
      23.  chloroform
      29.  1,1-dichloroethylene
      86.  toluene
     123.  mercury

Toxic Pollutants Detected in a Small Number of Sources.  Para-
graph 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 are not selected for
limitation on this basis:
 1.  acenaphthene                   64.
 5.  benzidene                      65.
11.  1,1,1-trichloroethane          66.
13.  1,1-dichloroethane
22.  parachlorometa cresol          67.
28.  3,3'-dichloroenzidine          68.
34.  2,4-dimethylphenol             73.
36.  2,6-dinitrotoluene             80.
39.  fluoranthene                   81.
44.  methylene chloride             84.
55.  -naphthalene                   114.
57.  2-nitrophenol                 115.
58.  4-nitrophenol                 117.
60.  4,6-dinitro-o-cresol          121.
62.  N-nitrosodiphenylamine        125.
63.  N-nitrosodi-n-propylamine     126.
                                   127.
pentachlorophenol
phenol
bis(2-ethylhexyl)
phthalate
butyl benzyl phthalate
di-n-butyl phthalate
benzo(a)pyrene
fluorene
phenanthrene
pyrene
ant imony
arsenic
beryllium
cyanide
selenium
silver
thallium
Although these pollutants are not selected in establishing
nationwide limitations, it may be appropriate, on a case-by-case
basis, for the local permitter to specify effluent limitations.

Toxic Pollutants Effectively Controlled by Technologies Which
Other Effluent Limitations and Guidelines are Based Upon.   As
discussed above,paragraph 8(a)(iii)allowsfor the exclusion of
a toxic pollutant which will be effectively controlled by the
technologies upon which other effluent limitations and guide-
lines, or pretreatment standards are based.  The following
pollutants are not selected for limitation on this basis:

     118.  cadmium
     120.  copper
     122.  lead
     128.  zinc
                              489

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Toxic Pollutants Selected for Limitation.   The toxic pollutants
listed below are selected for limitation for this subcategory
because they were detected at treatable concentrations in
untreated wastewater:

     119.  chromium
     124.  nickel

Pollutant Selection for Zinc Forming

Conventional and Nonconventional Pollutant Parameters

This study considered samples from the zinc forming subcategory
for three conventional pollutant parameters and 26
nonconventional pollutant parameters.

Conventional and Nonconventional Pollutant Parameters Selected
for Limitation"]  The conventional pollutants and pollutant
parameters selected for limitation in this subcategory are:

     total suspended solids (TSS)
     oil and grease
     pH

No nonconventional pollutants or pollutant parameters are
selected for limitation in this subcategory.

Toxic Pollutants

Raw wastewater samples collected during the sampling program were
analyzed for the acid extractable, base neutral, and volatile
toxic organic pollutants.  However, the results of the analysis
for these pollutants were not received prior to proposal.  There
is no reason to expect that the presence of organic toxic pollu-
tants in the zinc forming subcategory would be different: than the
presence of organic toxic pollutants in the eight subcategories
for which analytical results have been received.  In those eight
subcategories, only insignificant amounts  of toxic organic pollu-
tants were found.  Therefore, EPA is not selecting organic toxic
pollutants for limitation in the zinc forming subcategory.  How-
ever, if the analytical results, when received, show significant,
treatable concentrations of organic toxic  pollutants, the Agency
would modify this proposal.

The frequency of occurrence of the toxic pollutants in the waste-
water samples taken is presented in Table  VI-4.  These data pro-
vide the basis for the categorization of specific pollutants, as
discussed below.  Table VI-4 is based on the raw wastewater
sampling data.
                               490

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Toxic Pollutants Never Found Above Their Analytical Quantifica-
tion Level.The provision of Paragraph 8(a)(ill) 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 quantification concentration in any wastewater samples
from this subcategory; therefore, they are not selected for
limitation:

114.  antimony                     122.  lead
115.  arsenic                      123.  mercury
117.  beryllium                    125.  selenium
118.  cadmium                      126.  silver
120.  copper                       127.  thallium

Toxic Pollutants Effectively Controlled by Technologies Which
Other Effluent Limitations and Guidelines Are Based Upon.   As~
discussed above,paragraph 8(a)(iii)allowsfor the exclusion of
a toxic pollutant which will be effectively controlled by the
technologies upon which are based other effluent limitations and
guidelines, or pretreatment standards.  The following pollutant
is not selected for limitation on this basis:

     124.  nickel

Toxic Pollutants Selected for Limitation.  The toxic pollutants
listed below are selected for limitation for this subcategory
because they were detected at treatable concentrations in
untreated wastewater:

     119.  chromium
     121.  cyanide
     128.  zinc

Pollutant Selection for Beryllium Forming

Conventional and Nonconventional Pollutant Parameters

This study considered  samples from the beryllium forming subcate-
gory for three conventional pollutant parameters and 26 noncon-
ventional pollutant parameters.

Conventional and Nonconventional Pollutant Parameters Selected
for Limitation.  The conventional and nonconventional pollutants
and pollutant parameters selected for limitation in this
subcategory are:
                              491

-------
     total suspended solids (TSS)
     oil and grease
     pH
     fluoride

Toxic Pollutants

Raw wastewater samples collected during the sampling program were
analyzed for the acid extractable, base neutral, and volatile
toxic organic pollutants.  However, the results of the analysis
for these pollutants were not received prior to proposal.   There
is no reason to expect that the presence of organic toxic  pollu-
tants in the beryllium forming subcategory would be different
than the presence of organic toxic pollutants in the eight sub-
categories for which analytical results have been received.  In
those eight subcategories only insignificant amounts of toxic
organic pollutants were found.  Therefore, EPA is not selecting
organic toxic pollutants for limitation in the beryllium forming
subcategory.  However, if the analytical results, when received,
show significant, treatable concentrations of organic toxic
pollutants, the Agency would modify this proposal.

The frequency of occurrence of the toxic pollutants in the waste-
water samples taken is presented in Table VI-5.  These data pro-
vide the basis for the categorization of specific pollutants, as
discussed below.  Table VI-5 is based on the raw wastewater
sampling data.

Toxic Pollutants Never Found Above Their Analytical Quantifica-
tion Level.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 quantification concentration in any wastewater  samples
from this subcategory; therefore, they are not selected for
limitation:

     114.  antimony
     115.  arsenic
     122.  lead
     125.  selenium
     127.  thallium

Toxic Pollutants Present Below Concentrations Achievable by
Treatment.Paragraph 8(a)(iii)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 limitation because they  were
                              492

-------
not found in any wastewater samples from this subcategory above
concentrations considered achievable by existing or available
treatment technologies:

     123.  mercury
     126.  silver

Toxic Pollutants Effectively Controlled by Technologies Which
Other Effluent Limitations and Guidelines Are Based Upon.  As
discussed above,paragraph 8(a)(iii)allowsfor the exclusion of
a toxic pollutant which will be effectively controlled by the
technologies upon which are based other effluent limitations and
guidelines, or pretreatment standards.  The following pollutants
are not selected for limitation on this basis:

     118.  cadmium
     119.  chromium
     124.  nickel
     128.  zinc

Toxic Pollutants Selected for Limitation.  The toxic pollutants
listed below are selected for limitation for this subcategory
because they were detected at treatable concentrations in
untreated wastewater:

     117.  beryllium
     120.  copper
     121.  cyanide

Pollutant Selection for Precious Metals Forming

Conventional and Nonconventional Pollutant Parameters

This study considered samples from the precious metals forming
subcategory for three conventional pollutant parameters and 26
nonconventional pollutant parameters.

Conventional and Nonconventional Pollutant Parameters Selected
for Limitation.  The conventional pollutants and pollutant
parameters selected for limitation in this subcategory are:

     total suspended solids (TSS)
     oil and grease
     pH

No nonconventional pollutants or pollutant parameters are
selected for limitation in this subcategory.
                               493

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Toxic Pollutants
The frequency of occurrence of the toxic pollutants in the waste-
water samples taken is presented in Table VI-6.  These data pro-
vide the basis for the categorization of specific pollutants, as
discussed below.  Table VI-6 is based on the raw wastewater
sampling data.

Toxic Pollutants Never Detected.  Paragraph 8(a)(iii)  of the
Revised Settlement Agreement allows the Administrator to exclude
from regulation those toxic pollutants 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 subcategory; therefore, they are not selected
for limitation:
 1.  acenaphthene                  40,
 2.  acrolein
 3.  acrylonitrile                 41,
 5.  benzidene                     42,
 6.  carbon tetrachloride
 7.  chlorobenzene                 43.
 8.  1,2,4-trichlorobenzene        46.
 9.  hexachlorobenzene             47.
10.  1,2-dichloroethane            48,
12.  hexachlorethane               49.
13.  1,1-dichloroethane            50.
15.  1,1,2,2-tetrachloroethane     51.
16.  chloroethane                  52.
17.  bis (chloromethyl) ether      53.
18.  bis (2-chloroethyl) ether     54.
19.  2-chloroethyl vinyl ether     55.
20.  2-chloronaphthalene           56.
21.  2,4,6-trichlorophenol         57.
22.  parachlorometa cresol         58,
23.  chloroform                    59.
24.  2-chlorophenol                60.
25.  1,2-dichlorobenzene           61.
26.  1,3-dichlorobenzene           62.
27.  1,4-dichlorobenzene           63.
28.  3,3'-dichlorobenzidine        64.
31.  2,4-dichlorophenol            67.
32.  1,2-dichloropropane           68.
33.  1,2-dichloropropylene         69.
34.  2,4-dimethylphenol            70.
35.  2,4-dinitrotoluene            71.
36.  2,6-dinitrotoluene            72.
37.  1,2-diphenylhydrazine         73.
38.  ethylbenzene                  74.
39.  fluoranthene                  75.
4-chlorophenyl phenyl
ether
4-bromophenyl phenyl ether
bis (2-chloroisopropyl)
ether
bis (2-choroethoxy) methane
methyl bromide
bromoform
dichlorobromomethane
trichlorofluoromethane
dichlorodifluoromethane
chlorodibromomethane
hexachlorobutad iene
hexachlorocyclopentadiene
isophorone
naphthalene
nitrobenzene
2-nitrophenol
4-nitrophenol
2 ,4-dinitrophenol
4,6-dinitro-o-cresol
N-nitrosodimethylamine
N-nitrosodiphenylamine
N-nitrosodi-n-propylamine
pentachlorophenol
butyl benzyl phthalate
di-n-butyl phthalate
di-n-octyl phthalate
diethyl phthalate
dimethyl phthalate
benzo(a)anthracene
benzo(a)pyrene
benzo(b)fluoranthene
benzo(b)fluoranthene
                              494

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 76.  chrysene
 77.  acenaphthylene
 78.  anthracene
 79.  benzo(ghi)perylene
 80.  fluorene
 81.  phenanthrene
 82.  dibenzo (a,h)anthracene
 83.  indeno (1,2,3-cd)pyrene
 84.  pyrene
 88.  vinyl chloride
 89.  aldrin
 90.  dieldrin
 91.  chlordane
 92.  4,4'-DDT
 93.  4,4'-DDE
 94.  4,4'-ODD
 95.  alpha-endosulfan
 96.  beta-endosulfan
 97.  endosulfan sulfate
 98.  endrin
 99.  endrin aldehyde
100.  heptachlor
101.  heptachlor epoxide
102.  alpha-BHC
103.  beta-BHC
104.  gamma-BHC
105.  delta-BHC
106.  PCB-1242
107.  PCB-1254
108.  PCB-1221
109.  PCB-1232
110.  PCB-1248
111.  PCB-1260
112.  PCB-1016
113.  toxaphene
116.  asbestos
129.  2,3,7,8-tetra chlorodi-
      benzo-p-dioxin (TCDD)
Toxic Pollutants Never Found Above Their Analytical Quantifica-
tion Level.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 quantification concentration in any wastewater samples
from this subcategory; therefore, they are not selected for
limitation:

      14.  1,1,2-trichloroethane
     115.  arsenic
     117.  beryllium
     125.  selenium
     127.  thallium

Toxic Pollutants Present Below Concentrations Achievable by
Treatment.Paragraph 8(a)(iii)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 limitation because they were
not found in any wastewater samples from this subcategory above
concentrations considered achievable by existing or available
treatment technologies:

      66.  bis (2-ethylhexyl) phthalate
      85.  tetrachloroethylene
     114.  antimony
     123.  mercury
                              495

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Toxic Pollutants Detected In a Small Number of Sources.  Para-
graph 8(a)(ill) 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 are not selected for
limitation on this basis:

       4.  benzene
      11.  1,1,1-trichloroethane
      29.  1,1-dichloroethylene
      30.  1,2-trans-dichloroethylene
      44.  methylene chloride
      45.  methyl chloride
      65.  phenol
      86.  toluene
      87.  trichloroethylene

Although these pollutants  are 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.

Toxic Pollutants Effectively Controlled by Technologies Which
Other Effluent Limitations and Guidelines Are Based Upon.,  As
discussed above,paragraph 8(a)(iii)allowsfor the exclusion of
a toxic pollutant which will be effectively controlled by the
technologies upon which are based other effluent limitations and
guidelines,  or pretreatment standards.   The following pollutants
are not selected for limitation on this basis:

     119.  chromium
     122.  lead
     124.  nickel
     128.  zinc

Toxic Pollutants Selected  for Limitation.  The toxic pollutants
listed below are selected  for limitation for this subcategory
because they were detected at treatable concentrations in
untreated wastewater:

     118.  cadmium
     120.  copper
     121.  cyanide
     126.  silver
                               496

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Pollutant Selection for Iron and Steel/Copper/Aluminum Metal
Powder Production and Powder Metallurgy

Conventional and Nonconventional Pollutant Parameters

This study considered samples from the iron and steel/copper/
aluminum metal powder production and powder metallurgy subcate-
gory for three conventional pollutant parameters and 26 noncon-
ventional pollutant parameters.

Conventional and Nonconventional Pollutant Parameters Selected
for Limitation.Theconventional and nonconventional pollutants
and pollutant parameters selected for limitation in this
subcategory are:

     total suspended solids (TSS)
     oil and grease
     pH
     aluminum
     iron

Although no other nonconventional pollutants are selected in
establishing nationwide limitations, it may be appropriate, on a
case-by-case basis, for the local permitter to specify effluent
limitations for boron, magnesium, manganese, molybdenum, tin, and
titanium.

Toxic Pollutants

The frequency of occurrence of the toxic pollutants in the waste-
water samples taken is presented in Table VI-7.  These data pro-
vide the basis for the categorization of specific pollutants, as
discussed below.   Table VI-7 is based on the raw wastewater
sampling data.

Toxic Pollutants Never Detected.  Paragraph 8(a)(iii) of the
Revised Settlement Agreement allows the Administrator to exclude
from regulation those toxic pollutants 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 subcategory; therefore, they are not selected
for limitation:
 1.   acenaphthene
 2.   acrolein
 3.   acrylonitrile
 5.   benzidene
 7.   chlorobenzene
 8.   1,2,4-trichlorobenzene
 9.   hexachlorobenzene
10.  1,2-dichloroethane
12.  hexachlorethane
13.  1,1-dichloroethane
14.  1,1,2-trichloroethane
15.  1,1,2 ,2-tetrachloroethane
16.  chloroethane
17.  bis (chloromethyl) ether
                              497

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18.  bis (2-chloroethyl) ether      66.
19.  2-chloroethyl vinyl ether
20.  2-chloronaphthalene            67.
21.  2,4,6-trichlorophenol          68.
22.  parachlorometa cresol          69.
23.  chloroform                     70.
24.  2-chlorophenol                 71.
25.  1,2-dichlorobenzene            72.
26.  1,3-dichlorobenzene            73.
27.  1,4-dichlorobenzene            74.
28.  3,3'-dichlorobenzidine         75.
29.  1,1-dichloroethylene           76.
30.  1,2-trans-dichloroethylene     77.
31.  2,4-dichlorophenol             78.
32.  1,2-dichloropropane            79.
33.  1,2-dichloropropylene          80.
34.  2,4-dimethylphenol             81.
35.  2,4-dinitrotoluene             82.
36.  2,6-dinitrotoluene             83.
37.  1,2-diphenylhydrazine          84.
38.  ethylbenzene                   85.
39.  fluoranthene                   87.
40.  4-chlorophenyl phenyl          88.
     ether                          89.
41.  4-bromophenyl phenyl ether     90.
42.  bis(2-chloroisopropyl)         91.
     ether                          92.
43.  bis(2-choroethoxy) methane     93.
45.  methyl chloride                94.
46.  methyl bromide                 95.
47.  bromoform                      96.
48.  dichlorobromomethane           97.
49.  trichlorofluoromethane         98.
50.  dichlorodifluoromethane        99.
51.  chlorodibromomethane          100.
52.  hexachlorobutadiene           101.
53.  hexachlorocyclopentadiene     102.
54.  isophorone                    103.
55.  naphthalene                   104.
56.  nitrobenzene                  105.
57.  2-nitrophenol                 106.
58.  4-nitrophenol                 107.
59.  2,4-dinitrophenol             108.
60.  4,6-dinitro-o-cresol          109.
61.  N-nitrosodimethylamine        110.
62.  N-nitrosodiphenylamine        111.
63.  N-nitrosodi-n-propylamine     112.
64.  pentachlorophenol             113.
65.  phenol                        116.
                                   129.
bis(2-ethylhexyl)
phthalate
butyl benzyl phthalate
di-n-butyl phthalate
di-n-octyl phthalate
diethyl phthalate
dimethyl phthalate
benzo(a)anthracene
benzo(a)pyrene
benzo(b)fluoranthene
benzo(b)fluoranthene
chrysene
acenaphthylene
anthracene
benzo(ghi)perylene
fluorene
phenanthrene
dibenzo (a,h)anthracene
indeno  (1,2,3-cd)pyrene
pyrene
tetrachloroethylene
trichloroethylene
vinyl chloride
aldrin
dieldrin
chlordane
4,4'-DDT
4,4'-DDE
4,4'-DDD
alpha-endosulfan
beta-endosulfan
endosulfan sulfate
endrin
endrin aldehyde
heptachlor
heptachlor epoxide
alpha-BHC
beta-BHC
gamma-BHC
delta-BHC
PCB-1242
PCB-1254
PCB-1221
PCB-1232
PCB-1248
PCB-1260
PCB-1016
toxaphene
asbestos
2 ,3,7,8-tetra chlorodi-
benzo-p-dioxin (TCDD)
                              498

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Toxic Pollutants Never Found Above Their Analytical Quantifica-
tion Level.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 quantification concentration in any wastewater samples
from this subcategory; therefore, they are not selected for
limitation:

       4.  benzene
     117.  beryllium
     118.  cadmium
     123.  mercury
     125.  selenium
     126.  silver

Toxic Pollutants Present Below Concentrations Achievable by
Treatment.Paragraph 8(a)(iii)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 limitation because they were
not found in any wastewater samples from this subcategory above
concentrations considered achievable by existing or available
treatment technologies:

       6.  carbon tetrachloride
      44.  methlyene chloride
      86.  toluene
     114.  antimony
     115.  arsenic
     127.  thallium

Toxic Pollutants Detected in a Small Number of Sources.  Para-
graph 8(a)(iii)allowsfor 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 pollutant is not selected for
limitation on this basis:

     11.  1,1,1-trichloroethane

Although this pollutant is not selected for establishing
nationwide limitations,  it may be appropriate, on a case-by-case
basis,  for the local permitter to specify effluent limitations.
                              499

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Toxic Pollutants Effectively Controlled By Technologies which
Other Effluent Limitations and Guidelines Are Based Upon.  As
discussed above, Paragraph 8(a) (ill) allows for the exclusion of
a toxic pollutant which will be effectively controlled by the
technologies upon which are based other effluent limitations and
guidelines, or pretreatment standards.  The following pollutants
are not selected for limitation on this basis:

    119.  chromium
    124.  nickel
    128.  zinc

Toxic Pollutants Selected for Further Consideration for Limita-
tion.  The toxic pollutants listed below are selected for
limitation for this subcategory because they were detected at
treatable concentrations in untreated wastewater:

     120.  copper
     121.  cyanide
     122.  lead

Pollutant Selection for Titanium Forming

Conventional and Nonconventional Pollutant Parameters

This study considered samples from the titanium forming
subcategory for three conventional pollutant parameters and 26
nonconventional pollutant parameters.

Conventional and Nonconventional Pollutant Parameters Selected
for Limitation.  The conventional and nonconventional pollutants
andpollutantparameters selected for limitation in this
subcategory are:

     total suspended solids (TSS)
     oil and grease
     pll
     ammonia
     fluoride
     titanium

Although no other nonconventional pollutants are selected in
establishing nationwide limitations, it may be appropriate, on a
case-by-case basis, for the local permitter to specify effluent
limitations for aluminum, boron, cobalt, iron, manganese, molyb-
denum,  and vanadium.
                              500

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Toxic Pollutants
The frequency of occurrence of the toxic pollutants in the waste-
water samples taken is presented in Table VI-8.   These data pro-
vide the basis for the categorization of specific pollutants,  as
discussed below.  Table VI-8 is based on the raw wastewater
sampling data.

Toxic Pollutants Never Detected.  Paragraph 8(a)(iii) of the
Revised Settlement Agreement allows the Administrator to exclude
from regulation those toxic pollutants 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 subcategory; therefore, they are not selected
for limitation:
 1.  acenaphthene                  36.
 2.  acrolein                      37.
 3.  acrylonitrile                 38.
 4.  benzene                       39.
 5.  benzidene                     40.
 7.  chlorobenzene
 8.  1,2,4-trichlorobenzene        41.
 9.  hexachlorobenzene             42.
10.  ,1,2-dichloroethane
11.  1,1,1-trichloroethane         43.
12.  hexachloroethane              45.
13.  1,1-dichloroethane            46.
14.  1,1,2-trichloroethane         47.
15.  1,1,2,2-tetrachloroethane     48.
16.  chloroethane                  49.
17.  bis (chloromethyl) ether      50.
18.  bis (2-chloroethyl) ether     51.
19.  2-chloroethyl vinyl ether     52.
20.  2-chloronaphthalene           53.
21.  2,4,6-trichlorophenol         54.
22.  parachlorometa cresol         55.
23.  chloroform                    56.
24.  2-chlorophenol                57.
25.  1,2-dichlorobenzene           58.
26.  1,3-dichlorobenzene           59.
27.  1,4-dichlorobenzene           60.
28.  3,3'-dichlorobenzidine        61.
29.  1,1-dichloroethylene          62.
30.  1,2-trans-dichloroethylene    63.
31.  2,4-dichlorophenol            64.
32.  1,2-dichloropropane           65.
33.  1,2-dichloropropylene         66.
34.  2,4-dimethylphenol
35.  2,4-dinitrotoluene            67.
2,6-dinitrotoluene
1,2-diphenylhydrazine
ethylbenzene
fluoranthene
4-chlorophenyl phenyl
ether
4-bromophenyl phenyl ether
bis (2-chloroisopropyl)
ether
bis(2-choroethoxy) methane
methyl chloride
methyl bromide
bromoform
dichlorobromomethane
trichlorofluoromethane
dichlorodifluoromethane
chlorodibromomethane
hexachlorobutadiene
hexachlorocyclopentadiene
isophorone
naphthalene
nitrobenzene
2-nitrophenol
4-nitrophenol
2,4-dinitrophenol
4,6-dinitro-o-cresol
N-nitrosodimethylamine
N-nitrosodiphenylamine
N-nitrosodi-n-propylamine
pentachlorophenol
phenol
bis (2 -ethylhexyl)
phthalate
butyl benzyl phthalate
                              501

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 68.  di-n-butyl phthalate
 69.  di-n-octyl phthalate
 70.  diethyl phthalate
 71.  dimethyl phthalate
 72.  benzo (a)anthracene
 73.  benzo (a)pyrene
 74.  3,4-benzofluoranthene
 75.  benzo(k)fluoranthene
 76.  chrysene
 77.  acenaphthylene
 78.  anthracene
 79.  benzo(ghi)perylene
 80.  fluorene
 81.  phenanthrene
 82.  dibenzo (a,h)anthracene
 83.  indeno (1,2,3-cd)pyrene
 84.  pyrene
 85.  tetrachloroethylene •
 86.  toluene
 87.  trichloroethylene
 88.  vinyl chloride
 89.  aldrin
 90.  dieldrin
 91.  chlordane
 92.  4,4'-DDT
 93.  4,4'-DDE
 94.  4,4'-DDD
 95.  alpha-endosulfan
 96.  beta-endosulfan
 97.  endosulfan sulfate
 98.  endrin
 99.  endrin aldehyde
100.  heptachlor
101.  heptachlor epoxide
102.  alpha-BHC
103.  beta-BHC
104.  gamma-BHC
105.  delta-BHC
106.  PCB-1242
107.  PCB-1254
108.  PCB-1221
109.  PCB-1232
110.  PCB-1248
111.  PCB-1260
112.  PCB-1016
113.  toxaphene
114.  antimony
115.  arsenic
116.  asbestos
117.  beryllium
118.  cadmium
119.  chromium
120.  copper
121.  cyanide
122.  lead
123.  mercury
124.  nickel
125.  selenium
126.  silver
127.  thallium
128.  zinc
129.  2,3,7,8-tetra chlorodi-
      benzo-p-dioxin (TCDD)
Toxic Pollutants Never Found Above Their Analytical Quantifica-
tion Level .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 quantification concentration in any wastewater samples
from this subcategory; therefore, they are not selected for
limitation:

       6.  carbon tetrachloride
      44.  methylene chloride
     117.  beryllium
     118.  cadmium
     125.  selenium
     126.  silver
                              502

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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 limitation because they were
not found in any wastewater samples from this subcategory above
concentrations considered achievable by existing or available
treatment technologies:

     114.  antimony
     115.  arsenic
     123.  mercury
     127.  thallium

Toxic Pollutants Effectively Controlled by Technologies Which
Other Effluent Limitations and Guidelines Are Based Upon.  As
discussed above, paragraph 8(a)(iii) allowsfor the exclusion of
a toxic pollutant which will be effectively controlled by the
technologies upon which are based other effluent limitations and
guidelines, or pretreatment standards.  The following pollutants
are not selected for limitation on this basis:

     119.  chromium
     120.  copper
     124.  nickel

Toxic Pollutants Selected for Limitation.  The toxic pollutants
listed below are selected for limitation for this subcategory
because they were detected at treatable concentrations in
untreated wastewater:

     121.  cyanide
     122.  lead
     128.  zinc

Pollutant Selection for Refractory Metals Forming

Conventional and Nonconventional Pollutant Parameters

This study considered samples from the refractory metals forming
subcategory for three conventional pollutant parameters and 26
nonconventional pollutant parameters.

Conventional and Nonconventional Pollutant Parameters Selected
for Limitation.  The conventional and nonconventional pollutants
and pollutant parameters selected for limitation in this
subcategory are:
                              503

-------
     total suspended solids (TSS)
     oil and grease
     PH
     fluoride
     molybdenum
     vanadium
     tungsten
     tantalum
     columbium

Toxic Pollutants

The frequency of occurrence of the toxic pollutants in the waste-
water samples taken is presented in Table VI-9.   These data pro-
vide the basis for the categorization of specific pollutants, as
discussed below.  Table VI-9 is based on the raw wastewater
sampling data.

Toxic Pollutants Never Detected.  Paragraph 8(a)(iii)  of the
Revised Settlement Agreement allows the Administrator  to exclude
from regulation those toxic pollutants 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 subcategory; therefore, they are not
selected for limitation:
 1.  acenaphthene                  30.
 2.  acrolein                      31.
 3.  acrylonitrile                 32,
 4.  benzene                       35.
 5.  benzidene                     36.
 6.  carbon tetrachloride          37.
 7.  chlorobenzene                 38,
 8.  1,2,4-trichlorobenzene        40.
 9.  hexachlorobenzene
10.  1,2-dichloroethane            41.
12.  hexachloroethane              42.
14.  1,1,2-trichloroethane
16.  chloroethane                  43,
17.  bis (chloromethyl) ether      45,
18.  bis (2-chloroethyl) ether     46,
19.  2-chloroethyl vinyl ether     47.
20.  2-chloronaphthalene           48,
21.  2,4,6-trichlorophenol         49.
22.  parachlorometa cresol         50,
25.  1,2-dichlorobenzene           51.
26.  1,3-dichlorobenzene           52,
27.  1,4-dichlorobenzene           53,
28.  3,3'-dichlorobenzidine        54,
1,2-trans-dichloroethylene
2,4-dichlorophenol
1,2-dichloropropane
2,4-dinitrotoluene
2,6-dinitrotoluene
1,2-diphenylhydrazine
ethylbenzene
4-chlorophenyl phenyl
ether
4-bromophenyl phenyl ether
bis(2-chloroisopropyl)
ether
bis(2-choroethoxy) methane
methyl chloride
methyl bromide
bromoform
dichlorobromomethane
trichlorofluoromethane
dichlorodifluoromethane
chlorodibromomethane
hexachlorobutadiene
hexachlorocyclopentadiene
isophorone
                              504

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 58.  4-nitrophenol
 59.  2,4-dinitrophenol
 61.  N-nitrosodimethylamine
 64.  pentachlorophenol
 71.  dimethyl phthalate
 73.  benzo (a)pyrene
 74.  3,4-benzofluoranthene
 75.  benzo(k)fluoranthene
 79.  benzo(ghi)perylene
 82.  dibenzo (a,h)anthracene
 83.  indeno (1,2,3-cd)pyrene
 86.  toluene
 87.  trichloroethylene
 88.  vinyl chloride
 89.  aldrin
 90.  dieldrin
 91.  chlordane
 92.  4,4'-DDT
 93.  4,4'-DDE
 94.  4,4'-DDD
 96.  beta-endosulfan
 97.  endosulfan sulfate
 98.  endrin
 99.  endrin aldehyde
100.  heptachlor
101.  heptachlor epoxide
103.  beta-BHC
105.  delta-BHC
106.  PCB-1242
107.  PCB-1254
108.  PCB-1221
109.  PCB-1232
110.  PCB-1248
111.  PCB-1260
112.  PCB-1016
113.  toxaphene
116.  asbestos
129.  2,3,7,8-tetra chlorodi-
      benzo-p-dioxin (TCDD)
Toxic Pollutants Never Found Above Their Analytical Quantifica-
tion LevelL.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 quantification concentration in any wastewater samples
from this subcategory; therefore, they are not selected for
limitation:
13.  1,1-dichloroethane             84,
15.  1,1,2,2-tetrachloroethane      95
23.  chloroform                    102,
24.  2-chlorophenol                104
29.  1,1-dichloroethylene          125,
      pyrene
      alpha-endosulfan
      alpha-BHC
      gamma-BHC
      selenium
Toxic Pollutants Present Below Concentrations Achievable by
Treatment.Paragraph 8(a)(iii)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 limitation because they were
not found in any wastewater samples from this subcategory above
concentrations considered achievable by existing or available
treatment technologies:
                              505

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      33.  1,2-dichloropropylene
      34.  2,4-dimethylphenol
      56.  nitrobenzene
     114.  antimony
     115.  arsenic
     117.  beryllium
     123.  mercury
     127.  thallium

Toxic Pollutants Detected In a Small Number of Sources,.   Para-
graph 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 are not selected for
limitation on this basis:
11.  1,1,1-trichloroethane
39.  fluoranthene
44.  methylene chloride
55.  naphthalene
57.  2-nitrophenol
60.  4,6-dinitro-o-cresol
62.  N-nitrosodiphenylamine
63.  N-nitrosodi-n-propylamine
65.  phenol
66.  bis (2-ethylhexyl)
     phthalate
67.  butyl benzyl phthalate
                         68.  di-n-butyl phthalate
                         69.  di-n-octyl phthalate
                         70.  diethyl phthalate
                         72.  benzo(a)anthracene
                         76.  chrysene
                         77.  acenaphthylene
                         78.  anthracene
                         80.  fluorene
                         81.  phenanthrene
                         85.  tetrachloroethylene
                        121.  cyanide
                        122.  lead
Although these pollutants are 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.

Toxic Pollutants Effectively Controlled by Technologies Which
Other Effluent Limitations and Guidelines are Based Upon.  As
discussed above,Paragraph 8(a)(iii)allowsfor the exclusion of
a toxic pollutant which will be effectively conntrolled by the
technologies upon which are based other effluent limitations and
guidelines,  or pretreatment standards.   The following pollutants
are not selected for limitation on this basis:
     118.
     119.
     126.
     128.
cadmium
chromium
silver
zinc
                              506

-------
Toxic Pollutants Selected for Limitation.  The toxic pollutants
listed below are selected for limitation for this subcategory
because they were detected at treatable concentrations in
untreated wastewater:

     120.  copper
     124.  nickel

Pollutant Selection for Zirconium/Hafnium Forming

Conventional and Nonconventional Pollutant Parameters

This study considered samples from the zirconium/hafnium forming
subcategory for three conventional pollutant parameters and 26
nonconventional pollutant parameters.

Conventional and Nonconventional Pollutant Parameters Selected
for Limitation.  The conventional and nonconventional pollutants
and pollutant parameters selected for limitation in this
subcategory are:

     total suspended solids (TSS)
     oil and grease
     pH
     ammonia
     fluoride
     zirconium
     hafnium

Toxic Pollutants

The frequency of occurrence of the toxic pollutants in the waste-
water samples taken is presented in Table VI-10.   These data pro-
vide the basis for the categorization of specific pollutants, as
discussed below.  Table VI-10 is based on the raw wastewater
sampling data,

Toxic Pollutants Never Detected.  Paragraph 8(a)(iii) of the
Revised Settlement Agreement allows the Administrator to exclude
from regulation those toxic pollutants 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 subcategory; therefore, they are not selected
for limitation:
                               507

-------
 1.  acenaphthene                   60.
 3.  acrylonitrile                  61.
 5.  benzidene                      62.
 6.  carbon tetrachloride           63.
 8.  1,2,4-trichlorobenzene         64.
 9.  hexachlorobenzene              65.
12.  hexachloroethane               71.
16.  chloroethane                   72.
17.  bis (chloromethyl) ether       73,
18.  bis (2-chloroethyl) ether      74.
19.  2-chloroethyl vinyl ether      75.
20.  2-chloronaphthalene            76.
21.  2,4,6-trichlorophenol          77.
22.  parachlorometa cresol          79.
24.  2-chlorophenol                 80.
25.  1,2-dichlorobenzene            82.
26.  1,3-dichlorobenzene            83.
27.  1,4-dichlorobenzene            89.
28.  3,3'-dichlorobenzidine         90.
30.  1,2-trans-dichloroethylene     91.
31.  2,4-dichlorophenol             92.
32.  1,2-dichloropropane            93.
33.  1,2-dichloropropylene          94.
34.  2,4-dimethylphenol             95.
35.  2,4-dinitrotoluene             96.
36.  2,6-dinitrotoluene             97.
37.  1,2-diphenylhydrazine          98.
40.  4-chlorophenyl phenyl          99.
     ether                         100.
41.  4-bromophenyl phenyl ether    101.
42.  bis(2-chloroisopropyl)        102.
     ether                         103.
43.  bis(2-choroethoxy) methane    104.
45.  methyl chloride               105.
46.  methyl bromide                106.
47.  bromoform                     107.
48.  dichlorobromomethane          108.
49.  trichlorofluoromethane        109.
50.  dichlorodifluoromethane       110.
52.  hexachlorobutadiene           111.
53.  hexachlorocyclopentadiene     112.
54.  isophorone                    113.
55.  naphthalene                   116.
56.  nitrobenzene                  129.
58.  4-nitrophenol
59.  2,4-dinitrophenol
4,6-dinitro-o-cresol
N-nitrosodimethylamine
N-nitrosodiphenylamine
N-nitrosodi-n-propylamine
pentachlorophenol
phenol
dimethyl phthalate
benzo (a)anthracene
benzo (a)pyrene
3,4-benzofluoranthene
benzo(k)fluoranthene
chrysene
acenaphthylene
benzo(ghi)perylene
fluorene
dibenzo (a,h)anthracene
indeno  (1,2,3-cd)pyrene
aldrin
dieldrin
chlordane
4,4'-DDT
4,4'-DDE
4,4'-ODD
alpha-endosulfan
beta-endosulfan
endosulfan sulfate
endrin
endrin aldehyde
heptachlor
heptachlor epoxide
alpha-BHC
beta-BHC
gamma-BHC
delta-BHC
PCB-1242
PCB-1254
PCB-1221
PCB-1232
PCB-1248
PCB-1260
PCB-1016
toxaphene
asbestos
2,3,7,8-tetra chlorodi-
benzo-p-dioxin (TCDD)
                              508

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Toxic Pollutants Never Found Above Their Analytical Quantifica-
tion Level.The provision of Paragraph 8(a)(ill)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 quantification concentration in any wastewater samples
from this subcategory; therefore, they are not selected for
limitation:
 4.  benzene                        69.
 7.  chlorobenzene                  70.
14.  1,1,2-trichloroethane          78.
15.  1,1,2,2-tetrachloroethane      81.
39.  fluoranthene                   84.
51.  chlorodibromomethane           87.
57.  2-nitrophenol                 117.
67.  butyl benzyl phthalate        125.
68.  di-n-butyl phthalate          126.
      di-n-octyl phthalate
      diethyl phthalate
      anthracene
      phenanthrene
      pyrene
      trichloroethylene
      beryllium
      selenium
      silver
Toxic Pollutants Present Below Concentrations Achievable by
Treatment.Paragraph 8(a)(iii) 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 limitation because they were
not found in any wastewater samples from this subcategory above
concentrations considered achievable by existing or available
treatment technologies:

      10.  1,2-dichloroethane
      23.  chloroform
      38.  ethylbenzene
      86.  toluene
     123.  mercury

Toxic Pollutants Detected in a Small Number of Sources.  Para-
graph 8(a)(iii) allowsfor 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 are not selected for
limitation on this basis:
 2.  acrolein
11.  1,1,1-trichloroethane
13.  1,1-dichloroethane
29.  1,1-dichloroethylene
44.  methylene chloride
66.  bis (2-ethylhexyl)
     phthalate
 85.  tetrachloroethylene
 88.  vinyl chloride
118.  cadmium
120.  copper
127.  thallium
128.  zinc
                              509

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Although these pollutants are 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.

Toxic Pollutants Effectively Controlled by Technologies Which
Other Effluent Limitations and Guidelines are Based Upon.  As
discussed above,paragraph 8(a)(iii)allowsfor the exclusion of
a toxic pollutant which will be effectively controlled by the
technologies  upon which are based other effluent limitations and
guidelines, or pretreatment standards.  The following pollutants
are not selected for limitation on this basis:

     114.  antimony
     115.  arsenic
     122.  lead

Toxic Pollutants Selected for Limitation.  The toxic pollutants
listed below are selected for limitation for this subcategory
because they  were detected at treatable concentrations in
untreated wastewater:

     119.  chromium
     121.  cyanide
     124.  nickel

Pollutant Selection for Magnesium Forming

Conventional  and Nonconventional Pollutant Parameters

This study considered samples from the magnesium forming subcate-
gory for three conventional pollutant parameters and 26 noncon-
ventional pollutant parameters.

Conventional  and Nonconventional Pollutant Parameters Selected
for Limitation.  The conventional and nonconventional pollutants
and pollutant parameters selected for limitation in this
subcategory are:

     total suspended solids (TSS)
     oil and  grease
     PH
     ammonia
     fluoride
     magnesium
                              510

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Toxic Pollutants
The frequency of occurrence of the toxic pollutants in the waste-
water samples taken is presented in Table VI-11.   These data pro-
vide the basis for the categorization of specific pollutants, as
discussed below.   Table VI-11 is based on the raw wastewater
sampling data.

Toxic Pollutants Never Detected.  Paragraph 8(a)(iii)  of the
Revised Settlement Agreement allows the Administrator  to exclude
from regulation those toxic pollutants 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 subcategory; therefore, they are not selected
for limitation:
 1.  acenaphthene                  35.
 2.  acrolein                      36.
 3.  acrylonitrile                 37.
 4.  benzene                       38.
 5.  benzidene                     39.
 6.  carbon tetrachloride          40.
 7.  chlorobenzene
 8.  1,2,4-trichlorobenzene        41.
 9.  hexachlorobenzene             42.
10.  1,2-dichloroethane
12.  hexachloroethane              43.
13.  1,1-dichloroethane            45.
14.  1,1,2-trichloroethane         46.
15.  1,1,2,2-tetrachloroethane     47.
16.  chloroethane                  48.
17.  bis (chloromethyl) ether      49.
18.  bis (2-chloroethyl) ether     50.
19.  2-chloroethyl vinyl ether     51.
20.  2-chloronaphthalene           52.
21.  2,4,6-trichlorophenol         53.
22.  parachlorometa cresol         54.
23.  chloroform                    55.
24.  2-chlorophenol                56.
25.  1,2-dichlorobenzene           58.
26.  1,3-dichlorobenzene           59.
27.  1,4-dichlorobenzene           60.
28.  3,3'-dichlorobenzidine        61.
29.  1,1-dichloroethylene          62.
30.  1,2-trans-dichloroethylene    63.
31.  2,4-dichlorophenol            64.
32.  1,2-dichloropropane           66.
33.  1,2-dichloropropylene
34.  2,4-dimethylphenol            67.
2,4-dinitrotoluene
2,6-dinitrotoluene
1,2-diphenylhydrazine
ethylbenzene
fluoranthene
4-chlorophenyl phenyl
ether
4-bromophenyl phenyl ether
bis(2-chloroisopropyl)
ether
bis(2-choroethoxy) methane
methyl chloride
methyl bromide
bromoform
dichlorobromomethane
trichlorofluoromethane
dichlorodifluoromethane
chlorodibromomethane
hexachlorobutadiene
hexachlorocyclopentadiene
isophorone
naphthalene
nitrobenzene
4-nitrophenol
2,4-dinitrophenol
4,6-dinitro-o-cresol
N-nitrosodimethylamine
N-nitrosodiphenylamine
N-nitrosodi-n-propylamine
pentachlorophenol
bis(2-ethylhexyl)
phthalate
butyl benzyl phthalate
                               511

-------
68.  di-n-butyl phthalate
69.  di-n-octyl phthalate
70.  diethyl phthalate
71.  dimethyl phthalate
72.  benzo  (a)anthracene
73.  benzo  (a)pyrene
74.  3,4-benzofluoranthene
75.  benzo(k)fluoranthene
76.  chrysene
77.  acenaphthylene
78.  anthracene
79.  benzo(ghi)perylene
80.  fluorene
81.  phenanthrene
82.  dibenzo (a,h)anthracene
83.  indeno  (1,2,3-cd)pyrene
84.  pyrene
85.  tetrachloroethylene
86.  toluene
87.  trichloroethylene
88.  vinyl chloride
89.  aldrin
90.  dieldrin
91.  chlordane
                         92.  4,4'-DDT
                         93.  4,4'-DDE
                         94.  4,4'-DDD
                         95.  alpha-endosulfan
                         96.  beta-endosulfan
                         97.  endosulfan sulfate
                         98.  endrin
                         99.  endrin aldehyde
                        100.  heptachlor
                        101.  heptachlor epoxide
                        102.  alpha-BUG
                        103.  beta-BHC
                        104.  gamma-BHC
                        105.  delta-BHC
                        106.  PCB-1242
                        107.  PCB-1254
                        108.  PCB-1221
                        109.  PCB-1232
                        110.  PCB-1248
                        111.  PCB-1260
                        112.  PCB-1016
                        113.  toxaphene
                        116.  asbestos
                        129.  2,3,7,8-tetra chlorodi-
                              benzo-p-dioxin (TCDD)
Toxic Pollutants Never Found Above Their Analytical Quantifica-
tion Level.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 quantification concentration in any wastewater samples
from this subcategory; therefore, they are not selected for
limitation:
     115.
     118.
     124.
     125.
     127.
arsenic
cadmium
nickel
selenium
thallium
Toxic Pollutants Present Below Concentrations Achievable by
Treatment.Paragraph 8(a)(iii)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
                              512

-------
selected for limitation because they were not found in any waste-
water samples from this subcategory above concentrations consid-
ered achievable by existing or available treatment technologies:

      11.  1,1,1-trichloroethane
      57.  2-nitrophenol
      65.  phenol
     114.  antimony
     120.  copper
     123.  mercury
     126.  silver

Toxic Pollutants Detected in a Small Number of Sources.  Para-
graph 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 are not selected for
limitation on this basis:

      44.  methylene chloride
     117.  beryllium
     121.  cyanide
     122.  lead

Although these pollutants are 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.

Toxic Pollutants Selected for Limitation.  The toxic pollutants
listed below are selected for limitation for this subcategory
because they were detected at treatable concentrations in
untreated wastewater:

     119.  chromium
     128.  zinc

Pollutant Selection for Uranium Forming

No raw wastewater samples were collected from uranium forming
facilities prior to proposal.  The Agency intends to obtain data
on toxic pollutants in wastewater at uranium forming plants after
proposal.  These data will be added to the record of rulemaking
when they become available and will be considered in promulgating
the final effluent limitations and standards.

However, based on long-term data from DMR's from one direct
discharger and raw wastewater sampling data provided in dcp's,
the following conventional, nonconventional, and toxic pollutants
are selected for limitation in this subcategory:
                              513

-------
total suspended solids (TSS)
oil and grease
pH
fluoride
radium
uranium
118.  cadmium
120.  copper
124.  nickel
                          514

-------
                            Table VI-1

                   LIST OF 129 TOXIC POLLUTANTS
Compound Name

   1.   acenaphthene
   2.   acrolein
   3.   acrylonitrile
   4.   benzene
   5.   benzidene
   6.   carbon tetrachloride (tetrachloromethane)

     Chlorinated benzenes (other than dichlorobenzenes)

   7.   chlorobenzene
   8.   1,2,4-trichlorobenzene
   9.   hexachlorobenzene

     Chlorinated ethanes (including 1,2-dichloroethane,
     1,1,1-trichloroethane,  and hexachloroethane)

  10.   1,2-dichloroethane
  11.   1,1,1-trichloroethane
  12.   hexachloroethane
  13.   1,1-dichloroethane
  14.   1,1,2-trichloroethane
  15.   1,1,2,2-tetrachloroethane
  16.   chloroethane

     Chloroalkyl ethers (chloromethyl,  chloroethyl,  and
     mixed ethers)

  17.   bis (chloromethyl) ether
  18.   bis (2-chloroethyl)  ether
  19.   2-chloroethyl vinyl ether (mixed)

     Chlorinated naphthalene

  20.   2-chloronaphthalene

     Chlorinated phenols (other than those listed elsewhere;
     includes trichlorophenols  and chlorinated cresols)

  21.   2,4,6-trichlorophenol
  22.   parachlororaeta cresol
  23.   chloroform (trichloromethane)
  24.   2-chlorophenol
                             515

-------
                      Table VI-1 (Continued)

                   LIST OF 129 TOXIC POLLUTANTS
   Dlchlorobenzenes

25.  1,2-dichlorobenzene
26.  1,3-dichlorobenzene
27.  1,4-dichlorobenzene

   Dichlorobenzidine

28.  3,3'-dichlorobenzidine

   Dichloroethylenes (1.1-dichloroethylene and
   1,2-dichloroethylene)

29.  1,1-dichloroethylene
30.  1,2-trans-dichloroethylene
31.  2,4-dichlorophenol

   Dichloropropane and dichloropropene

32.  1,2-dichloropropane
33.  1,2-dichloropropylene (1,3-dichloropropene)
34.  2,4-dimethylphenol

   Dinitrotoluene

35.  2,4-dinitrotoluene
36.  2,6-dinitrotoluene
37.  1,2-diphenylhydrazine
38.  ethylbenzene
39.  fluoranthene

   Haloethers (other than those listed elsewhere)

40.  4-chlorophenyl phenyl ether
41.  4-bromophenyl phenyl ether
42.  bis(2-chloroisopropyl) ether
43.  bis(2-choroethoxy) methane

   Halomethanes (other than those listed elsewhere)

44.  methylene chloride (dichloromethane)
45.  methyl chloride (chlororaethane)
46.  methyl bromide (bromomethane)
47.  bromoform (tribromomethane)
48.  dichlorobromomethane
                               516

-------
                     Table VI-1 (Continued)

                  LIST OF 129 TOXIC POLLUTANTS


  Halomethanes (other than those listed elsewhere) (Cont.)

49.  trichlorofluoromethane
50.  dichlorodifluoromethane
51.  chlorodibromomethane
52.  hexachlorobutadiene
53.  hexachlorocyclopentadiene
54.  isophorone
55.  naphthalene
56.  nitrobenzene

  Nitrophenols (including 2,4-dinitrophenol and dinitrocresol)

57.  2-nitrophenol
58.  4-nitrophenol
59.  2,4-dinitrophenol
60.  4,6-dinitro-o-cresol

  Nitrosamines

61.  N-nitrosodimethylamine
62.  N-nitrosodiphenylamine
63.  N-nitrosodi-n-propylamine
64.  pentachlorophenol
65.  phenol

  Phthalate esters

66.  bis(2-ethylhexyl) phthalate
67.  butyl benzyl phthalate
68.  di-n-butyl phthalate
69.  di-n-octyl phthalate
70.  diethyl phthalate
71.  dimethyl phthalate

  Polynuclear aroma.tic hydrocarbons

72.  benzo(a)anthracene (1,2-benzanthracene)
73.  benzo(a)pyrene (3,4-benzopyrene)
74.  3,4-benzofluoranthene
75.  benzo(k)fluoranthene (11,12-benzofluoranthene)
76.  chrysene
77.  acenaphthylene
78.  anthracene
79.  benzo(ghi)perylene (1,11-benzoperylene)
                             517

-------
                      Table VI-1  (Continued)

                  LIST OF  129 TOXIC POLLUTANTS


    Polynuclear aromatic hydrocarbons  (Cont.)

 80.  fluorene
 81.  phenanthrene
 82.  dibenzo(a,h)anthracene (1,2,5,6-dibenzanthracene)
 83.  indeno(l,2,3-cd)pyrene (w,e,-o-phenylenepyrene)
 84.  pyrene
 85.  tetrachloroethylene
 86.  toluene
 87.  trichloroethylene
 88.  vinyl chloride (chloroethylene)

    Pesticides and metabolites

 89.  aldrin
 90.  dieldrin
 91.  chlordane (technical mixture and metabolites)

    DDT and rngtabqlites

 92.  4,4'-DDT
 93.  4,4'-DDE(p,p'DDX)
 94.  4,4'-DDD(p,plTDE)

    Endosulfan and metabolites

 95.  a-endosulfan-Alpha
 96.  b-endosulfan-Beta
 97.  endosulfan sulfate

    Endrin and metabolites

 98.  endrin
 99.  endrin aldehyde

    Heptachlor and metabolies

100.  heptachlor
101.  heptachlor epoxide
                              518

-------
                  Table VI-1 (Continued)



              LIST OF  129 TOXIC POLLUTANTS
Hexachlorocyclohexane (all isomers)
102.
103.
104.
105.
a-BHC-Alpha
b-BHC-Beta
r-BHC (lindane) -Gamma
g-BHC-Delta
Polychlorinated biphenyls (PCB's)
106.
107.
108.
109.
110.
111.
112.

114.
115.
116.
117.
118.
119.
120.
121.
122.
123.
124.
125.
126.
127.
128.

113.
129.
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PCB-1254
PCB-1221
PCB-1232
PCB-1248
PCB-1260
PCB-1016
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copper
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1260)
1016)
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2,3 ,7,8-tetra chlorodibenzo-p-d
                                       (TCDD)
                          519

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                                               559

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                           SECTION VII

                 CONTROL AND TREATMENT TECHNOLOGY
This section describes the treatment techniques  currently used  or
available to remove or recover wastewater pollutants  normally
generated by the nonferrous metals  forming  industrial point
source category.  Included are discussions  of  individual end-of-
pipe treatment technologies and in-plant technologies.  These
treatment technologies are widely used  in many  industrial cate-
gories and data and information to  support  their  effectiveness
have been drawn from a similarly wide range of  sources  and data
bases.

This discussion of control and treatment technology is  divided
into four parts:  the major technologies; the  effectiveness  of
major technologies; the minor technologies;  and  the in-plant
technologies.

END-OF-PIPE TREATMENT TECHNOLOGIES

Individual recovery and treatment technologies  are described
which are used or are suitable for  use  in treating wastewater
discharges from nonferrous metals forming facilities.   Each
description includes a functional description  and discussions of
application and performance, advantages and limitations, oper-
ational factors (reliability, maintainability,  solid waste
aspects), and demonstration status.  The treatment processes
described include both technologies presently  demonstrated within
the nonferrous metals forming category, and technologies demon-
strated in treatment of similar wastes  in other  industries.

Nonferrous metals forming wastewater streams characteristically
contain significant levels of toxic inorganic  pollutants.  Anti-
mony, cadmium, chromium, copper, cyanide, lead, nickel, and  zinc
are found in nonferrous metals forming wastewater streams at sub-
stantial concentrations.  These toxic inorganic pollutants con-
stitute the most significant wastewater pollutants in this
category.  Oils and emulsions are also present  in waste streams
emanating from operations using oil-based lubricants  and emul-
sions.  Ammonia is present in waste streams  associated  with
pickling operations where ammonium  bifluoride  is used.  One  plant
reported the use of ammonia in a pickling rinse operation as
well.

In general, these pollutants are removed by oil removal (skimming
and emulsion breaking),  ammonia stripping,  hexavalent chromium
reduction, chemical precipitation and sedimentation,  or filtra-
tion.  Most of them may be effectively removed by precipitation
of metal hydroxides or carbonates utilizing the reaction with
lime, sodium hydroxide,  or sodium carbonate.
                              561

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MAJOR TECHNOLOGIES

In Sections IX, X, XI, and XII, the  rationale  for  selecting
treatment systems is discussed.  The individual  technologies used
in the system are described here.  The major end-of-pipe  technol-
ogies are:  chemical emulsion breaking, oil skimming, ammonia
steam stripping, hexavalent chromium reduction,  cyanide precipi-
tation, chemical precipitation and sedimentation,  and multimedia
filtration.  In practice, precipitation of metals  and settling  of
the resulting precipitates is often  a unified  two-step operation.
Suspended solids originally present  in raw wastewaters are not
appreciably affected by the precipitation operation and are
removed with the precipitated metals in the settling operations.
Settling operations can be evaluated independently of hydroxide
or other chemical precipitation operations, but  hydroxide and
other chemical precipitation operations can only be evaluated in
combination with a solids removal operation.

Chemical Emulsion Breaking

Chemical treatment is often used to  break stable oil-in-water
(0-W) emulsions.  An 0-V7 emulsion consists of  oil  dispersed in
water, stabilized by electrical charges and emulsifying agents.
A stable emulsion will not separate  or break down without some
form of treatment.

Once an emulsion is broken, the difference in  specific gravities
allows the oil to float to the surface of the  water.  Solids usu-
ally form a layer between the oil and water, since some oil is
retained in the solids.  The longer  the retention time, the more
complete and distinct the separation between the oil, solids, and
water will be.  Often other methods  of gravity differential
separation, such as air flotation or rotational  separation (e.g.,
centrifugation), are used to enhance and speed separation.  A
schematic flow diagram of one type of application  is shown in
Figure VII-1.

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

Emulsifiers may be used in the plant to aid in stabilizing or
forming emulsions.  Emulsifiers are  surface-active agents which
alter the characteristics of the oil and water interface.  These
surfactants have rather long polar molecules.  One end of the
molecule is particularly soluble in water (e.g., carboxyl, sul-
fate, hydroxyl, or sulfonate groups) and the other end is readily
soluble in oils (an organic group which varies greatly with the
different surfactant type).  Thus, the surfactant  emulsifies or
suspends the organic material (oil)  in water.  Emulsifiers also
                              562

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lower the  surface  tension  of  the 0-W  emulsion as  a result  of
solvation  and  ionic  complexing.  These  emulsions  must  be
destabilized  in  the  treatment system.

Application and  Performance.   Emulsion  breaking is applicable to
waste streams  containing emulsified oils  or  lubricants  such as
rolling  and drawing  emulsions.

Treatment  of  spent 0-W  emulsions involves  the use of chemicals to
break the  emulsion followed by gravity  differential  separation.
Factors  to be  considered for  breaking emulsions are  type of chem-
icals, dosage  and  sequence of addition, pH,  mechanical  shear and
agitation, heat, and retention time.

Polymers,  alum,  ferric  chloride, and  organic emulsion  breakers
break emulsions  by neutralizing repulsive  charges between  par-
ticles,  precipitating or salting out  emulsifying  agents,  or
altering the  interfacial film between the  oil  and water so it is
readily  broken.  Reactive  cations  (e.g., H(+l), Al(+3),  Fe(+3),
and cationic polymers)  are particularly effective in breaking
dilute 0-W emulsions.   Once the charges have been neutralized or
the interfacial  film broken,  the small  oil droplets  and suspended
solids wil be  adsorbed  on  the surface of  the floe that  is  formed,
or break out and float  to  the top.  Various  types of
emulsion-breaking  chemicals are used  for  the various types of
oils.

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

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

Mixing is  important  in  breaking 0-W emulsions.  Proper  chemical
feed and dispersion  is  required for effective  results.  Mixing
also causes collisions  which  help  break the  emulsion, and  sub-
sequently helps  to agglomerate droplets.
                              563

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

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

Advantages and Limitations.  Advantages gained from the  use of
chemicalsfor breaking 0-W emulsions are the high removal  effi-
ciency potential and the possibility of reclaiming the oily
waste.  Disadvantages are corrosion problems associated with
acid-alum systems, skilled operator requirements for batch  treat-
ment, and chemical sludges produced.

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

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

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

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

Skimming

Pollutants with a specific gravity less than water will  often
float unassisted to the surface of the wastewater.  Skimming
removes these floating wastes.   Skimming normally takes  place in
a tank designed to allow the floating material to rise and  remain
on the surface, while the liquid flows to an outlet located below
the floating layer.  Skimming devices are therefore suited  to the
removal of non-emulsified oils from raw waste streams.   Common
skimming mechanisms include the rotating drum type, which picks
up oil from the surface of the water as it rotates.  A blade
                              564

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scrapes oil  from the drum and  collects  it  in  a  trough  for  dis-
posal or reuse.  The water portion  is allowed to  flow  under  the
rotating drum.  Occasionally,  an underflow baffle is installed
after the drum; this has the advantage  of  retaining any  floating
oil which escapes the drum skimmer.  The belt type skimmer is
pulled vertically through the  water, collecting oil which  is
scraped off  from the surface and collected in a drum.  Gravity
separators (Figure VH-2), such as  the  API type,  utilize overflow
and underflow baffles to skim  a floating oil  layer from  the
surface of the wastewater.  An overflow-underflow baffle allows a
small amount of wastewater (the oil portion) to flow over  into a
trough for disposition or reuse while the  majority of  the  water
flows underneath the baffle.   This  is followed  by an overflow
baffle, which is set at a height relative  to the  first baffle
such that only the oil bearing portion  will flow  over  the  first
baffle during normal plant operation.   A diffusion device, such
as a vertical slot baffle, aids in  creating a uniform  flow
through the  system and increasing oil removal efficiency.

Application  and Performance.   Skimming  is  applicable to  any  waste
stream containing pollutants which  float to the surface.   It is
commonly used to remove free oil, grease,  and soaps.   Skimming
may be used  in conjunction with air flotation or  clarification in
order to increase its effectiveness.

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

API or other gravity-type separators tend  to be more suitable for
use where the amount of surface oil flowing through the  system is
continuous and substantial.  Drum and belt type skimmers are
applicable to waste streams which evidence smaller amounts of
floating oil and where surges  of floating  oil are  not  a problem.
Using an API separator system  in conjunction with a drum type
skimmer would be a very effective method of removing floating
contaminants from non-emulsified oily waste streams.

The sampling and analytical data described in Section V  show low
concentrations, generally 50 ug/1 or less, of toxic organic  pol-
lutants.  When the toxic organics are present,  they are  found in
or are commingled with oil-containing waste streams.  The  toxic
organics are soluble in the oil and will therefore be  removed
from the water through oil skimming.  The  Agency has not estab-
lished effluent limitations and standards  for the few  toxic
                              565

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organics found at quantifiable concentrations because the con-
centrations are low and when present they will be effectively
removed by oil skimming.

Advantages and Limitations.  Skimming as a pretreatment is effec-
tive in removing naturally floating waste material.  It also
improves the performance of subsequent downstream treatments.

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

Operational Factors.  Reliability:  Because of its simplicity,
skimming is a very reliable technique, requiring little operator
supervision.

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

Solid Waste Aspects:  The collected layer of debris is disposed
of by contractor removal, landfill, incineration or it may be
re-refined.  One plant reported that oil was reclaimed through
distillation on-site.  Because relatively large quantities of
water are present in the collected wastes, incineration is not
always a viable disposal method.

Demonstration Status.  Skimming is a common operation utilized
extensively by industrial waste treatment systems.  It is
operated in 30 plants in this category.

Ammonia Stripping

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

Air stripping takes place in a packed or lattice tower; air is
blown through the packed bed or lattice, over which the ammonia-
laden stream flows.  Usually, the wastewater is heated prior to
delivery to the tower, and air is used at ambient temperature.

The term "ammonia steam stripping" refers to the process of
desorbing aqueous ammonia by contacting the liquid with a suffi-
cient amount of ammonia-free steam.  The steam is introduced
countercurrent to the wastewater  to maximize removal of ammonia.
The operation is commonly carried out in packed bed or tray
columns, and the pH is adjusted to 12 or more with lime or


                               566

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caustic.  Simple tray designs  (such as disk and  doughnut  trays)
are used in steam stripping because of the presence of apprecia-
ble suspended solids and the scaling produced by lime.  These
allow easy cleaning of the tower, at the expense of somewhat
lower steam water contact efficiency, necessitating the use of
more trays for the same removal efficiency.

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

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

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

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

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

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

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

Column temperature:  The temperature of the stripping column
affects the equilibrium between gaseous and dissolved ammonia, as
well as the equilibrium between the molecular and ionized forms
of ammonia in water.  An increase in the temperature reduces the
ammonia solubility and increases the fraction of aqueous  ammonia
that is in the molecular form, both exhibiting favorable  effects
on the desorption rate.
                              567

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

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

Steam stripping can recover significant quantities of reagent
ammonia from wastewater containing extremely high initial ammonia
concentrations, which partially offsets the capital and energy
costs of the technology.

Advantages and Limitations.  Strippers are widely used in indus-
try to remove a variety of materials, including hydrogen sulfide
and volatile organics as well as ammonia, from aqueous streams.
The basic techniques have been applied both in process and in
wastewater treatment applications and are well understood.  The
use of steam strippers with and without pH adjustment is standard
practice for the removal of hydrogen sulfide and ammonia in the
petroleum refining industry and has been studied extensively in
this context.  Air stripping has treated municipal and industrial
wastewater and is recognized as an effective technique of broad
applicability.  Both air and steam stripping have successfully
treated ammonia-laden wastewater within the nonferrous forming
category and closely related industries.  Four primary tungsten
plants in the nonferrous metals manufacturing category use steam
stripping to recover ammonia from process wastewater and reuse
the ammonia in the manufacture of ammonium paratungstate.  The
condensed ammonia may be reused in nonferrous metals forming,
incinerated or sold for reuse.

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

Operational Factors.  Reliability and Maintainability:  Strippers
are relatively easy to operate.  The most complicated part of a
steam stripper is the boiler.  Periodic maintenance will prevent
unexpected shutdowns of the boiler.
                               568

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

Demonstration Status.  Steam stripping has proved to be  an effi-
cient, reliable process for the  removal  of ammonia from  many
types of industrial wastewaters  that contain high concentrations
of ammonia.  Industries using ammonia steam stripping technology
include the fertilizer industry, iron and steel, petroleum refin-
ing, organic chemicals manufacturing, and nonferrous metals
manufacturing.  There is currently one plant  operating a steam
stripping unit on nonferrous metals  forming wastewater.

Cyanide Precipitation

Cyanide precipitation can be used to treat cyanide-containing
wastewater.  The treatment occurs in two steps:  reaction with
ferrous sulfate or zinc sulfate  at an alkaline pH to form iron  or
zinc cyanide complexes followed  by reaction at a low pH  with
additional ferrous sulfate or ferric chloride to form insoluble
iron cyanide precipitates.  Cyanide precipitation is applicable
to all cyanide-containing wastewater and, unlike many oxidation
technologies, is not limited by  the presence  of complexed
cyanides.  The oxidation technologies discussed later in this
section are applicable for waste streams containing only non-
complexed cyanides.  Cyanide precipitation has been selected as
the technology basis for cyanide control because of the  presence
of iron, nickel, and zinc in wastewaters in this category.   These
toxic metals are known to form stable complexes with cyanide.

Cyanide-containing wastewater is introduced into a mixing chamber
where ferrous sulfate (as the heptahydrate (FeSCv,. • 7H20)),
is added to form a hexacyanoferrate complex.  The hexacyanofer-
rate complex is most stable at a pH of 9 (standard units) (1).
Thus, the complexation reaction  is performed  at pH 9.  The amount
or dosage of ferrous sulfate is  dependent upon the chemical  form
of the cyanide in the wastewater.  Cyanide may be present in one
of two forms, free or complexed  (sometimes referred to as fixed).
Various analytical methods to determine  the portions of  free and
complexed cyanides in wastewater have been presented in  the  lit-
erature (2, 3, 4).  Free cyanide, which  refers to the portion of
total cyanide that freely dissociates in water (e.g., HCN),
reacts with the ferrous sulfate  to form  the complex, according
to:
                              569

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     FeSC>4 + 6CN~ -> Fe(CN)e4" + 8042-  (complexation
                                         reaction)

Complexed cyanide, present as the hexacyanoferrate  or  metallocya-
nide complexes, is already in the desired  chemical  form.   In
theory, the ferrous sulfate dosage is determined by calculating
the stoichiometric equivalent required  for the  free cyanide
present, that is, one mole of ferrous sulfate per six^moles of
cyanide.  In actual practice, the dosage requirements  are  greater
than the stoichiometric equivalent (5,  6).  One reason that
excess  ferrous sulfate is required is that the  complexation
reaction is very slow and the excess of reactants increases the
reaction rate.  Another reason is that  in  treatment systems,
where lime or other sources of hydroxide ions are added to raise
the pH  to 9, some of the lime will react with the ferrous  sulfate
to form calcium sulfate.

After forming the complex, the wastewater  is then mixed with
ferric  chloride or additional ferrous sulfate and the  pH adjusted
using acid (e.g., H2SOA) in the range of 2  to 4.  The  ferric
chloride or ferrous sulfate reacts with the hexacyanoferrate  to
form ferrihexacyanoferrate or ferrohexacyanoferrate, respec-
tively, according to:

     4FeCl3 + 3Fe(CN)64- -> Fe4(Fe(CN)6)3

     2FeSC>4 + Fe(CN>6^-  -> Fe2(Fe(CN)6)

The wastewater is then introduced into  a clarifier  to  allow these
insoluble precipitates to settle.

Application and Performance.  Cyanide precipitation can be used
when cyanide destruction is not feasible because of the presence
of cyanide complexes which are difficult to destroy.   Effluent
concentrations of cyanide well below 0.07  mg/1  are  possible.

Advantages and Limitations.  Cyanide precipitation  is  an inexpen-
sive method of treating cyanide.  Problems  may  occur when  metal
ions, such as cadmium, interfere with the  formation of the com-
plexes.  The sludge formed as a result  of  the precipitation of
cyanide is hazardous and must be handled appropriately.

Demonstration Status.  Although no plants  currently use cyanide
precipitation to treat nonferrous metals forming wastewaters, it
is used in at least six coil coating plants, two of which  have
both aluminum forming and aluminum coil coating operations.

The Agency believes that the technology is  transferable to the
nonferrous metals forming category because untreated  (raw) waste-
water cyanide concentrations are of the same order  of  magnitude
                              570

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as those  observed  in  coil  coating wastewater.   In general,  the
concentrations of  cyanide  found  in  nonferrous  metals  forming
wastewater are within the  range  of  concentrations found  in  coil
coating wastewaters.   In that  this  technology  converts all
cyanide species  (that is,  the  entire  range  of  cyanide species
present)  to complex cyanides,  it is reasonable  to assume  that  the
technology would achieve the same performance  in both categories.

In assessing the homogeneity of  the combined metals  data  base
(CMDB) discussed in detail  later in this  section,  the Agency
compared  raw waste concentrations for metals among all of the
categories considered, including nonferrous metals forming  and
coil coating.  Raw wastewaters from both  categories  are homoge-
neous with respect to mean  pollutant  concentrations.  Conse-
quently,  to the extent that there are metals present  that inter-
fere with the performance  of this technology,  they are accounted
for in the performance data used in developing  the coil coating
treatment effectiveness concentrations.   Therefore, nonferrous
metals forming plants using this technology would be  expected  to
achieve performance comparable to that experienced by plants in
the coil  coating category.

Chemical Reduction of Chromium

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

Sulfur dioxide, sodium bisulfite, and sodium metabisulfite  exist
as sulfurous acid when introduced into water.  The sulfurous acid
reduces the hexavalent chromium to  the trivalent  form.  The  sul-
fur is in turn oxidized.  When using  ferrous sulfate, the chro-
mium is reduced and the ferrous iron  is oxidized  to ferric  iron.
The reduction is favored by low pH  and the rate  of reaction even
at low pH is slow.   Operation at a  pH of  2 to 3 with  30 to  45
minutes retention  time is necessary for complete  chromium
reduction.  At pH  levels above 5, the reduction rate  becomes even
slower; and at a pH of > 7  dichromate is  converted to chromate
which cannot be reduced by  the reducing agents discussed  above.
Oxidizing agents such as dissolved  oxygen and  ferric  iron
interfere with the reduction process by consuming  the reducing
agent.
                               571

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A typical treatment consists of 45 minutes retention  in  a
reaction tank.  The reaction tank has an electronic recorder-
controller device to control process conditions with  respect to
pH and oxidation-reduction potential (ORP).  Gaseous  sulfur
dioxide is metered to the reaction tank to maintain the  ORP
within the range of 250 to 300 millivolts.  Sulfuric  acid is
added to maintain a pH level of 2.5 standard units.   The reaction
tank is equipped with a propeller agitator designed to provide
approximately one turnover per minute.  Figure VII-3  shows a
continuous chromium reduction system.

Application and Performance.  Chromium reduction is used in
nonferrous metalsforming for treating rinses of chromic acid
etching solutions used for magnesium and zinc.  Cooling  tower
blowdown may also contain chromium as a biocide in waste streams.
Electroplating and coil coating operations, frequently found
on-site with nonferrous metals forming operations, are sometimes
a source of chromium-bearing wastewaters.   Reduction  followed by
chemical precipitation can achieve final total chromium  concen-
trations of 0.05 mg/1, and concentrations of 0.01 mg/1 are
considered to be attainable by properly maintained and operated
equipment.

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

Barium chloride can be used to remove hexavalent chromium.  Use
of barium chloride is generally only economical if the product,
barium chromate, can be sold for subsequent metal recovery.
Barium chromate is hazardous and would not be suitable for
disposal in landfills.

One limitation of chemical reduction of hexavalent chromium is
that for high concentrations of chromium,  the cost of treatment
chemicals may be prohibitive.  When this situation occurs, other
treatment techniques are likely to be more economical.   Chemical
interference by oxidizing agents is possible in the treatment of
mixed wastes, and the treatment itself may introduce  pollutants
if not properly controlled.  Storage and handling of  sulfur
dioxide may be somewhat hazardous.  Sodium bisulfite, sodium
metabisulfite, and ferrous sulfate, which are purchased  as
solids, can be used instead of sulfur dioxide to avoid storage
and handling problems.  In fact, for lower flow systems, the
sodium bisulfite, sodium metabisulfite, and ferrous sulfate are
more economical than sulfur dioxide.
                               572

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Operational Factors.  Reliability:  Maintenance  consists  of
periodic removalof sludge, the frequency of which  is a function
of the input concentrations of detrimental constituents.

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

Demonstration Status.  The reduction of chromium  waste by sulfur
dioxide or sodium bisulfite is a classic process  and is used by
numerous plants which have hexavalent chromium compounds  in
wastewaters from operations such as inorganic chemicals,  metal
finishing, electroplating, and coil coating.  Six nonferrous
metals forming plants report the use of chromium  reduction to
treat chromic acid etching baths and rinses.

Chemical Precipitation

Dissolved toxic metal ions and certain anions may be chemically
precipitated for removal by physical means such as  sedimentation,
filtration, or centrifugation.  Precipitation is  sometimes con-
fused with coagulation, which is the destabilization (a surface
charge phenomenon) of colloidal (very small) particles, or floc-
culation, which is the growth or aggregation of particles that
results in material with better settling properties.  These
distinctions are frequently disregarded, since two  and often all
three processes occur in a single treatment sequence.  Examples
of coagulant aids include alum and ferric chloride, while poly-
electrolytes are commonly used to enhance flocculation.   Several
reagents are commonly used to effect this precipitation.

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

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

     3.   Ferrous sulfate, zinc sulfate, or both (as is required)
         may be used to precipitate cyanide as a  ferro or zinc
         ferricyanide complex.
                              573

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     4.  Carbonates may be used to precipitate  metals  as  metal
         carbonates.  Hydroxide ions are formed as a result  of
         hydrolysis of water after carbonate  addition,  so that
         metal hydroxides are also formed through the  use of
         carbonates .

In hydroxide precipitation, the reagents most commonly  used  are
hydrated lime  (Ca(OH)2), quicklime (CaO), or  caustic soda
(NaOH) .  To illustrate the precipitation of a generic  divalent
metal  ion, M2+, the important chemical reactions are:

     M2+ + Ca(OH)2   -> M(OH)2 + Ca2+

     M2+ + CaO + H20 -> M(OH)2 + Ca2+

     M2+ + 2NaOH     -> M(OH>2 + 2Na+

The carbonate precipitation system most commonly uses  soda ash
(Na2C03) as the carbonate-supplying reagent.  The simplified
reaction may be represented in the following manner:
M2+ + Na2C03 -> MC03 + 2Na
                               +

These reactions replace calcium or sodium ions in the base with
the metal ions, which are then removed from the wastewater
through sedimentation or filtration.  The calcium or sodium  ions
are usually left in solution, however, if appreciable amounts  of
sulfaie, carbonate, or fluoride are present, calcium will combine
with these ions to form insoluble precipitates which are  also
removed from solution.  Sodium ions will not combine with anions
in solution to form insoluble precipitants .

The equilibria indicated by these reaction equations can  be
strongly affected in metals processing wastewaters by complexa-
tion, chelation, and co-precipitation.  Complexation is a general
term which describes the tendency of most transition metal ions
to react with ions or molecules in water to form stable species
which usually are difficult to remove by chemical precipitation.
The molecules or ions that bond with the centrally located metal
ion are called ligands.  Examples of ligands typically present in
metals processing wastewaters include sulfate, halides, ammonia,
and cyanide.  The metal- ligand complexes that form are very
important in the treatment of metals processing wastewaters . For
instance, this phenomena is the basis of cyanide precipitation,
which entails the capture of cyanide ions by addition of  a
complexing agent, such as iron or zinc ions, and sedimentation of
the resulting complex.  In most instances, however, complexing
has a negative effect on treatment system performance.  The
complexation of cyanide by metals is the most significant com-
plexation problem in this category.  Complexed cyanide-- requires
treatment with ferrous sulfate and ferric chloride and cannot  be
oxidized through conventional means.
                              574

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Chelation is a special form of complexation  that  involves  the
formation of chemical bonds between a central metal  ion and  a
ligand that contains two or more active sites (the ligands cited
above usually contain only one active site,  and are  referred to
as monodentate ligands).  Those with multiple active sites are
termed polydentate ligands.  They are almost exclusively organic
in nature, with active sites located on each end  of  the compound,
and are collectively referred to as chelating agents.  A charac-
teristic number of these will bond with the  ion and  form a
chelate, or complex, that is highly stable in solution.  Chela-
tion will occur in metals processing wastewaters  when organic
compounds are at a significant concentration.  As discussed
earlier, organics are not present at elevated concentrations and
consequently, chelation is not likely to impact treatment  system
performance in this category.

Co-precipitation involves the simultaneous precipitation under
alkaline conditions of certain metal ions with other metal ions,
usually iron.  Such reactions include atom replacement in  the
ferric hydroxide polymeric complex and physical entrapment or
adsorption of the metal ion in a settling ferric  hydroxide floe.
As discussed in the major technology effectiveness section,  this
increased removal (often beyond solubility limits) of toxic  metal
ions in the presence of iron results in low  concentrations of
metal ions.

The concentrations attainable assuming equilibrium chemistry by
hydroxide precipitation can be predicted from the knowledge  of
the pH of the water.  Table VII-1 shows the  solubility product
constants for several toxic metal hydroxides.  For comparison,
the sulfide solubility product constants are shown as well.
Figure VII-4 shows the theoretical solubility curves  for toxic
metals forming insoluble metal hydroxides.

As discussed later in this section, EPA did  not base proposed
limitations and standards on the theoretical equilibrium chemical
assumptions.  Rather, the limitations and standards  were based on
long-term data from full-scale plants with the technology operat-
ing.  Data from actual operating systems take into acount  equi-
librium chemistry.  They also take into account phenomena such as
chelation, complexation, and co-precipitation that cannot be
predicted reliably based on theory.

It can be seen from Figure VII-4 that from the range of optimum
pH's illustrated for wastewaters containing  more  than one  metal,
no single optimum pH exists.  In general, the optimum pH is  seen
to be in the range of 8.5 to 9.5 standard units.  However, each
plant should determine the optimum pH for their wastewater during
the treatment system design.  This is generally determined by
conducting jar tests. (7)
                               575

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The chemical feed system will typically  include bulk  storage
tanks, a metering device and mixer and metering pump  for  slurry
operations.  A quicklime feed system  is  illustrated in Figure
VII-5.  A hydrated lime system would  be  similar but not require
the slaker.  A caustic soda feed  system  is much simpler,  since
the reagent is usually purchased  as a 50 percent  solution, while
a soda ash feed system is very similar to the  lime feed system,
with the only difference being replacement of  the slaker  with a
dissolver.  Pumping requirements  and  feed system  maintenance  are
less complicated with the soda ash system than the lime system
because soda ash is very soluble  in water.  The soda  ash  solution
is easier to pump and less susceptible to scaling.

The dosage of reagent required is commonly determined by  conduc-
ting jar tests in the field or laboratory.  In the absence of
this information, a preliminary gross estimate may be made if the
acidity and significant metals concentrations  are known.  The
dosage rate may be calculated from stoichiometric relationships
and a design excess value that may vary  from 5 percent to 100
percent.  This excess accounts for variability in raw wastewater
characteristics, system inefficiencies,  incomplete understanding
of all occurring chemical reactions,  net reaction rates,  and com-
plexation reactions.  The dosage  will require  periodic retesting
to account for daily, weekly, and seasonal variations in
wastewater characteristics.

The chemical precipitant is metered into a rapid  mix  tank with a
recycle sludge stream from the clarifier to provide sites for
initiation of the precipitation reaction.  Detention  time in the
mix tank is from 30 seconds to 5  minutes.  In a sulfide precipi-
tation system, the sulfide reagent may be added with  an alkaline
agent in the rapid mix tank or directly  to the clarifier.  The pH
will be elevated to 9 to 11 by addition  of alkaline chemicals.

The resulting precipitates may be coagulated and  flocculated by
addition of a coagulant aid in the flocculator before settling in
the clarifier.  Sludge is removed from the bottom of  the  clar-
ifier and the clarifier overflow  is discharged or routed  to
further treatment.

The choice and dosage of precipitating reagent is an  important
factor in system performance.  Hydrated  lime, which is introduced
as an aqueous slurry or as a dry  powder, combines ease of handl-
ing with reasonable cost and relatively  rapid reactivity, which
explain its wide use in metals processing treatment plants.
Quicklime is slightly less expensive  than hydrated lime but often
requires slaking equipment within the lime feed system, adding to
the initial cost.  Caustic soda is much  more expensive than
either form of lime, but reacts rapidly  and is easy to handle.
The sludge formed is fluffy and gelatinous and difficult  to
                              576

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dewater  (10).  Larger clarifiers  are  also  associated with  the  use
of caustic.  The hydroxide-based  systems are widely demonstrated,
achieve  consistent performance, and generate stable sludges
(i.e., sludges that do not degrade appreciably over time).
Disadvantages include ineffective removal  of some  ions  and com-
plexes,  increase in the total dissolved solids content, a  poor
settling sludge that is sometimes costly to dewater, and,  with
lime, calcium deposition problems.

Carbonate precipitation has the advantages of an easily settled
or filtered precipitate, lower operating pH, safe  handling,  and
particular effectiveness in precipitating  lead.  Another advan-
tage is  the generation of a dense sludge that is easily
dewatered.  Soda ash, however, is significantly more expensive
than lime and reacts more slowly.

The chemistry of sulfide precipitation utilizes the low solubili-
ties of  many metallic sulfides to remove these ions from solu-
tion.  Reagents supplying the sulfide ions are ferrous  sulfide
(FeS), sodium sulfide (Na2S), and sodium hydrosulfide  (NaHS).
Their reactions with the divalent metal ion, M2+,  are  as
follows:

     M2+ + FeS  -> MS + Fe2+

     M2+ + Na2S -> MS + 2Na+

Hexavalent chromium is also reduced to the trivalent form  in both
the soluble and insoluble systems.  In the insoluble sulfide
process hexavalent chromium is reduced according to:

     H2Cr04 + FeS + 4H20 -> Cr(OH)3j + Fe(OH)3j +  Sj, + 2H20

In the soluble sulfide process, the sulfide ion is capable of
reducing hexavalent chromium as follows:

     2H2Cr04 + 3NaHS + 8H20 -> 2Cr(OH)3j + 3SJ, + 7H20 + 3NaOH

Ferrous  sulfide is only slightly  soluble in water, while sodium
sulfide  is totally water-soluble.  This difference in  solubili-
ties results in different advantages  and disadvantages  for each
of the two reagents.  In the soluble  system, dissolved sulfide
concentrations are initially quite high, leading to rapid  reac-
tion rates with metal ions.  This rapid precipitation may  encour-
age the  formation of finely divided (colloidal) particles  that
are more difficult to settle from solution.  The excess sulfide,
at certain pH conditions, can also react with hydrogen  ions  to
form H2S, a toxic gas.

These difficulties are partially overcome  in the insoluble sul-
fide system.  Only small amounts of sulfide ion are present  in
                               577

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solution at one time, so l^S formation  is greatly restricted.
However, slower reaction rates are also a consequence of  the low
sulfide ion concentration.  The  ferrous ions  liberated  during
sulfide precipitation are simultaneously precipitated at  alkaline
pH as ferrous hydroxide (11).

Application and Performance.  Chemical precipitation is used in
nonferrous metals forming for precipitation of dissolved  metals.
It can be used to remove metal ions such as aluminum, antimony,
arsenic, beryllium, cadmium, chromium, cobalt, copper,  iron,
lead, manganese, mercury, molybdenum, tin, and "zinc.  The process
is also applicable to any substance that can be transformed into
an insoluble form such as fluorides, phosphates, soaps, sulfides,
and others.  Because it is simple and effective, chemical precip-
itation is extensively used for  industrial waste treatment.

The performance of chemical precipitation depends on several
variables.   The most important factors affecting precipitation
effectiveness are:

     1.  Maintenance of proper pH throughout the precipitation
         reaction and subsequent settling;

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

     3.  Addition of an adequate supply of sacrificial  ions
         (such as iron or aluminum), coagulant aids, and
         flocculants to ensure precipitation and removal  of
         specific target ions;  and

     4.  Effective removal of precipitated solids (see  appro-
         priate technologies discussed under "Sedimentation").

Control of pH.  Irrespective of  the solids removal technology
employed,proper control of pH is absolutely essential  for favor-
able performance of precipitation-sedimentation technologies
because of the amphoteric nature of metal hydroxides (8,  9, 12,
13).  The amphoteric properties  of the metal hydroxides are
clearly illustrated by solubility curves for selected metals
hydroxides shown in Figure VII-5.

Co-precipitation with Iron - The presence of substantial  quanti-
tiesof Iron in metal-bearing wastewaters before treatment has
been shown to improve the removal of toxic metals.  In  some cases
this iron is an integral part of the industrial wastewater; in
other cases iron is deliberately added as a preliminary or first
step of treatment.  The iron functions to improve toxic metal
removal by three mechanisms:  the iron co-precipitates with toxic
metals forming a stable precipitate which desolubilizes the toxic
metal; the iron improves the settleability of the precipitate;
                               578

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and the  large  amount  of  iron  reduces  the  fraction of toxic metal
in the precipitate.   Co-precipitation with  iron  has  been  prac-
ticed for many years,  incidentally when iron  was a substantial
constituent of raw wastewater,  and intentionally when iron salts
were added as  a  coagulant  aid.  Aluminum  or mixed iron-aluminum
salt also have been used.

Co-precipitation using large  amounts  of ferrous  iron salts is
known as ferrite co-precipitation because magnetic iron oxide or
ferrite  is formed.  The  addition of ferrous salts (sulfate)  is
followed by alkali precipitation and  air  oxidation.   The  resul-
tant precipitate is easily removed by filtration and may  be
removed  magnetically.

Advantages and Limitations.   Chemical precipitation  has proven  to
be an effective technique  for removing many pollutants  from
industrial wastewater.   It operates at ambient conditions and is
well suited to automatic control.  The use  of chemical  precipita-
tion may be limited because of  interference by chelating  agents,
because of possible chemical  interference of  mixed wastewaters
and treatment  chemicals, or because of the  potentially  hazardous
situation involved with  the storage and handling of  those chemi-
cals.  Lime is usually added  as a slurry  when used in hydroxide
precipitation.  The slurry must be kept well  mixed and  the addi-
tion lines periodically  checked to prevent  blocking,  which may
result from a  buildup of solids.  Also, hydroxide precipitation
usually makes  recovery of  the precipitated  metals difficult,
because of the heterogeneous  nature of most hydroxide sludges.

The major advantage of the sulfide precipitation process  is  that
the extremely  low solubility  of most  metal  sulfides  promotes very
high metal removal efficiencies; the  sulfide  process  also has the
ability  to remove chromates and dichromates without  preliminary
reduction of the chromium to  its trivalent  state.  In addition,
sulfide  can precipitate  metals  complexed  with most complexing
agents.   The process  demands  care, however, in maintaining the  pH
of the solution at approximately 10 in order  to  prevent the  gen-
eration of toxic hydrogen sulfide gas.  For this  reason,  ventila-
tion of the treatment tanks may be a  necessary precaution in most
installations.  The use  of insoluble  sulfides reduces the problem
of hydrogen sulfide evolution.  As with hydroxide precipitation,
excess sulfide ion must be present to drive the  precipitation
reaction to completion.  Since  the sulfide  ion itself is  toxic,
sulfide addition must be carefully controlled to  maximize heavy
metals precipitation with a minimum of excess sulfide to  avoid
the necessity  of post treatment.  At  very high excess sulfide
levels and high pH, soluble mercury-sulfide compounds may also  be
formed.   Where excess sulfide is present, aeration of the efflu-
ent stream can aid in oxidizing residual  sulfide  to  the less
harmful  sodium sulfate (^2804). The  cost of  sulfide  precip-
itants is high in comparison  with hydroxide precipitants,  and
                              579

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disposal of metallic sulfide sludges may pose problems.  An
essential element in effective sulfide precipitation is the
removal of precipitated solids from the wastewater and proper
disposal in an appropriate site.   Sulfide precipitation will also
generate a higher volume of sludge than hydroxide precipitation,
resulting in higher disposal and dewatering costs.  This is
especially true when ferrous sulfide is used as the precipitant.

The use of sulfide precipitation prior to filtration was consid-
ered as a polishing step for further toxic pollutant removals.
However, it was rejected because treatability studies performed
on inorganic chemicals wastewater did not show significant
improvement in toxic metals removals over those achieved by
chemical precipitation and sedimentation alone.

Operational Factors.  Reliability:  Alkaline chemical precipita-
tion is highly reliable, although proper monitoring and control
are required.

Maintainability:   Major maintenance involves periodic upkeep of
monitoring equipment, automatic feeding equipment, mixing equip-
ment, and other hardware.  Removal of accumulated sludge is
necessary for efficient operation of precipitation-sedimentation
systems.

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

Demonstration Status.  Chemical precipitation of metal hydroxides
is a classic waste treatment technology used in many industrial
waste treatment systems designed to remove toxic metals.  Chemi-
cal precipitation of metals in the carbonate form alone has been
found to be feasible and is commercially used to permit metals
recovery and water reuse.  Forty-six plants in this category
currently operate chemical precipitation (lime or caustic) sys-
tems.

Sedimentation

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

Settling is often preceded by chemical precipitation which
converts dissolved pollutants to solid form and by coagulation
which enhances settling by coagulating suspended precipitates
into larger, faster settling particles.
                              580

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

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

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

Application and Performance.  Settling and clarification  are used
in the nonferrous metals forming category to remove precipitated
metals.  Settling can be used to remove most suspended  solids in
a particular waste stream; thus, it is used extensively by many
different industrial waste treatment  facilities.   Because most
metal ion pollutants are readily converted to solid metal hydrox-
ide precipitates, settling is of particular use in those  indus-
tries associated with metal production, metal forming,  metal
finishing, metal working, and any other industry with high
concentrations of metal ions in their wastewaters.  In  addition
to toxic metals, suitably precipitated materials  effectively
removed by settling include aluminum, iron, manganese,  cobalt,
molybdenum, fluoride, phosphate, and many others.  The  treatment
effectiveness concentrations that can be achieved with  the use of
sedimentation in conjunction with chemical precipitation  are dis-
cussed later in this section in Major Technology Ef feet^iyeness.
                              581

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

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

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

Inclined plate, slant tube, and lamellar settlers have been
observed to achieve higher removal efficiencies than conventional
clarifiers, and greater capacities per unit area are possible.
Installed costs for these advanced clarification systems  are
claimed to be one half the cost of conventional systems of
similar capacity.   However, as  discussed below they are prone  to
upsets and are sensitive to fluctuations in flow and waste  loads.
For plants with severe space limitations, these settling  technol-
ogies used in conjunction with a filter  offer an effective means
of achieving the same performance of a conventional clarifier.

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

Those advanced settlers using  slanted  tubes,  inclined  plates,  or
a lamellar network may require prescreening of the waste  in  order
to eliminate any  fibrous materials which  could potentially clog
the system.  Some installations are especially vulnerable to
shock loadings (e.g., storm water runoff  not  contacting process
areas), but proper system design may alleviate this.

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

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

Granular Bed Filtration

Granular bed filtration may be used to further reduce  suspended
solids concentrations in wastewater exiting chemical precipita-
tion and sedimentation systems.  Filtration occurs in  nature as
the surface ground waters are  cleansed by sand.   Silica sand,
anthracite coal,   and garnet are common filter media used.  These
are usually supported by gravel.  The media may be used singly or
in combination.  The multi-media filters may be arranged to
maintain relatively distinct layers by balancing  the  forces  of
gravity, flow, and buoyancy on the individual particles.  This is
accomplished by selecting appropriate  filter  flow rates
(gpm/sq-ft), media grain size, and density.

Granular bed filters may be classified in terms of filtration
rate, filter media, flow pattern, or method of pressurization.
Traditional rate classifications are slow sand, rapid  sand,  and
high rate mixed media.  In the slow sand  filter,  flux  or
hydraulic loading is relatively low, and removal  of collected
solids to clean the filter is therefore relatively infrequent.
The filter is often cleaned by scraping off the inlet  face (top)
of the sand bed.   In the higher rate filters, cleaning is fre-
quent and is accomplished by a periodic backwash, opposite to the
direction of normal flow.
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A filter may use a single medium such  as  sand  or  diatomaceous
earth  (Figure VII-6a), but dual (Figure VII-6d) and mixed  (multi-
ple) media  (Figure VII-6e) filters allow  higher flow  rates  and
efficiencies than single medium filters.  The  dual media filter
usually consists of a  fine bed of sand under a coarser  bed  of
anthracite coal.  The  coarse coal removes most of the influent
solids, while the fine sand performs a polishing  function.  At
the end of the backwash, the fine sand settles to the bottom
because it is denser than the coal, and the filter is ready for
normal operation.  The mixed media filter operates, on the same
principle, with the finer, denser media at the bottom and the
coarser, less dense media at the top.  The usual arrangement is
garnet at the bottom (outlet end) of the  bed,  sand in the middle,
and anthracite coal at the top.  Some mixing of these layers
occurs and is, in fact, desirable.

The flow pattern is usually top-to-bottom, but other  patterns are
sometimes used.  Upflow filters (Figure VII-6b) are sometimes
used, and in a horizontal filter the flow is horizontal.  In a
biflow filter (Figure  VII-6c), the influent enters both the top
and the bottom and exits laterally.  The  advantage of an upflow
filter is that with an upflow backwash the particles  of a single
filter medium are distributed and maintained in the desired
coarse-to-fine (bottom-to-top) arrangement.  The disadvantage is
that the bed tends to  become fluidized, which  lowers  filtration
efficiency.  The biflow design is an attempt to overcome this
problem.

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

Figure VII-7 depicts a high rate, dual media,  gravity downflow
granular bed filter, with self-stored backwash.  Both filtrate
and backwash are piped around the bed in  an arrangement that per-
mits gravity upflow of the backwash, with the  stored  filtrate
serving as backwash.

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

An important feature for successful filtration and backwashing is
the underdrain.  This  is the support structure for the  bed.  The
underdrain provides an area for collection of  the filtered  water
                              584

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without clogging from either the filtered solids or the media
grains.  In addition, the underdrain prevents loss of the media
with the water, and during the backwash cycle it provides even
flow distribution over the bed.  Failure to dissipate the veloc-
ity head during the filter or backwash cycle will result in bed
upset and the need for major repairs.

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

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

Application and Performance.  Wastewater treatment plants often
use granular bed filters for polishing after clarification, sedi-
mentation, or other similar operations.  Granular bed filtration
thus has potential application to nearly all industrial plants.
Chemical additives which enhance the upstream treatment equipment
may or may not be compatible with or enhance the filtration pro-
cess.  Normal operation flow rates for various types of filters
are as follows:

      Slow Sand                 2.04 - 5.30 1/sq m-hr
      Rapid Sand               40.74 - 51.48 1/sq m-hr
      High Rate Mixed Media    81.48 - 122.22 1/sq m-hr

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

Properly operated filters following sedimentation to reduce
suspended solids below 200 mg/1 should produce water with less
than 10 mg/1 TSS as discussed later in this section in Major
Technology Effectiveness.  Data available for plants in this
category show that several plants, using an additional pond,
lagoon, or multiples of these, following chemical precipitation
and sedimentation, are achieving the same treatment effectiveness
concentrations as multimedia filters; however, filters are gen-
erally easier to operate and maintain.  In many cases, polishing
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lagoons do not achieve the treatment effectiveness realized by
using a filter because they require special attention and careful
control.  However, the available data for the nonferrous metals
forming category show that properly managed polishing lagoons or
other multiple sedimentation treatment in this category are
achieving the same performance as a filter.  Filters are the
obvious choice for plants with limited space availability.  Ten
plants in this category use multiple ponds and lagoons for solids
removal after lime and settle treatment; three plants tise
multimedia filters.

Advantages and Limitations.  The principal advantages of granular
bed filtration are its comparatively (to other filters) low ini-
tial and operating costs, and reduced land requirements over
other methods to achieve the same level of solids removal.

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

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

Solid Waste Aspects:  Filter backwash is generally recycled
within the wastewater treatment system, so that the solids ulti-
mately appear in the clarifier sludge stream for subsequent
dewatering.  Alternatively, the backwash stream may be dewatered
directly or, if there is no backwash, the collected solids may be
disposed of in a suitable landfill.  In either of these situa-
tions there is a solids disposal problem similar to that of
clarifiers.

Demonstration Status.  Deep bed filters are in common use in
municipal treatment plants.  Their use in polishing industrial
clarifier effluent is increasing, and the technology is proven
and conventional.  Granular bed filtration is used in many
manufacturing plants.  The Agency is aware of three plants in
this category with end-of-pipe filtration and 10 plants using
multiple ponds or lagoons.  Three of the 10 plants with multiple
ponds or lagoons were sampled by the Agency, and over the sam-
pling period all three achieved the filter treatment effective-
ness concentrations.  A fourth plant provided long-term data and
it did not achieve the filter concentrations.  Little data are
available characterizing the effectiveness of filters presently
in use within the nonferrous metals forming category.  The Agency
intends to obtain additional data after proposal.
                               586

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Vacuum Filtration

In wastewater treatment plants,  sludge  dewatering  by  vacuum fil-
tration generally uses cylindrical drum filters.   These  drums
have a filter medium which may be cloth made  of  natural  or  syn-
thetic fibers or a wire-mesh fabric.  The drum is  suspended above
and dips into a vat of sludge.   As^the  drum rotates slowly, part
of its circumference is subject  to an internal vacuum that  draws
sludge to the filter medium.  Water  is  drawn  through  the porous
filter cake thorugh the drum fabric  to  a discharge port,  and the
dewatered sludge, loosened by compressed air, is scraped from  the
filter mesh.  Because the dewatering of sludge on  vacuum filters
is relatively expensive per kilogram of water removed, the  liquid
sludge is frequently thickened prior to processing.   A vacuum
filter is shown in Figure VII-8.

Application and Performance.  Vacuum filters  are frequently used
both in municipal treatment plants and  in a wide variety of
industries.  They are most commonly  used in larger facilities,
which may have a thickener to double the solids content  of  clari-
fier sludge before vacuum filtering.  Often a precoat is  used  to
inhibit filter blinding.

The function of vacuum filtration is to reduce the water content
of sludge, so that the solids content increases  from  about  5
percent to between 20 and 30 percent, depending on the waste
characteristics.

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

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

Maintainability:  Maintenance consists  of the cleaning or
replacement of the filter media, drainage grids, drainage piping,
filter pans, and other parts of  the  equipment.  Experience  in a
number of vacuum filter plants indicates that maintenance
consumes approximately 5 to 15 percent  of the total time.
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If intermittent operation is used, the  filter equipment  should  be
drained and washed each time it is taken out of service,.  An
allowance for this wash time must be made in filtering schedules.

Solid Waste Aspects:  Vacuum filters generate a solid cake which
is usually trucked directly to landfill.  All of the metals
extracted from the plant wastewater are concentrated in  the
filter cake as hydroxides, oxides, sulfides, or other salts.

Demonstration Status.  Vacuum filtration has been widely used for
many years.It is a fully proven, conventional technology for
sludge dewatering.  Eighteen nonferrous metals forming plants
report its use.  Vacuum filters are selected over other  sludge
dewatering techniques for several reasons.  First, the annualized
cost in dollars per 1,000 gallons of sludge treated is lower than
for centrifuges, plate-and-frame filter presses, or pressure belt
filters.  Second, a reasonably dry, easily handled metal hydrox-
ide filter cake is produced.  This type of sludge does not
dewater as efficiently when using some  of the alternative tech-
niques.  Third, downtime due to breakdown is less with vacuum
filters than with centrifuges.  Finally, the majority of plants
in the nonferrous forming category with sludge dewatering
equipment are using vacuum filters.

MAJOR TECHNOLOGY EFFECTIVENESS

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

LSeS Performance - Combined Metals Data Base (CMDB)

Chemical analysis data were collected on raw waste (treatment
influent) and treated waste (treatment effluent) from 55 plants
(126 data days) sampled by EPA (or its  contractor) using EPA
sampling and chemical analysis protocols.  These data comprise
the initial data base for determining the effectiveness  of L&S
technology in treating nine pollutants  (cadmium, chromium,
copper, lead, iron, nickel, manganese,  zinc, and total suspended
solids).  Each of these plants belongs  to at least one of the
                              588

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following industry categories:  aluminum  forming, battery  manu-
facturing, coil coating, copper forming,  electroplating  and
porcelain enameling.  All of  the plants employ  pH adjustment  and
hydroxide precipitation using lime or caustic,  followed  by
settling  (tank, lagoon or clarifier) for  solids  removal.

An analysis of this data was  presented in the development  docu-
ment for the proposed regulations for coil coating and porcelain
enameling (January 1981).  Prior to analyzing the data,  some
values were deleted from the  data base.   These  deletions were
made to ensure that the data  reflect properly operated treatment
systems.  Data were deleted if:

        They came from plants where malfunctioning processes or
        treatment systems at  time of sampling were identified.

        They were taken on data days where pH was less than 7.0
        for extended periods  of time or TSS was  greater  than 50
        mg/1.  (These are prima facie indications of poor
        operation.)

In response to coil coating and porcelain enameling proposals,
some commenters claimed that  it was inappropriate to use data
from some categories for regulation of other categories.   In
response to these comments, the Agency reanalyzed the data.  An
analysis of variance was applied to the data for the 126 days of
sampling to test the hypothesis of homogeneous  plant mean  raw and
treated effluent levels across categories by pollutant.  This
analysis is described in the  report, "A Statistical Analysis  of
the Combined Metals Industries Effluent Data" which is in  the
administrative record supporting this rulemaking.  The main
conclusion drawn from the analysis of variance  is that,  with the
exception of electroplating,  the categories are  generally  homoge-
neous with regard to mean pollutant concentrations in both raw
and treated effluent.  That is, when data from  electroplating
facilities are included in the analysis,  the hypothesis  of homog-
eneity across categories is rejected.  When the  electroplating
data are removed from the analysis the conclusion changes  sub-
stantially and the hypothesis of homogeneity across categories is
not rejected.  On the basis of this analysis, the electroplating
data were removed from the data base used to determine treatment
effectiveness concentrations  for the final coil  coating, porce-
lain enameling, canmaking, copper forming, aluminum forming, and
nonferrous metals manufacturing (phase I) regulations.

The statistical analysis provides support for the technical engi-
neering judgement that electroplating wastewaters are suffi-
ciently different from the wastewaters of other  industrial
categories in the data base to warrant removal  of electroplating
data from the data base used  to determine treatment effective-
ness.  These differences may be further explained by differences
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 in the  constituents  and  relative  amounts  of  pollutants  in the raw
wastewaters.  Therefore,  the wastewater data derived  from plants
 that only  electroplate are  not used  in developing limitations for
the nonferrous metals forming category.

For the purpose of determining treatment  effectiveness,  addi-
tional  data were deleted  from the  combined metals data  base.
These deletions were made,  almost  exclusively,  in cases  where
effluent data points were associated with low influent  values.
This was done in two steps.  First,  effluent values measured  on
the same day as influent  values that were less  than or  equal  to
0.1 mg/1 were deleted.  Second, the remaining data were  screened
 for cases  in which all influent values at a  plant were  low
although slightly above the 0.1 mg/1 value.   These data  were
deleted not as individual data points but as plant clusters  of
data that were consistently low and thus  not relevant to assess-
ing treatment.  A few data  points  were also  deleted where
malfunctions not previously identified were  recognized.

The CMDB was used as the  basis for limitations  in nonferrous
metals  forming because the  model  treatment technology for non-
ferrous metals forming, lime and  settle,  is  the  same as  for the
categories represented in the CMDB.  The  selection of lime and
settle was based on the judgment  that the process steps  and
wastewater characteristics  in nonferrous  metals  forming  were
similar to other categories that process  metals  for which lime
and settle is an appropriate and  demonstrated technology.

The basic  approach in analyzing the combined metals data was  to
establish statistical homogeneity  of the  categories with respect
to observed mean pollutant  concentrations in both raw and treated
effluent wastewater.  For the proposed nonferrous metals forming
regulation, the available wastewater sampling data from  nonfer-
rous metals forming facilities were analyzed along with  the CMDB
wastewater sampling data.   In the homogeneity analysis,  available
nonferrous forming data were treated as one  aggregate sample  of
data and compared to the  homogeneous aggregate  sample of: CMDB
data.   The same general statistical approach, used to assess
homogeneity of the combined metals categories,  was used  to
compare the nonferrous metals forming data with  the CMDB data.

Homogeneity is the absence  of statistically  discernible  differ-
ences among categorical data groups of interest  while heteroge-
neity is the opposite, i.e., the presence of statistically
discernible differences.

The CMDB was reviewed following its use in a number of proposed
regulations.  Comments pointed out a few  errors  in the data and
the Agency's review identified a  few transcription errors and
some data points that were  appropriate for inclusion in  the data
                              590

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that had not been used previously because  of  errors  in  data
record identification numbers.  Documents  in  the record  of this
rulemaking identify all the changes,  the reasons for the changes,
and the effect of these changes on the data base.  Other comments
on the CMDB asserted that the data base was too small and that
the statistical methods used were overly complex.  Responses  to
specific comments are provided  in a  document  included in the  can-
making rulemaking.  The Agency  believes that  the combined metals
data base is adequate to determine effluent concentrations
achievable with lime and settle treatment.  The statistical
methods employed in the analysis are well  known and  appropriate
statistical references are provided  in the documents  in  the
record that describe the analysis.

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

The same procedures used in developing proposed limitations from
the combined metals data base were then used  on the  revised data
base.  That is, certain effluent data associated with low influ-
ent values were deleted, and then the remaining data were fit to
a lognormal distribution to determine limitations values.  The
detection of data was done in two steps.   First, effluent values
measured on the same day as influent  valxaes that were less than
or equal to 0.1 mg/1 were deleted.   Second, the remaining data
were screened for cases in which all  influent values  at  a plant
were low although slightly above the  0.1 mg/1 value.  These data
were deleted not as individual  data  points but as plant  clusters
of data that were consistently  low and thus not relevant  to
assessing treatment.

The revised combined metals data base used for this  proposal  con-
sists of 162 data points from 18 plants.

The pollutants compared in the  combined metals data  base  and  non-
ferrous metals forming data bases were cadmium, chromium, copper,
iron, lead, nickel, zinc, and total  suspended solids  (TSS).   In
addition, nonferrous metals forming  data for  aluminum were com-
pared to wastewater sampling data from the aluminum  forming point
source category.  The details of these comparisons are  documented
in a technical memorandum available  in the administrative record
for this rulemaking.

For the influent comparisons, no statistical  differences  were
found between the CMDB and nonferrous metals  forming average  con-
centrations for cadmium, iron,  lead,  TSS,  and zinc.  In  addition,
average influent aluminum concentrations for nonferrous  metals
                              591

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forming and aluminum forming plants also did  not  differ  statis-
tically (i.e., they were homogeneous).  Influent  average concen-
trations of chromium, copper, and nickel were  statistically
different  (heterogeneous) for CMDB and nonferrous metals forming.
However, comparison of the influent copper concentrations  of  the
CMDB copper forming plants with the nonferrous metals  forming
copper levels revealed no significant difference  in  average
influent copper concentrations between CMDB copper forming data
and nonferrous metals forming copper data.  As explained later,
copper forming plants were used as the basis  for  the CMDB  copper
treatment  effectiveness concentrations.  The  nonferrous metals
forming nickel data initially included data from  three nickel-
cobalt forming plants; these plants had very  high influent
concentrations of nickel.  Excluding the three nickel-cobalt
facilities from the nonferrous metals forming  nickel data  for a
recomparison with the CMDB nickel data resulted in no  statistical
difference between CMDB influent nickel data  and  this  subset  of
nonferrous metals forming influent nickel data.  While influent
chromium concentrations between CMDB and nonferrous metals
forming were statistically different (i.e., heterogeneous), the
average effluent chromium concentration comparisons were not
statistically different (i.e., CMDB and nonferrous metals  forming
were found to be homogeneous with respect to  effluent  chromium
average concentrations).

For the effluent comparisons, no statistical  differences (homoge-
neity) were found between the CMDB and nonferrous metals forming
average concentrations for cadmium, chromium,  iron, TSS, and
zinc.  In  addition, no statistical difference was observed
between the average effluent aluminum concentrations for nonfer-
rous metals forming and aluminum forming.  Effluent comparisons
of copper, nickel, and lead revealed statistical  differences
(heterogeneity) in comparing average concentrations for CMDB  and
nonferrous metals forming.  With respect to the significant
effluent copper comparison, CMDB copper forming plant  effluent
copper averages were compared to nonferrous metals forming efflu-
ent copper averages.  As with the analogous influent recompari-
son, no significant difference was determined between  the CMDB
subgroup of copper forming plants and the nonferrous metals
forming plant group with respect to average effluent copper
concentrations.  Again recall that copper forming plants were
used to determine the CMDB copper treatment effectiveness  con-
centrations.   Similarly,  exclusion of the three nickel-cobalt
plants' effluent nickel averages from the nonferrous metals
forming group, resulted in the CMDB and nonferrous metals  forming
effluent nickel averages  not being statistically  different.

In examining the significant difference for lead, a subgroup  of
battery manufacturing plants from the revised CMDB was compared
to the nonferrous metals  forming plants with  respect to their
average influent and effluent lead concentrations.  This subgroup


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of CMDB plants was examined because battery manufacturing plant
data from the revised CMDB contributed in part to the determina-
tion of lead limitations.  The proposed lead  limitations rely  on
battery manufacturing plant data from the revised CMDB and addi-
tional data submitted to the Agency.  A technical memorandum is
available in the administrative record for this rulemaking docu-
menting the revised lead limitations.  The influent comparison
revealed no significant difference between average lead concen-
trations for battery manufacturing plants in  the revised CMDB  and
nonferrous metals forming plants.  The effluent comparison was
inconclusive because of limited information for this subgroup  of
plants using only the revised CMDB information.

In general, the majority of CMDB and nonferrous metals forming
influent and effluent pollutant comparisons were not found to  be
significantly different.  For those pollutant comparisons where
significant differences were found, recomparisons of meaningful
subsets of plants usually eliminated the source of heterogeneity.
For the most part, the available limited nonferrous forming sam-
pling data are homogeneous with the CMDB sampling data.

Aluminum was not one of the pollutants included in the CMDB.
Limitations for aluminum were developed from  aluminum effluent
data collected by EPA at three aluminum forming plants and one
aluminum coil coating plant.  The use of these aluminum data in
nonferrous metals forming was supported by comparison with alumi-
num data collected by industry at nonferrous  metals forming
plants with appropriate lime and settle treatment.  Comparison of
the nonferrous metals forming effluent data (five plants, 15
observations) with the aluminum forming effluent data (four
plants, 11 observations) showed no significant difference between
the two groups.  Also, comparison of nonferrous metals forming
influent aluminum data and the influent aluminum data correspond-
ing to the effluent data used to determine the aluminum limita-
tions showed no significant difference among  the two groups.   The
details of this comparison are also described in the nonferrous
metals forming record.

One-Day Effluent Values

The basic assumption underlying the determination of treatment
effectiveness is that the data for a particular pollutant are
lognormally distributed by plant.  The lognormal has been found
to provide a satisfactory fit to plant effluent data in a number
of effluent guidelines categories.  In the case of the combined
metals categories data base, there are too few data from any one
plant to verify formally the lognormal assumption.  Thus, mea-
surements of each pollutant from a particular plant (denoted by
X) were assumed to follow a lognormal distribution with a log
mean u and log variance a2.  The mean, variance, and 99th
percentile of X are then:
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     mean of X = E(X) = exp(y + a2/2)

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

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

where exp is e, the base of the natural  logarithm.   The  term
lognormal is used because the logarithm  of X has a normal  dis-
tribution with mean y and variance a2.   Using  the  basic
assumption of log normality, the actual  treatment  effectiveness
was determined using a lognormal distribution  that,  in a sense,
approximates the distribution of an average of the plants  in the
data base (i.e., an "average plant" distribution).   The  notion of
an "average plant" distribution is not a  strict statistical  con-
cept but is used here to determine limits that would represent
the performance capability of an average  of the plants in  the
data base.

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

The one-day effluent values were determined as follows:

Let Xjj = the jth  observation on a particular  pollutant  at
plant i where

          •? — 1         T
          j- — j-, . . . , a.
          j = 1, . . . , J ^
          I = total number of plants
         jj_ = number of observations at  plant  i.

Then    Yjj = In Xjj

where    In means  the natural logarithm.

Then      y = log  mean over all plants

               I    Jt
            =  I    £
               i-1  J-l
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where      n  =  total  number of  observations

                I

                1=1

and    V(y)  =  pooled log  variance
                L
                1=1
                1=1
                     Ui-1)
where   Si2  =  log variance  at  plant  i
                Ji
                I
        y^ =  log mean at plant  i.

Thus, y and V(y) are the log mean and  log variance,  respectively,
of the lognormal distribution used  to  determine  the  treatment
effectiveness.  The estimated mean  and 99th percentile  of  this
distribution  form the basis for the long term  average and  daily
maximum effluent limitations, respectively.  The  estimates  are

      mean = E (X)  = exp (y)ijjn(O . 5V(y) )

      99th percentile = £.99 =  exp[y + 2.33Vv(y)]

  where ^ (.)  is a Bessel function and  exp is e,  the  base of the
natural logarithms (see Aitchison,  J.  and J. A.  C. Brown,  The
Lognormal Distribution, Cambridge University Press,  1963).   In
cases where zerosor detection  limit values were  present in the
data, a generalized form of the  lognormal, known  as  the delta
distribution was used (see Aitchison and Brown,  op.  cit.,  Chapter
9).

For certain pollutants, this approach  was modified slightly to
accommodate situations in which a category or  categories stood
out as being marginally different from the others.   For instance,
after excluding the electroplating  data and other data  that did
not reflect pollutant removal or proper treatment, the  effluent
copper concentrations from the  copper  forming  plants were  statis-
tically significantly greater than  the copper  concentrations from
the other plants. Thus, copper  effluent values shown in Table
VII-2 are based only on the copper  effluent data  from the  copper
forming plants.  That is, the log mean for copper is the mean of
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the logs of all copper values from the copper  forming plants  only
and the log variance is the pooled log variance of the copper
forming plant data only. In the case of cadmium, after excluding
the electroplating data and data that did not  reflect removal or
proper treatment, there were insufficient data to estimate  the
log variance for cadmium.  The variance used to determine the
values shown in Table VII-2 for cadmium was estimated by pooling
the within plant variances for all the other metals.  Thus, the
cadmium variability is the average of the plant variability
averaged over all the other metals.  The log mean for cadmium is
the mean of the logs of the cadmium observations only.  As  stated
earlier, the CMDB lead concentrations have been revised to  incor-
porate additional information received on battery manufacturing.
A complete discussion of the data and calculations for all  the
metals is contained in the administrative record for this
rulemaking.

Average Effluent Values

Average effluent values that form the basis for the monthly
limitations were developed in a manner consistent with the  method
used to develop one-day treatment effectiveness in that the log-
normal distribution used for the one-day effluent values was  also
used as the basis for the average values.  That is, we assume a
number of consecutive measurements are drawn from the distribu-
tion of daily measurements.  The approach used for the 10 mea-
surements values was employed previously for the electroplating
category (see "Development Document for Existing Sources
Pretreatment Standards for the Electroplating  Point Source
Category," EPA 440/1-79/003, U.S. Environmental Protection
Agency, Washington, D.C., August, 1979).  That is, the distri-
bution of the average of 10 samples from a lognormal was
approximated by another lognormal distribution.  Although the
approximation is not precise theoretically, there is empirical
evidence based on effluent data from a number  of categories that
the lognormal is an adequate approximation for the distribution
of small samples.  In the course of previous work the approxi-
mation was verified in a computer simulation study.  The average
values were developed assuming independence of the observations
although no particular sampling scheme was assumed.

Ten-Sample Average:

The formulas for the 10-sample limitations were derived on  the
basis of simple relationships between the mean and variance of
the distributions of the daily pollutant measurements and the
average of 10 measurements.  We assume that the daily concentra-
tion measurements for a particular pollutant (denoted by X)
follow a lognormal distribution with log mean  and log variance
denoted by  y  and <^2t respectively.  Let X^Q denote the mean
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of 10 consecutive measurements.  The  following  relationships  then
hold, assuming the daily measurements are independent:
     mean of XIQ = E(XIQ) = E(X)

     variance of XIQ = V(X10) = V(X) - 10
where E (X) and V(X) are the mean and variance of X, respectively,
defined above.  We then assume that X-^Q follows a  lognormal
distribution with log mean y^Q an^ l°g standard deviation
a io« The mean and variance of X^Q are then
                      + 0.5a210)

     V(X10) = exp(2y10 + a210)[exp(o2io) - 1].

Now, yio and o2io can be derived in terms of  y and a2 as

     MIO =  y + o2/2 + 0.51n[l + (exp(a2 -

     °210 = !n[l +  (exp(o2) - 1
Therefore, y IQ and a2io can be estimated using the above
relationships and the estimates of  y and c2 obtained for the
underlying lognormal distribution.  The 10-sample limitation
value was determined by the estimate of the approximate 99th
percentile of the distribution of the 10 sample average given by

     X10(.99) = exp(yio + 2.33 o10)
where y^Q and O^Q are the estimates of y^Q an<^ alQ>
respectively.

30-Sample Average:

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

30-Sample Average Calculation

The formulas for the 30-sample average were based on an applica-
tion of the Central Limit Theorem.  According to the Theorem, the
average of 30 observations drawn from the distribution of daily
measurements, denoted by X3Q, is approximately normally dis-
tributed.  The mean and variance of X3Q are

     mean of X3Q = E(X3o) = E(X)

     variance of XQ = V(X) = V(X) -  30.
The 30-sample average value was determined by the estimate of the
approximate 99th percentile of the distribution of the 30-sample
average given by
     X30(.99) = E(X) + 2.33v(X) ^ 30

where     E (X) = exp(y)^n(0.5V(y) )

ard       V(X) = exp (2y) |>n(2V(y) ) - ^n   /n-2\ V(y)
                 A        A
The formulas for E(X) and V(X) are estimates of E(X) and V(X),
respectively, given in Aitchison, J. and J. A. C. Brown, The
Lcgnormal Distribution, Cambridge University Press, 1963, page
557

Application

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

In applying the treatment effectiveness values to regulations,
the Agency has considered the comments, examined  the sampling
frequency required by many permits, and considered the change in
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values of averages depending on the number  of  consecutive  sampl-
ing days in the averages.  The frequency of sampling required  in
permits is about one to  four samples per month.  The 99th  percen-
tiles of the distribution of averages of 10 consecutive sampling
days are not substantially different from the  99th percentile  of
the distribution's 30-day average.  (Compared  to the one-day
maximum, the 10-day average is about 80 percent of the difference
between one and 30-day values).  Hence, the 10-day average
provides a reasonable basis for a monthly average and is typical
of the sampling frequency required by existing permits.

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

Additional Pollutants

A number of other pollutant parameters were considered with
regard to the performance of lime and settle treatment systems in
removing them from industrial wastewater.   Performance data for
these parameters are not readily available, so data available  to
the Agency in other categories have been selectively used  to
determine the long-term  average performance of lime and settle
technology for each pollutant.  These data  indicate that the
concentrations shown in  Table VII-3 are reliably attainable with
hydroxide precipitation  and settling.

In establishing which data were suitable for use in Table  VII-3
two factors were heavily weighed:  (1) the nature of the waste-
water; and (2) the range of pollutants or pollutant matrix in  the
raw wastewater.  These data have been selected from processes
that generate dissolved  metals in the wastewater and which are
generally free from complexing agents.  The pollutant matrix was
evaluated by comparing the concentrations of pollutants found  in
the raw wastewaters with the range of pollutants in the raw
wastewaters of the combined metals data set.  These data are
displayed in Tables VII-4 and VII-5 and indicate that there is
sufficient similarity in the raw wastes to  logically assume
transferability of the treated pollutant concentrations to the
combined metals data base.  The available data on these added
pollutants do not allow  a homogeneity analysis as was performed
on the combined metals data base.  The data source for each added
pollutant is discussed separately.

Antimony (Sb) - The achievable performance  for antimony is based
on data from a battery and secondary lead plant.  Both EPA sam-
pling data and recent permit data (1978 - 1982) confirm the
achievability of 0.7 mg/1 in the battery manufacturing wastewater
matrix included in the combined data set.  The 0.7 mg/1 concen-
tration is achieved at a battery manufacturing and secondary lead
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plant with the comparable untreated wastewater matrix shown  in
Table VII-6.

Beryllium (Be) - The treatability of beryllium is transferred
from the nonferrous metals manufacturing industry.  The 0.3  mg/1
concentration is achieved at a beryllium plant with the compara-
ble untreated wastewater matrix shown in Table VTI-5.

Silver (Ag) - The treatability of silver is based on a 0.1 mg/1
treatability estimate from the inorganic chemicals industry.
Additional data supporting a treatability as stringent or more
stringent than 0.1 mg/1 are also available from seven nonferrous
metals manufacturing plants.  The untreated wastewater matrix for
these plants is comparable and summarized in Table VII-5.

Fluoride (F) - The 14.5 mg/1 treatability of fluoride is based on
the mean performance of an electronics and electrical component
manufacturing plant.  The untreated wastewater matrix for this
plant shown in Table VII-5 is comparable to the combined metals
data set.

Radium22^ (Ra22^) _ The 5.0 picocuries per liter treatability
is based on the water quality criterion for radium226>

No treatment effectiveness concentrations are available for
columbium,  hafnium, magnesium, molybdenum,  tantalum, titanium,
uranium,  vanadium, and zirconium, metals which are proposed  for
limitation in some subcategories.  We believe that lime and
settle technology will result in effluent concentrations of  these
metals of not more than 0.50 mg/1.  This estimate is based on the
ability of the lime and settle technology to reduce the concen-
tration of the majority of the metals in the combined metals data
base to this value or less.  Sampling data from one nonferrous
metals forming plant with significant titanium concentrations in
the raw waste show that lime and settle treatment achieved a
titanium effluent concentration of 0.5 mg/1 or less at that
plant.  The Agency intends to obtain additional data on treatment
effectiveness for these metals after proposal.

Ammonia Steam Stripping Performance

Chemical  analysis data were collected of raw waste (treatment
influent) and treated waste (treatment effluent) from one plant
of the iron and steel category.   A contractor for EPA, using EPA
sampling and chemical analysis protocols, collected six paired
samples in a two-month period.  These data are the data base for
determining the effectiveness of ammonia steam stripping technol-
ogy and are contained within the public record supporting this
document.  Ammonia treatment at this coke plant consisted of two
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steam stripping columns  in  series with  steam injected  countercur-
rently to the flow of the wastewater.   A  lime reactor  for pH
adjustment  separated the two  stripping  columns.

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

As discussed above under Demonstration  Status for  Ammonia Strip-
ping, steam stripping is demonstrated at  one plant within this
category.   EPA believes  the performance data from  the  iron  and
steel category provide a valid measure  of  this technology's per-
formance on nonferrous category wastewater due to  similar (con-
centrations of the same  order of magnitude)  concentrations  of
ammonia in  the respective raw wastewater  matrices.  A  comparison
of raw (untreated) wastewater samples from the nonferrous metals
forming point source category and the iron and steel facility
from which  the ammonia data was transferred is contained in the
public record.

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

LSSeF Performance

Tables VII-6 and VII-7 show long-term data from two plants  which
have well operated precipitation-settling  treatment followed by
filtration.  The wastewaters  from both  plants contain  pollutants
from metals processing and finishing operations (multi-category).
Both plants reduce hexavalent chromium  before neutralizing  and
precipitating metals with lime.  A clarifier is used to  remove
much of the solids load  and a filter is used to "polish" or
complete removal of suspended solids.   Plant A uses pressure
filtration, while Plant B uses a rapid  sand  filter.

Raw waste data were collected only occasionally at each  facility
and are presented as an  indication of the  nature of the  waste-
water treated.  Data from Plant A were  received as a statistical
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summary and are presented as received.  Raw  laboratory  data  were
collected at Plant B and reviewed for spurious points and  dis-
crepancies.  The method of treating the data base  is discussed
below under lime, settle, and filter treatment effectiveness.

Table VII-8 shows long-term data for zinc and cadmium removal at
Plant C, a primary zinc smelter, which operates  a  LSScF  system.
These data represent about four months (103 data days)  taken
immediately before the smelter was closed, and have been arranged
similarily to Plants A and B for comparison and use.

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

It should be noted that the iron content of the raw waste  of
plants A and B is high while that for Plant C is low.   This
results, for plants A and B, in co-precipitation of toxic  metals
with iron.  Precipitation using high-calcium lime  for pH control
yields the results shown in Table VII-8.  Plant operating  per-
sonnel indicate that this chemical treatment combination (some-
times with polymer assisted coagulation) generally produces
better and more consistent metals removal than other combinations
of sacrificial metal ions and alkalis.

The LSStF performance data presented here are based on systems
that provide polishing filtration after effective  LStS treatment.
As previously shown, L&S treatment is equally applicable to
wastewaters from the five categories because of the homogene-
ity of its raw and treated wastewaters, and other  factors.
Because of the similarity of the wastewaters after L&cS  treatment,
the Agency believes these wastewaters are equally  amenable to
treatment using polishing filters added to the L&S treatment
system.  The Agency concludes the LS&cF data based  on porcelain
enameling and nonferrous smelting and refining is  also  directly
applicable to the nonferrous metals forming, aluminum forming,
copper forming, battery manufacturing, coil coating, and metal
molding and casting categories.

Analysis of Treatment System Effectiveness

Data are presented in Table VII-9 showing the mean, one-day, 10-
day, and 30-day values for nine pollutants examined in  the L&S
metals data base.  The mean variability factor for eight pollu-
tants (excluding cadmium because of the small number of data
points) was determined and is used to estimate one-day, 10-day,
and 30-day values.  (The variability factor is the ratio of  the
value of concern to the mean:  the average variability  factors
are:  one-day maximum - 4.100; ten-day average - 1.821; and
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30-day average -  1.618.)  For values  not  calculated  from the com-
mon data base as  previously discussed,  the  mean  values  for  pollu-
tants shown in Table VII-3 were  multiplied  by  the  variability
factors to derive the value to obtain  the one-,  ten-  and 30-day
values.  These are  tabulated in  Table  VII-9.

LS&F technology data are presented  in  Tables VII-6 and  VII-7.
These data represent two operating  plants  (A and B)  in  which the
technology has been installed and operated  for some  years.   Plant
A data were received as a statistical  summary  and  are presented
without change.   Plant B data were  received as raw laboratory
analysis data.  Discussions with plant  personnel indicated  that
operating experiments and changes in  materials and reagents and
occasional operating errors had  occurred  during  the  data collec-
tion period.  No  specific information  was available  on  those
variables.  To sort out high values probably caused  by  method-
ological factors  from random statistical  variability, or data
noise, the Plant  B  data were analyzed.  For each of  the four
pollutants (chromium, nickel, zinc, and iron), the mean and
standard deviation  (sigma) were  calculated  for the entire data
set.  A data day  was removed from the  complete data  set when any
individual pollutant concentration  for  that day  exceeded the sum
of the mean plus  three sigma for that  pollutant.   Fifty-one data
days (from a total  of about 1,300)  were eliminated by this
method.

Another approach  was also used as a check on the above  method of
eliminating certain high values.  The  minimum  values  of raw
wastewater concentrations from Plant B  for  the same  four pol-
lutants were compared to the total  set  of values for  the corre-
sponding pollutants.  Any day on which  the  pollutant  concentra-
tion exceeded the minimum value  selected  from  raw  wastewater
concentrations for  that pollutant was  discarded.   Forty-five days
of data were eliminated by that  procedure.  Forty-three days of
data in common were eliminated by either  procedures.  Since
common engineering  practice (mean plus  3  sigma)  and  logic
(treated waste should be less than  raw  waste)  seem to coincide,
the data base with  the 51 spurious  data days eliminated is  the
basis for all further analysis.  Range, mean,  standard  deviation
and mean plus two standard deviations  are shown  in Tables VII-6
and VII-7 for Cr, Cu, Ni, Zn, and Fe.

The Plant B data  were separated  into 1979,  1978, and  total  dat i
base (six years)  segments.  With the statistical analysis from
Plant A for 1978  and 1979 this in effect  created five data  sets
in which there is some overlap between  the  individual years  anc1
total data sets from Plant B.  By comparing these  five  parts it
is apparent that  they are quite  similar and all  appear  to be f r- >m
the same family of  numbers.  The largest  mean  found  among the
five data sets for each pollutant was  selected as  the long-term
mean for LS&F technology and is  used  as the LS&F mean in Table
VII-9.
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Plant C data were used as a basis  for cadmium  removal performance
and as a check on the zinc values  derived from Plants A and B.
The cadmium data is displayed in Table VII-8 and  is  incorporated
into Table VII-9 for LS&F.  The zinc data were analyzed for com-
pliance with the one-day and 30-day values in  Table  VII-9; no
zinc value of the 103 data points  exceeded the one-day zinc value
of 1.02 mg/1.  The 103 data points were separated  into blocks  of
30 points and averaged.  Each of the three full 30-day averages
was less than the Table VII-9 value of 0.31 mg/1.  Additionally,
the Plant C raw wastewater pollutant concentrations  (Table VII-8)
are well within the range of raw wastewater concentrations of  the
combined metals data base (Table VII-2), further  supporting the
conclusion that Plant C wastewater data are compatible with
similar data from Plants A and B.

Concentration values for regulatory use are displayed in Table
VII-9.  Mean one-day, ten-day, and 30-day values  for L&S for nine
pollutants were taken from Table VII-2; the remaining LStS values
were developed using the mean values in Table  VII-3  and the mean
variability factors discussed above.

LSStF mean values for Cd, Cr, Ni, Zn, and Fe are derived from
Plants A, B, and C as discussed above.  One-,  ten-,  and 30-day
values are derived by applying the variability factor developed
from the pooled data base for the  specific pollutant to the mean
for that pollutant.  Other LS&F values are calculated using the
long-term average or mean and the  appropriate  variability
factors."  Mean values for LS&F for pollutants  not  already discus-
sed are derived by reducing the L&S mean by one-third.  The one-
third reduction was established after examining the  percent
reduction in concentrations going  from L&S to  LS&F data for Cd,
Cr, Ni, Zn, and Fe.  The average reduction is  0.3338 or one-
third.

Copper levels achieved at Plants A and B may be lower than gener-
ally achievable because of the high iron content and low copper
content of the raw wastewaters.  Therefore, the mean concentra-
tion value achieved is not used; LS&F mean used is derived from
the L&S technology.

L&S cyanide mean levels shown in Table VII-9 are  ratioed to one-
day, ten-day, and 30-day values using mean variability factors.
LS&F mean cyanide is calculated by applying the ratios of
removals for L&S and LS&F as discussed previously  for LS&F metals
limitations.  The cyanide performance was arrived  at by using  the
average metal variability factors.  The treatment  method used
here is cyanide precipitation.  Because cyanide precipitation  is
limited by the same physical processes as the  metal  precipita-
tion, it is expected that the variabilities will  be  similar.
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 Therefore,  the average of the metal variability factors has been
 used  as  a basis for calculating the cyanide one-day, ten-day, and
 30-day average treatment effectiveness values.

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

 Although iron was reduced in some LSScF operations,  some facili-
 ties  using that treatment introduce iron compounds  to aid
 settling.  Therefore,  the one-day, ten-day, and 30-day values for
 iron  at LSScF were held at the IAS level so as to not unduly
 penalize the operations which use the relatively less objection-
 able  iron compounds to enhance removals of toxic metals.

 MINOR TECHNOLOGIES

 Several other treatment technologies were considered and
 ultimately rejected for the basis of BPT, BAT, and  NSPS.  These
 technologies are presented here with a brief discussion of each
 of them.

 Flotation

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

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

 Flotation is generally applicable to streams characterized by
 heavy loads of finely divided suspended solids and  widely dis-
 persed oil  droplets.   These characteristics are not common in
 nonferrous metals forming wastewater and as such this technology
 would not achieve any more effective concentrations than sedimen-
 tation and oil skimming.  Therefore, this technology was rejected
 as a  basis  for these technology-based limitations and standards.

 Centrifugation

 Centrifugation is the  application of centrifugal force to sepa-
 rate  solids and liquids in a liquid-solid mixture or to effect
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concentration of the solids.  The application  of  centrifugal
force is effective because of the density differential normally
found between the insoluble solids and the  liquid in which  they
are contained.  As a waste treatment procedure, centrifugation is
most often applied to dewatering of sludges.

There are three common types of centrifuges:   the disc, basket,
and conveyor type.  All three operate by removing solids under
the influence of centrifugal force.  The fundamental difference
between the three types is the method by which solids are col-
lected in and discharged from the bowl.

Special consideration must also be given to providing sturdy
foundations and soundproofing because of the vibration and  noise
that result from centrifuge operation.  Adequate  electrical power
must also be provided since large motors are required.  Extensive
operational experience also shows that vacuum  filtration and
plate and frame filtration are more appropriate sludge dewatering
technologies for plants in this category.   Because of the higher
energy costs and prevalence of other technology,  the Agency
rejected this technology as the basis of these limitations  and
standards.

Coalescing

The basic principle of coalescence involves the preferential
wetting of a coalescing medium by oil droplets which accumulate
on the medium and then rise to the surface  of  the solution  as
they combine to form larger particles.  The most  important
requirements for coalescing media are wettability for oil and
large surface area.  Monofilament line is sometimes used as a
coalescing medium.

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

Coalescing allows removal of oil droplets too  finely dispersed
for conventional gravity separation-skimming technology.  It also
can significantly reduce the residence times (and therefore
separator volumes) required to achieve separation of oil from
some wastes.  Most oily waste streams in this  category are  com-
prised of free floatable oils or emulsions.  Coalescing is  not
generally effective in removing soluble or  chemically stabilized
emulsified oils.  To avoid plugging, coalescers must be protected
by pretreatment from the very high concentrations of free oil and
grease and suspended solids.  Frequent replacement of prefilters
may be necessary when raw waste oil concentrations are high.
VThile this technology may be applicable in  some applications in
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this category, oil skimming and chemical emulsion breaking are
better suited to achieve effective oil removal in this category.
Therefore, coalescing was not adopted as a treatment technology.

Cyanide Oxidation by Chlorine

Cyanide oxidation using chlorine is widely used in industrial
waste treatment to oxidize cyanide. " For applications in which
the cyanide is present in a non-complexed form, this technology
will achieve treatment effectiveness concentrations comparable to
cyanide precipitation.  Chlorine can be utilized in either the
elemental or hypochlorite forms.  This classic procedure can be
illustrated by the following two step chemical reaction:

1.  Cl2 + NaCN + 2NaOH  +  NaCNO + 2NaCl + H20

2.  3C12 + 6NaOH + 2NaCNO  ->  2NaHC03 + N2 + 6NaCl + 2H20

The reaction presented as equation (2) for the oxidation of cya-
nate is the final step in the oxidation of cyanide.

Cyanide oxidation by chlorine was not selected as the basis for
these technology-based limitations and standards because the
technology does not remove complexed cyanides which are known to
be present in nonferrous forming wastewater.  Plants with non-
complexed cyanide could use this technology and achieve the same
performance as cyanide precipitation.

Cyanide Oxidation by Ozone

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

Oxidation of cyanide to cyanate is illustrated below:

     CN- +03  +  CNO- + 02

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

Ozone oxidation of cyanide to cyanate requires 1.8 to 2.0 pounds
ozone per pound of CN~; complete oxidation requires 4.6 to 5.0
pounds ozone per pound of CN~.  Zinc, copper, and nickel cya-
nides are easily destroyed to a nondetectable level, but cobalt
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and iron cyanides are more resistant  to ozone  treatment.   Conse-
quently, ozone technologies were not  selected  as  the basis  of
these technology-based  limitations and standards.

Cyanide Oxidation by Ozone with UV Radiation

One of the modifications of the ozonation process  is the  simulta-
neous application of ultraviolet light and ozone  for the  treat-
ment of wastewater, including treatment of halogenated  organics.
The combined action of  these two forms produces reactions  by
photolysis, photosensitization, hydroxylation, oxygenation, and
oxidation.  The process is unique because several  reactions and
reaction species are active simultaneously.

Ozonation is facilitated by ultraviolet absorption because  both
the ozone and the reactant molecules  are raised to a higher
energy state so that they react more  rapidly.  In  addition, free
radicals for use in the reaction are  readily hydrolyzed by  the
water present.  The energy and reaction intermediates created by
the introduction of both ultraviolet  and ozone greatly  reduce the
amount of ozone required compared with a system using ozone
alone.   A system to treat mixed cyanides requires  preliminary
treatment that involves chemical coagulation,  sedimentation,
clarification, equalization, and pH adjustment.  Again, this
technology was rejected because of the high capital expense.

Evaporation

Evaporation is a concentration process.  Water is  evaporated from
a solution, increasing  the concentration of solute in the remain-
ing solution.  If the resulting water vapor is condensed  back to
liquid water, the evaporation-condensation process is called dis-
tillation.  However, to be consistent with industry terminology,
evaporation is used in  this report to describe both processes.
Both atmospheric and vacuum evaporation are commonly used  in
industry today.

Both atmospheric and vacuum evaporation are used  in many  indus-
trial plants, mainly for the concentration and recovery of  pro-
cess solutions.  Many of these evaporators also recover water for
rinsing in electroplating and metal finishing.  Evaporation has
also been applied to recovery of phosphate metal-cleaning
solutions.

The major disadvantage  is that the evaporation process  consumes
relatively large amounts of energy for the evaporation  of water.
The recovery of waste heat from many  industrial processes  (e.g.,
diesel generators, incinerators, boilers, and  furnaces) should be
considered as a source  of this heat for a totally  integrated
evaporation system.  Evaporation has  not been  included  in  the
technology basis for this category because of  the  high  energy
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costs associated with  it.  However,  some  plants with  excess  waste
heat available may choose to implement this  technology  to  achieve
the process wastewater flow reduction.

Gravity Sludge Thickening

In the gravity thickening process, dilute  sludge  is fed from a
primary settling tank or clarifier to a thickening tank where
rakes stir the sludge gently to dens ify it and to push  it  to a
central collection well.  The supernatant  is returned to the
primary settling tank.  The thickened sludge that collects on the
bottom of the tank is pumped to dewatering equipment  or hauled
away.

Thickeners are generally used in  facilities where the sludge
requires dewatering prior to entering by a compact mechanical
device such as a vacuum filter or filter press.  Extensive
operating experience in this industry has  shown that  the sludges
generated by wastewater treatment systems  can be  dewatered solely
with a vacuum filter or filter press.

Ion Exchange

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

Ion exchange is a versatile technology applicable to a  great many
situations.  This flexibility, along with  its compact nature and
performance, makes ion exchange a very effective  method  of waste-
water treatment.  However, the resins in these systems  can prove
to be a limiting factor.  The thermal limits of the anion resins,
generally in the vicinity of 60°C, could prevent  its use in
certain situations.  Similarly, nitric acid, chromic acid, and
hydrogen peroxide can all damage the resins, as will  iron, manga-
nese, and copper when present with sufficient concentrations  of
dissolved oxygen.  Removal of a particular trace  contaminant may
be uneconomical because of the presence of other  ionic  species
that are preferentially removed.  The regeneration of the resins
presents its own problems.  The cost of the regenerative chemi-
cals can be high.  In addition, the waste  streams originating
from the regeneration process are extremely high  in pollutant
concentrations, although low in volume.  These must be  further
processed for proper disposal.  As such, ion exchange has not
been selected to form the basis of these technology-based
limitations and standards.
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Membrane Filtration

Membrane filtration is a treatment system for removing precipi-
tated metals from a wastewater stream.  It must therefore be
preceded by those treatment techniques which will properly pre-
pare the wastewater for solids removal.  Typically, a membrane
filtration unit is preceded by pH adjustment or sulfide addition
for precipitation of the metals.  These steps are followed by the
addition of a proprietary chemical reagent which causes the pre-
cipitate to be non-gelatinous, easily dewatered, and highly
stable.  The resulting mixture of pretreated wastewater and
reagent is continuously recirculated through a filter module and
back into a recirculation tank.  The filter module contains tubu-
lar membranes.  While the reagent-metal hydroxide precipitate
mixture flows through the inside of the tubes, the water and any
dissolved salts permeate the membrane.  When the recirculating
slurry reaches a concentration of 10 to 15 percent solids, it is
pumped out of the system as sludge.

Removal efficiencies are claimed to be excellent, even with sud-
den variation of pollutant input rates; however, the effective-
ness of the membrane filtration system can be limited by clogging
of the filters.  Because pH changes in the waste stream greatly
intensify clogging problems, the pH must be carefully monitored
and controlled.  Clogging can force the shutdown of the system
and may interfere with production.  In addition, the relatively
high capital cost of this system may limit its use.  As such, we
have not selected this technology as the basis for these
limitations and standards.

Reverse Osmosis

The process of osmosis involves the passage of a liquid through a
semipermeable membrane from a dilute to a more concentrated solu-
tion.  Reverse osmosis (RO) is an operation in which pressure is
applied to the more concentrated solution, forcing the p»ermeate
to diffuse through the membrane and into the more dilute solu-
tion.  This filtering action produces a concentrate and a perme-
ate on opposite sides of the membrane.  The concentrate can then
be further treated or returned to the original production opera-
tion for continued use, while the permeate water can be recycled
for use as clean water.

A limitation of the reverse osmosis process for treatment of pro-
cess effluents is its limited temperature range for satisfactory
operation.  For cellulose acetate systems, the preferred limits
are 18°C to 30°C (65°F to 85°F); higher temperatures will
increase the rate of membrane hydrolysis and reduce system life,
while lower temperatures will result in decreased fluxes with no
damage to the membrane.  Another limitation is inability to han-
dle certain solutions.  Strong oxidizing agents, strongly acidic
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or basic solutions,  solvents,  and  other  organic  compounds  can
cause dissolution of the membrane.  Poor  rejection  of  some  com-
pounds such as borates  and  low molecular  weight  organics  is
another problem.  Fouling of membranes by slightly  soluble
components in solution  or colloids  has caused  failures,  and foul-
ing of membranes by  feed waters with high levels  of suspended
solids can be a problem.  A final  limitation  is  inability  to
treat or achieve high concentration with  some  solutions.   Some
concentrated solutions  may  have initial  osmotic  pressures  which
are so high that they either exceed available  operating  pressures
or are uneconomical  to  treat.  As  such, we have  not selected this
technology as the basis for these  limitations  and standards.

Sludge Bed Drying

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

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

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

Its disadvantages are the large area of land required  and  long
drying times that depend, to a great extent, on  climate and
weather.  The full sludge drying bed must either  be abandoned or
the collected solids must be removed to a landfill.  These  solids
contain whatever metals or  other materials  were  settled  in  the
clarifier.   Metals will be  present  as hydroxides, oxides,
sulfides, or other salts.   They have the  potential  for leaching
and contaminating ground water, whatever  the location  of the
semidried solids.   Thus the abandoned bed or landfill  should
include provision for runoff control and  leachate monitoring.
This technology was not selected as the basis  for sludge treat-
ment for these limitations  and standards  because  vacuum filters
provide a sludge that can be managed more safely  and comply with
provisions  of RCRA.
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Thermal Emulsion Breaking

Dispersed oil droplets in a spent emulsion can be  destabilized  by
the application of heat to the waste.  One type of technology
commonly used in the metals and mechanical products  industries  is
the evaporation-decantation-condensation process,  also called
thermal emulsion breaking (TEB), which separates the emulsion
waste into distilled water, oils and other floating  materials,
and sludge.

Advantages of the thermal emulsion breaking process  include high
percentages of oil removal (at least 99 percent in most cases),
the separation of floating oil from settleable sludge solids, and
the production of distilled water which is available for process
reuse.  In addition, no chemicals are required and the operation
is automated, factors which reduce operating costs.  Disadvan-
tages of the process are the high energy requirement for water
evaporation and, if intermittently operated, the necessary
installation of a large storage tank.  This technology has not
been selected as the basis of these limitations and  standards
because chemical emulsion breaking achieves comparable
performance and at a lower cost.

Ultrafiltration

Ultrafiltration (UF) is a process which uses semipermeable poly-
meric membranes to separate emulsified or colloidal  materials
suspended in a liquid phase by pressurizing the liquid so that  it
permeates the membrane.  The membrane of an ultrafilter forms a
molecular screen which retains molecular particles based on their
differences in size, shape, and chemical structure.  The membrane
permits passage of solvents and lower molecular weight molecules.
At present, an ultrafilter is capable of removing  materials with
molecular weights in the range of 1,000 to 100,000 and particles
of comparable or larger sizes.  Most soluble materials in non-
ferrous forming wastewater including toxic metals have molecular
weight much less than 1,000.

A limitation of ultrafiltration for treatment of process efflu-
ents is its narrow temperature range (18°C to 30°C)  for satisfac-
tory operation.  Membrane life decreases with higher tempera-
tures, but flux increases at elevated temperatures.  Therefore,
surface area requirements are a function of temperature and
become a tradeoff between initial costs and replacement costs for
the membrane.  In addition, ultrafiltration cannot handle certain
solutions.  Strong oxidizing agents found in nonferrous metals
forming wastewater could dissolve the membrane.  EPA did not
select ultrafiltration as the basis for these limitations and
standards because chemical emulsion breaking and oil skimming are
better suited for nonferrous metals forming wastewater and are
less costly to operate and maintain.
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IN-PLANT TECHNOLOGIES

The intent of in-plant technology  for  the nonferrous  metals  form-
ing point source category is to reduce or eliminate the waste
load requiring end-of-pipe treatment and thereby  improve  the
efficiency of an existing wastewater treatment system or  reduce
the requirements of a new treatment system.   In-plant technology
involves improved rinsing, water conservation, process bath
conservation, reduction of dragout, automatic controls, good
housekeeping practices, recovery and reuse of process solutions,
process modification, and waste treatment.   Specific  in-plant
technologies applicable to this category are  discussed below.

Process Water Recycle

Recycling of process water is the  practice of recirculating  water
to be used again for the same purpose.  An example of recycling
process water is the return of casting contact cooling water to
the casting process after the water passes through a  cooling
tower.  Two types of recycle are possible—recycle with a bleed
stream  (blowdown) and total recycle.  Total  recycle may be pro-
hibited by the presence of dissolved solids.  Dissolved solids
(e.g.,  sulfates and chlorides) entering a totally recycled waste
stream may precipitate, forming scale if the  solubility limits of
the dissolved solids are exceeded.  A bleed  stream may be neces-
sary to prevent maintenance problems (pipe plugging or scaling,
etc.) that would be created by the precipitation  of dissolved
solids.  While the volume of bleed required  is a  function of the
amount  of dissolved solids in the  waste stream, 4 or  5 percent
bleed is a common value for a variety of process  waste streams in
the nonferrous metals forming category.  The  recycle  of process
water is currently practiced where it reduces operating costs,
where it is necessary due to water shortage,  or where the local
permitting authority has required  it.  Recycle, as compared  to
the once-through use of process water, is an  effective method of
conserving water.

Application and Performance.  Required hardware necessary for
recycleishighly site-specific.   Basic items include pumps  and
piping.  Additional materials are  necessary  if water  treatment
occurs before the water is recycled.  These  items will be dis-
cussed separately with each unit process.  Chemicals  may be
necessary to control scale buildup, slime, and corrosion  prob-
lems, especially with recycled cooling water.  Maintenance and
energy use are limited to that required by the pumps, and solid
waste generation is dependent on the type of  treatment system in
place.

Recycling through cooling towers is the most  common practice.
One type of application is shown in Figure VII-8.  Direct chill
casting cooling water is recycled  through a  cooling tower with a
blowdown discharge.
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A  cooling  tower  is  a  device which  cools  water by bringing the
water into contact  with air.  The  water  and  air  flows  are
directed in  such a  way as  to provide  maximum heat transfer.   The
heat is transferred to air primarily  by  evaporation  (about 75
percent), while  the remainder is removed by  sensible heat trans-
fer.

Factors influencing the rate of heat  transfer and, ultimately,
the temperature  range of the tower, include  water surface area,
tower packing and configuration, air  flow, and packing height.
A  large water surface area promotes evaporation,  and sensible
heat transfer rates are lower in proportion  to the water  surface
area provided.   Packing  (an internal  latticework contact  area)  is
often used to produce small droplets  of  water which evaporate
more easily, thus increasing the total surface area per unit  of
throughput.  For a  given water flow,  increasing  the air flow
increases  the amount  of heat removed  by  maintaining higher
thermodynamic potentials.  The packing height in  the tower should
be high enough so that the air leaving the tower is close to
saturation.

A mechanical-draft  cooling tower consists of  the  following major
components:

     (1)  Inlet-water distributor
     (2)  Packing
     (3)  Air fans
     (4)  Inlet-air louvers
     (5)  Drift  or  carryover eliminators
     (6)  Cooled water storage basin.

Advantages and Limitations.  Recycle  offers  economic as well  as
environmental advantages.  Water consumption  is  reduced and
wastewater handling facilities (pumps, pipes,  clarifiers,  etc.)
can thus be  sized for smaller flows.  By  concentrating the pollu-
tants in a much  smaller volume (the bleed stream), greaiter
removal efficiencies  can be attained  by  any  applied treatment
technologies.  Recycle may require some  treatment such as
sedimentation or cooling of water  before  it  is reused.

The ultimate benefit of recycling  process water  is the reduction
in total wastewater discharge and  the associated  advantages of
lower flow streams.  A potential problem  is  the  buildup of dis-
solved solids which could result in scaling.   Scaling  can  usually
be controlled by depressing the pH and increasing the  bleed flow.

Operational Factors.  Reliability  and Maintainability:  Although
the principal construction material in mechanical-draft towers is
wood, other materials are used extensively.   For  long  life and
minimum maintenance, wood is generally pressure-treated with  a
preservative.  Although the tower  structure  is usually made of
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treated redwood, a considerable amount of  treated  fir has been
used in recent years.  Sheathing and louvers are generally  made
of asbestos cement, and the fan stacks of  fiberglass.  There  is  a
trend to use fire-resistant extracted PVC  as fill  which, at
little or no increase in cost, offers the  advantage  of permanent
fire-resistant properties.

The major disadvantages of wood are its susceptibility to decay
and fire.  Steel construction is occasionally used,  but  not to
any great extent.  Concrete may be used but has relatively  high
construction labor costs, although it does offer the advantage of
fire protection.

Various chemical additives are used in cooling water systems  to
control scale, slime, and corrosion.  The  chemical additives
needed depend on the character of the make-up water.  All addi-
tives have definite limitations and cannot eliminate the need for
blowdown.  Care should be taken in selecting nontoxic or readily
degraded additives, if possible.

Solid Waste Aspects:  The only solid waste associated with  cool-
ing towers may be removed scale.

Demonstration Status.  Many different types of streams in the
nonferrous metalsforming category are currently recycled.  The
degree of recycle of these streams is 50 percent or  more, most
commonly in the 96 to 100 percent range.  Recycling  process
waters is a viable option for many nonferrous metals forming
process wastewaters as shown by the current practices in the
industry.

Most of the plants that use hot rolling oil emulsions and that
gave enough information to calculate discharge rates reported
using recycle of the emulsion with either a bleed  stream or peri-
odic discharge.  The recycled flow would often pass  through
in-line filters to prevent the buildup of  solids.  Settling tanks
and oil skimming devices were also used to separate  spent and
tramp oils from the emulsion.

Other nonferrous metals forming wastewaters may also be  recycled
in varying degrees, depending on the required quality of water
necessary for a specific operation.  Scrubber waters from
casting, forging, etch lines,  and annealing operations can  be
recycled because of the low water quality necessary  as make-up
water.  Forging solution heat treatment contact cooling waters
can be recycled in a  manner similar to that used  in casting
contact cooling water.
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Process Water Reuse

Reuse of process water is the practice of recirculating water
used in one production process for subsequent use in a different
production process.

Application and Performance and Demonstration Status.  Reuse
applications in the nonferrous metals forming category are
varied.  Water may be reused as cleaning or etching rinses
following caustic and acidic baths, as scrubber liquor, as
casting contact cooling water, or as heat treatment solution
contact cooling water.

Advantages and Limitations.  Advantages of reuse are similar to
the advantages of recycle.  Water consumption is reduced  and
wastewater treatment facilities can be sized for smaller  flows.
Also, in areas where water shortages occur, reuse is an effective
means of conserving water.

Operat ional. Fact or s.  The hardware necessary for reuse of process
wastewaters varies, depending on the specific application.  The
basic elements include pumps and piping.  Chemical addition is
not usually warranted, unless treatment is required prior to
reuse.  Maintenance and energy use are limited to that required
by the pumps.  Solid waste generated is dependent upon the type
of treatment used and will be discussed separately with each unit
process.

Countercurrent Cascade Rinsing

Rinsing is used to dilute the concentration of contaminants
adhering to the surface of a workpiece to an acceptable level
before the workpiece passes on to the next step in surface
treatment operations.  The amount of water required to dilute the
rinse solution depends on the quantity of chemical drag-in from
the upstream rinse or surface treatment tank, the allowable con-
centration of chemicals in the rinse water, and the contacting
efficiency between the workpiece and the water.

Process variations such as countercurrent cascade rinsing may
cause a decrease in process water use.  This technique reduces
water use by multiple stage rinsing with a water flow counter to
the movement of the workpiece.  Clean water contacts the  metal in
the last rinse stage.  The water, somewhat more contaminated,  is
routed stage by stage up the rinsing line.  After use in  the
first rinse stage, the contaminated water is discharged to
treatment.

As an example, Figure VII-9 illustrates three rinsing operations,
each designed to remove the residual acid in the water on the
surface of a workpiece.  In Figure VII-9 the piece is dipped into
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one tank with continuously  flowing water.   In  this  case,  the acid
on the surface of the workpiece  is essentially diluted  to the
required level.

In Figure VII-9, the  first  step  towards  countercurrent  opera-
tion is taken with the addition  of a  second  tank.   The  workpiece
is now moving in a direction  opposite to the rinse  water.   The
piece is rinsed with  fresh  makeup water  prior  to moving down the
assembly line.  However,  the  fresh water from  this  final  rinse
tank is directed to a second  tank, where it  meets the incoming,
more-contaminated workpiece.  Fresh makeup  water  is used  to give
a final rinse to the  article  before it moves out of the rinsing
section, but the slightly contaminated water is reused  to clean
the article just coming into  the rinsing section.   By increasing
the number of stages, as  shown  in Figure VII-9, further water
reduction can be achieved.  Theoretically,  the amount of  water
required is the amount of acid  being  removed by single-stage
requirements divided  by the highest tolerable  concentration in
the outgoing rinsewater.  The actual  flow reduction obtained is a
function of the dragout and the  type  of  contact occurring in the
tanks.  If reasonably good  contact is maintained major  reductions
in water use are possible.

Application and Performance.  As mentioned  above, rinse water
requirements and the  benefits of countercurrent cascade rinsing
may be influenced by  the  volume  of solution  dragout carried into
each rinse stage by the material being rinsed, by the number of
rinse stages used, by the initial concentrations of impurities
being  removed, and by the  final product cleanliness required.
The  influence of these factors  is expressed in the rinsing
equation which may be stated  simply as:
     Vr =  Co    n x VD
     Vr is the flow through each rinse stage.
     Co is the concentration of the  contaminant (s )  in  the  initial
        process bath.
     Cf is the concentration of the  contaminant (s)  in  the  final
        rinse to give acceptable product cleanliness.
      n is the number of rinse stages employed.
     VD is the dragout carried into  each rinse stage,  expressed
        as a flow.

For a multi-stage rinse, the total volume of  rinse  wastewater  is
equal to n times Vr while for a countercurrent rinse the total
volume of wastewater discharge equals Vr.

To calculate the benefits of countercurrent rinsing for
nonferrous metals forming, it can be assumed  that a two-stage
countercurrent cascade rinse is installed after  surface treatment
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operations.  As an example, the flow reduction  achieved  for
pickling a nickel sheet can be estimated.  The  mass of nickel  in
one square meter of sheet that is 6 mm  (0.006 m)  in thickness  can
be calculated using the density of nickel, 8.90 kkg/m^ (556
Ibs/cu ft), as follows:

=  (0.006 m) x  (8.90 kkg/m3) = Q.053 kkg/m2 Of sheet.

Using the mean surface treatment rinsewater discharge, Vr  can
then be calculated as follows:

Vr = (0.053 kkg  ) x[10,600 _J_ }   = 561.8 1/m2  of sheet
     \      ~~i£7  \       kkg/
Drag-out is solution which remains on the surface of material
being rinsed when it is removed from process baths or rinses.
Without specific plant data available to determine drag-out, an
estimate of rinsewater reduction to be achieved with two-stage
count ercurrent rinsing can be made by assuming a thickness  of any
process solution film as it is introduced into the rinse tank.
If the film on a piece of nickel sheet is 0.015 mm (0.6 mil)
thick, (equivalent to the film on a well-drained vertical
surface) then the volume of process solution, VD , carried into
the rinse tank on one square meter of sheet will be:
                  /          \              o
VD = (0.015 mm) x  _ 1  m/mm I  x  (1000 l/nP)
                  \IOTRJ     /

   =  0.015 l/m2 of sheet

Let r  = Co, then r 1/n = yr.
         57               VD

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

and r = 561.8   = 37,453
        0.015

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

     Vr = r !/2, therefore Vr = 193.5
     VD                    VD

But VD = 0.015 1/m2 of sheet; therefore, for 2-stage
countercurrent cascade rinsing, Vr is:

     Vr = 193.5 x 0.015 = 2.90 1/m2 of sheet
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In this theoretical calculation, a  flow reduction  of  greater  than
99 percent can be achieved.  The actual numbers may vary  depend-
ing on efficiency of squeegees or air knives,  and  the rinse ratio
desired.

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

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

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

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

Countercurrent cascade rinsing is currently practiced at  12
nonferrous metals forming plants.
                               619

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Spray Rinsing

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

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

Regeneration of Chemical Baths

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

Application and Performance.  Chemical bath regeneration is
applicabletorecover and reuse chemicals associated with  caustic
surface treatment baths, sulfuric acid surface  treatment baths,
chromic acid surface treatment baths, and alkaline  cleaning
baths.

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

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

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

Advantages and Limitations.   The advantages of  bath regeneration
are:(l)it reducesthe volume of discharge of the chemical  bath
water;  (2) the surface treatment operations are made more  effi-
cient because the bath can be kept at a relatively  constant
                              620

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strength; (3) it results  in reduced maintenance  labor  associated
with the bath; and  (4) it reduces chemical costs by recovering
chemicals and increasing  bath  life.

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

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

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

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

As discussed previously in this section, ultrafiltration is well
developed and commercially available for recovery of high  molecu-
lar weight liquids and solid contaminants.  EPA  is not aware of
any nonferrous metals forming plants that have applied ultrafil-
tration for the purpose of regenerating bath materials.  There
are two aluminum forming plants using ultrafiltration  to recover
spent lubricant which is similar to the types of lubricants used
in the nonferrous metals  forming industry.   Since alkaline clean-
ing baths are used to remove these lubricants from the aluminum
surface prior to further processing, it is reasonable  to assume
that ultrafiltration will be equally applicable  for separating
these same lubricants from alkaline cleaning baths.

The Agency did not  select regeneration of baths  as an  in-process
modification to be part of these limitations and standards
because it is not applicable on a nationwide basis.  It  may
however, be applicable in specific applications  in the nonferrous
forming category.
                               621

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Contract Hauling

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

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

Process Water Use Reduction

Process water use reduction is  the decrease in the amount of  pro-
cess water used as an influent  to a production process per unit
of production.  Section V discusses water use in  detail  for each
nonferrous metals forming operation.  A range of water use values
taken from the data collection  portfolios is presented for each
operation.   The range of values indicates that some plants use
process water more efficiently  than others for the same  opera-
tion.  Therefore, some plants can curb their water use;  in  some
cases it may be as simple as turning down a few valves.  Noncon-
tact cooling water may replace  contact cooling water in  some
applications; air cooling may also be an alternative to  contact
cooling water.  Conversion  to dry air pollution control  equip-
ment, discussed further on  in this section, is another way to
reduce water use.

Many production units in nonferrous metals forming plants operate
intermittently or at widely varying production rates.  The prac-
tice of shutting off process water streams during periods of  low
activity can prevent much unnecessary dilution of wastes and
reduce the volume of water  to be treated and discharged.  Water
may be shut off and adjusted manually or through automatically
controlled valves.  Manual  adjustment involves minimal capital
cost and can be just as reliable in actual practice.  Automatic
shut off valves are used in some nonferrous metals forming opera-
tions to turn off water flows when production units are  inactive.
                              622

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Automatic adjustment of  flow rates  according  to  production
levels requires more sophisticated  control  systems  incorporating
temperature or conductivity sensors.  Further reduction  in  water
use may be made possible by changes in production techniques  and
equipment.

The potential for reducing the water use  at many nonferrous
metals forming facilities is evident in the water use  and dis-
charge data presented  in Section V  of this  report.   While it  may
be argued that variations in water  flow per unit of production
are the necessary result of variations in process conditions,
on-site observations indicate that  they are more frequently the
result of imprecise control of water use.   This  is  confirmed  by
analysis of data from  surface treatment rinses which show a very
wide range of the concentrations of materials removed  from
product surfaces, and  by on-site temperature  observations in
contact cooling streams.

Reduction of water use in quenches  may also significantly reduce
discharge volumes.  Design of spray quenches  to  ensure that a
high percentage of the water contacts the product and  adjustments
of make-up water flow  rates on quench baths and  recirculating
spray quench systems to  the minimum practical value can  signifi-
cantly reduce effluent volumes.

Pollutant discharges from surface treatment operations may  also
be controlled through  the use of drag-out reduction technologies.
The volume of water used and discharged from  rinsing operations
may be substantially reduced without adversely affecting the  sur-
face condition of the  product processed.  Available technologies
to achieve these reductions include techniques which limit  the
amount of material to  be removed from product surfaces by
rinsing.

On automatic lines which continuously process strip through sur-
face treatment operations, measures are normally taken to reduce
the amount of process  bath solutions which  are dragged out  with
the product into subsequent rinses.  The  most commonly used means
of accomplishing this  are through the use of  squeegee  rolls and
air knives.  Both mechanisms are found at the point at which  the
strip exits from the process bath.  Squeegee  rolls,  one  situated
above the strip and another below,  return process solutions as
they apply pressure to both sides of the  continuously  moving
strip.  Air knives continuously force a jet of air  across the
width of each side of  the strip, forcing  solutions  to  remain  in
the process tank or chamber.  These methods are  also used to
reduce drag-out from soap and other lubricant tanks which are
often found as a final step in automatic  strip lines.
                               623

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Heating the  tank  containing  the process bath  can  also  help  reduce
drag-out of  process solutions in  two ways:  by  decreasing the
viscosity and  the surface  tension of the  solution.  A  lower
viscosity allows  the liquid  to flow more  rapidly  and therefore
drain at a faster rate  from  the product following application in
a process bath, thereby reducing  the amount of  process  solution
which dragged  out in succeeding rinses.   Likewise,  a higher tem-
perature will  result in lower surface tension in  the solution.
The amount of  work required  to overcome the adhesive force
between a liquid  film and  a  solid  surface is a  function  of  the
surface tension of the  liquid and  the contact angle.   Lowering
the surface  tension reduces  the amount of work  required  to  remove
the liquid and reduces  the edge effect (the bead  of liquid
adhering to  the edges of a product).

Operator performance can have a substantial effect  on  the amount
of drag-out  which results  from manual dip tank  processes.   Speci-
fically, proper draining time and  techniques can  reduce  the
amount of process solution dragged out into rinses.  After  dip-
ping the material into the process tank,  drag-out  can be reduced
significantly  by  simply suspending the product  above the process
tank while solution drains off.  Fifteen  to 20  seconds generally
seems sufficient  to accomplish this.  When processing  tubing,
especially,  lowering one end of the load  during this drain  time
allows solution to run off from inside the tubes.

All of the water  use reduction techniques discussed in this sec-
tion may be used  at nonferrous metals forming plants to  achieve
the average  production normalized  flows at plants  which  presently
discharge excessive amounts  of wastewater to treatment.

Waste-water Segregation

Application  and Performance.   The  segregation of  process waste
streams is a valuable control techology and may reduce treatment
costs.   Individual process waste streams  may exhibit very differ-
ent chemical characteristics, and  separating the  streams may
permit applying the most effective method of treatment or dispo-
sal to each  stream.  Relatively clean waters should be kept
segregated from contaminated streams.   Dissimilar  streams should
not be combined;  for example, an oily stream such  as direct chill
casting contact cooling water should not be combined with a non-
oily stream  such  as surface  treatment scrubber  liquors.  Segrega-
tion should be based on the  type of treatment to  be performed for
a given pollutant, avoiding  oversizing of equipment for  treating
flows unnecessarily.

Consider two waste streams,  one high in chromium  and other  dis-
solved solids; the other,  a  noncontact cooling water without
chromium.   Significant advantages  exist in segregating these  two
                               624

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waste streams.  If the combined waste  streams  are being  treated
to reduce chromium, the resulting high treatment cost will be
impractical.  Also, if chromium removal by  lime precipitation  is
being practiced, reduced removal efficiencies  will result  from
combining the waste streams  due to  dilution of chromium  concen-
tration.  In addition, recycle of the noncontact cooling water
will be made difficult by mixing the relatively pure noncontact
cooling water with the high  dissolved solids stream.  Many com-
binations of waste streams exist throughout the nonferrous metals
forming industry where segregation  affords  distinct advantages.

Equipment necessary for wastewater  segregation may include
piping, curbing, and possibly pumping.  Chemicals are not  needed
and maintenance and energy use is limited to the pumps.

Advantages.  The segregation of stormwater  runoff which  has not
come in contact with process materials from process-related
streams can eliminate overloading of sewer  and treatment facili-
ties.  Some plants located lower than  the surrounding terrain
have built flood control dams at higher elevations to minimize
the passage of stormwater runoff onto plant property.  The use of
curbing is an excellent control practice for minimizing  the com-
mingling of runoff with process wastewaters.   Also, retention
ponds should be lined to minimize infiltration of spring water
during periods of local flooding and exfiltration of the
wastewaters to a nearby aquifer.

Lubricating Oil and Deoiling Solvent Recovery

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

Reuse of oil from spent emulsions used in rolling and drawing  is
practiced at some plants.  The free oil skimmed from gravity oil
and water separation, following emulsion breaking, is valuable.
This free oil contains some solids  and water which must  be
removed before the oil can be reused.  The  traditional treatment
involves acidifying the oil in a heated cooker, using steam coils
                               625

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or live steam to heat the oil to  a rolling boil.  When  the  oil  is
sufficiently heated, the steam is shut off and  the oil  and  water
are permitted to separate.  The collected floating oil  layer is
suitable for use as supplemental  boiler fuel or for  some  other
type of in-house reuse.  Other plants choose to sell their  oily
wastes to oil scavengers, rather  than reclaiming the oil  them-
selves.  The water phase from this operation is either  sent to
treatment or, if of a high enough quality, it can be recycled and
used to make up fresh emulsion.

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

Demonstration Status and Operational Factors.   Using organic sol-
vents to deoil or degrease nonferrous metals is  usually performed
prior to sale or subsequent operations such as  coating.  Recycl-
ing the spent solvent can be economically attractive along  with
its environmental advantages.  No plants are known to xise distil-
lation units to reclaim spent solvent for recycling  in  this cate-
gory.  Most plants in this category contract haul spent:  solvents
or sell them to a reclaimer.  No  plants currently discharge spent
solvents as a direct discharge.  There are several plants that
discharge spent solvents to a POTW; however, this practice  is not
widespread and is subject to strict controls by  the  POTW  for
those that do discharge.  The Agency is establishing a  no dis-
charge requirement for this waste stream.  This  is discussed more
fully in Sections IX through XIII.

Dry Air Pollution Control Devices

Application and Performance.  The use of dry air pollution  con-
trol devices would allow the elimination of waste streams with
high pollution potentials.  The choice of air pollution control
equipment is complicated, and sometimes a wet system is  the
necessary choice.  The important  difference between  wet and dry
devices is that wet devices control gaseous pollutants  as well as
particulates.

Wet devices may be chosen over dry devices when any  of  the  fol-
lowing factors are found:  (1) the particle size is  predominantly
under 20 microns, (2) flammable particles or gases are  to be
treated at minimal combustion risk, (3) both vapors  and particles
are to be removed from the carrier medium, and  (4) the  gases are
corrosive and may damage dry air pollution control devices.
                               626

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

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

Melting prior to casting requires wet air pollution  control  only
when chlorine gas is present in the  offgases.   Dry air  pollution
control methods with inert  gas or salt furnace  fluxing  have  been
demonstrated in the aluminum forming industry.  It is possible to
perform all the metal treatment tasks of  removing hydrogen,
non-metallic inclusions, and undesirable  trace  elements and  meet
the most stringent quality  requirements without furnace fluxing,
using only in-line metal treatment units.  To achieve this,  the
molten aluminum is treated  in the transfer  system between the
furnace and casting units by flowing the  metal  through  a  region
of very fine, dense, mixed-gas bubbles generated by  a spinning
rotor or nozzle.  No process wastewater is generated  in this
operation.  Another similar alternate degassing method  is  to
replace the chlorine-rich degassing  agent with  a mixture  of  inert
gases and a much lower proportion of chlorine.  The  technique
provides adequate degassing while permitting dry scrubbing.

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

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

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

Common wet air pollution control  devices  are wet electrostatic
precipitators, venturi scrubbers, and packed tower scrubbers.
Collection efficiency for gases will depend on  the solubility of
the contaminant in the scrubbing  liquid.   Depending  on  the con-
taminant removed, collection efficiencies usually approach 99
percent for particles and gases.
                               627

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Demonstration Status.  The nonferrous metals forming  industry
reports the use of dry air pollution controls for forging.

Good Housekeeping

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

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

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

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

A conscientiously applied program of water use reduction can be a
very effective method of curtailing unnecessary wastewater  flows.
Judicious use of washdown water and avoidance of unattended
running hoses can significantly reduce water use.
                               628

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                            REFERENCES
 (1)   Reed,  A.  K. ,  et.  al.,  "An Investigation  of  Techniques  for
      Removal of Cyanide from Electroplating Wastes,"  Battelle
      Columbus  Laboratories,  Columbus,  Ohio, November  1971,  NTIS
      PB-208 210,  p.  45.

 (2)   Owerback, Daniel,  "Analysis  and Sample Stability of
      Cyanides  in Industrial  Effluents,"  Journal  of  the Water
      Pollution Control  Federation,  Volume  52,  Number  11,
      November  19BTF;
      p.  2648.

 (3)   Drew,  D.  M.,  "Simultaneous Determinations of Ferrocyanide
      and Ferricyanide  in Aqueous  Solutions Using Infrared
      Spectrometry,"  Analytical Chemistry,  Volume 45,  p. 2262
      (1973).

 (4)   Kruse, J. M.  and L. E.  Thibault,  "Determinations  of Free
      Cyanide in Ferro-  and Ferricyanides," Analytical Chemistry,
      Volume 45,  p. 2260 (1973)

 (5)   Southgate,  B. A.,  Treatment  and Disposal  of Industrial
      Wastewaters,  His Majesty's Stationary Office,  London,  1948,
      pp. 169-172.

 (6)   Bessent,  R.  A., et. al.,  "Removal of  Cyanides  from Coke
      Plant  Wastewaters  by Selective Ion  Exchange -  Results  of
      Pilot  Testing Program," Proceedings of the  34th  Industrial
      Waste  Conference,  Purdue  University,  Lafayette,  Indiana,
      May 8, 9, and 10,  1979, pp.  47-62.

 (7)   Adams, Carl E., Davis L.  Ford  and W.  Wesley Eckenfelder,
      Jr., Development of Design and Operational  Criteria for
      Wastevater Treatment, Enviro Press, Inc., Nashville,
      Tennessee (1981).

 (8)   Shinskey, F.  G., pH and plon Control,  John  Wiley & Sons,
      Inc.,  New York, New York, 1973.

 (9)   Moore, Ralph  L., Neutralization of  Wastewater  by pH
      Control,  ISA  Monograph  Series  //I, 1978.

(10)   Mace,  Guy R., and  Daniel  Casaburi,  Lime vs. Caustic for
      Neutralization  of  Power Plant  Effluent, paper  presented at
      American  Institute of Chemical Engineers  National Meeting,
      Houston,  Texas, March 1977.
                             629

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(11)   Summary Report,  Control  and  Treatment Technology  for  the
      Metal Finishing  Industry - Sulfide Precipitation, EPA
      625/8-80-003,  IERL,  Cincinnati, Ohio, April  1980.

(12)   Process Design Manual  for Suspended  Solids Removal, USEPA
      Technology Transfer, EPA b2i»/l-75-UU3a,  October 1975.

(13)   Brautner,  Karl A., and Edward  J. Cichon, Heavy Metals
      Removal:   Commparison  of Alternative Precipitation Pro
      cesses^proceedingsof the Thirteenth Mid-Atlantic
      Conference -  Industrial  Waste, University  of Delaware,
      1981.
                             630

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13
 Note:   Solubilities  of metal hydroxides/oxides are from data by
         M.  Pourbaix,  Atlas of Electrochemical Equilibria in
         Aqueous  Solutions, Pergamon Press, Oxford, 1966.



                             Figure VII-4

     THEORETICAL SOLUBILITIES OF TOXIC METAL HYDROXIDES/OXIDES
                         AS A FUNCTION OF pH
                                 634

-------
/A-
                 COLLECTOR
                  FILL PIPE (PNEUMATIC)
       BULK STORAGE
          BIN
                      DAY HOPPER
                      FOR DRY CHEMICAL
                      FROM BAGS OR DRUMS
                                                   \

                   BIN GATE
                   FLEXIBLE
                   CONNECTION

                      ALTERNATE SUPPLIES DEPENDING
                              ON STORAGE
                                                          DUST COLLECTOR
                                                               ,BAG FILL
                                                    -SCREEN
                                                     WITH  BREAKER
DUST AND  VAPOR REMOVER
WATER
                                         SCALE OR  SAMPLE CHUTE
           ( DRAIN
       SOLENOID  VALVE
     CONTROL
     PRESSURE REDUCING  A
          VALVE
                                                       GRAVITY TO
                                                       APPLICATION
                                                                      PUMP
                                                             OTO^APPLICATION
                               Figure  VII-5

                       TYPICAL DRY FEED SYSTEM
                                    635

-------
INFLUENT
L_i_-
(a)
FINE-1.- "-'."•'.
30-40 in -~Vv; SAND ;'•':
.,'•';/•; COARSi

EFFLUENT |
(b)
6- 10 ft —
DEPTH

r OVER FLOW
/ TROUSH

i n n n n nr
: FINE:. •/ ••-.'.••'
.* • *•-".*'* • ' •
• « » '» * ' * **
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f
X-6RIT TO
RETAIN i - \
SAND (C)
STRAINER -v
•
EFFLUENT
4-6H .
DEPTH J


s~
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t--.- • • : '. •_
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-


n

JV I k
T EFFLUENT \ fMFLUEMT UNDERDRAIN \
\ CHAMBER Lr )
UNDERDRAIN \
„..„ 	 CHAMBER — *
INFLUENT INFLUENT
L~_i_J L_J...J
(d)
COARSE MEDIA-—',*!
INTERMIX ZONE— —
FINER MEDIA— —•'..'
FINEST MEDIA — -Ptf

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1 EFFLUENT
Oi*
(e)
COARSE MEDIA-—
FINER MEDIA— -J-
FINEST MEDIA —
UNDERORAIN
CHAMBER
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V* ^.«kt«»^IB ZiW •
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_L

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\ 'EFFLUENT
                                                             INFLUENT
(a)   Single-Media Conventional Filter.
(b)   Single-Media Upflow Filter.
(c)   Single-Media Biflow Filter.
(d)   Dual-Media Filter.
(e)   Mixed-Media (Triple-
     Media) Filter.
                           Figure VII-6

                      FILTER CONFIGURATIONS
                               636

-------
                                                           INFLUENT
EFFLUENT
                           STORED
                          BACKWASH
                            WATER
                                ••-»—FILTER
                                HBACKWASH-*-
             COLLECTION CHAMBER
                                               DRAIN
                            Figure VII-7

                     GRANULAR BED FILTRATION
                                637

-------
           FABRIC OR WIRE
           FILTER MEDIA
           STRETCHED OVER
           REVOLVING DRUM
              ROLLER
SOLIDS SCRAPED
OFF FILTER MEDIA
                       DIRECTION OF ROTATION
STEEL
CYLINDRICAL
FRAME
                                                            LIQUID FORCE
                                                            THROUGH
                                                            MEDIA BY
                              -jv'><;-.-/r^•'-iv- -^'<:'';&^T^^&'^-^^^R^+i••;•£}  '
                              »•> ;:-•• -'• /'-.;.-:• *•-.-'*£ x-"i^-^v/:^i-*(i^.l--r--i>-W/;'v-i-.--:r-;^X;v?4
    SOLIDS COLLECTION
    HOPPER
                                       INLET LIQUID
                                       TO BE
                                       FILTERED
                                                                   FILTERED LIQUID
                                        Figure VII-8
                                    VACUUM FILTRATION
                                             638

-------
                          EVAPORATION
CONTACT COOLING
WATER
COOLING

 TOWER
SLOWDOWN
DISCHARGE
    RECYCLED  FLOW
                                MAKE-UP WATER
                 Figure VII-9

  FLOW DIAGRAM FOR RECYCLING WITH A COOLING TOWER
                     639

-------
                      SINGLE RINSE
OUTGOING WATER
                                     • WORK MOVEMENT
                                     .INCOMING WATfER
_ -

OUTGOING WATER-
•

DOUBLE COUNTERFLOW
RINSE
T-P r
_j* — 	 -r
K
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J
"• — i 	 -"$—•
Wtt

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— INCOMING WATER


TRIPLE COUNTERFLOW
RINSE

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-------
                           Table VII-1

               SOLUBILITY PRODUCTS OF TOXIC METALS


                          Solubility Product Constant  (Kgp)
          Metal          Metal Hydroxide      Metal Sulfide

      Antimony (III)     1.6 x 10~22 (1)

      Arsenic

      Beryllium          1.6 x 10~22 (1)

      Cadmium            2.5 x lO'l4 (1)     3.6 x 1CT29  (2)

      Chromium (ill)     6.3 x 10'31 (1)

      Copper             2.2 x 10"20 (1)     8.5 x 10'45  (2)

      Lead               1.2 x 10-15 (i)     3.4 x 10'28  (2)

      Mercury            3.0 x 10'26 (1)     2.0 x 10~49  (2)

      Nickel             2.0 x 10-15 Q)     ^4 x icr24  (2)

      Selenium

      Silver             2.0 x 10-8  Q)     1.5 x iQ-49  (2)

      Thallium (I)             --            5.0 x 10-21  (X)

      Zinc               1.2 x 10-17 (1)     1.2 x IQ-28  (2)
NOTE:  References for above values are shown below.

(1)  Dean, J. A., Ed., Lange's Handbook oj: Chemistry, 12th ed. ,
     McGraw-Hill Book Co., New York, 1979.

(2)  Weast, R. C., Ed., Handbook of Chemistry and Physics,
     57th ed., CRC Press, Cleveland, OH, 1976.
                               641

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                Table VII-2



COMBINED METALS DATA EFFLUENT VALUES (mg/1)
Cd
Cr
Cu
Pb
Ni
Zn
Fe
Mn
TSS
Mean
0.079
0.084
0.58
0.12
0.74
0.33
0.41
0.21
12.0
One-Day
Max.
0.34
0.44
1.90
0.15
1.92
1.46
1.23
0.43
41.0
10-Day Avg.
Max.
0.15
0.18
1.00
0.13
1.27
0.61
0.63
0.34
20.0
30-Day Avg.
Max.
0.13
0.12
0.73
0.12
1.00
0.45
0.51
0.27
15.5
                    642

-------
     Table VII-3

   L&S PERFORMANCE
ADDITIONAL POLLUTANTS
Pollutant
Sb
Be
Ag
F
Mg
Nb
Mo
Ta
W
V
Ti
U
Hf
Zr
Radium226
Average Performance (mg/1)
0.70
0.30
0.10
14.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
0.5
5.0 picocuries/liter
         643

-------
                     Table VII-4



   COMBINED METALS DATA SET - UNTREATED WASTEWATER





Pollutant     Min. Cone, (mg/1)     Max. Cone, (mg/1)



   Cd               <0.1                    3.83



   Cr               <0.1                  116



   Cu               <0.1                  108





   Pb               <0.1                   29.2



   Ni               <0.1                   27.5



   Zn               <0.1                  337.





   Fe               <0.1                  263



   Mn               <0.1                    5.98



   TSS               4.6                4,390
                          644

-------
                           Table VII-5

         MAXIMUM POLLUTANT LEVEL IN UNTREATED WASTEWATER
                      ADDITIONAL POLLUTANTS
                              (mg/1)
Pollutant
Be
Cd
Cr
Cu
Pb
Ni
Ag
Zn
F
Fe
OSS
TSS
As & Se Be
10.24
<0.1
0.18 8.60
33.2 1.24
6.5 0.35
__
__
3.62 0.12
__
646.0
16.9
352.0 796.0
Ag
--
<0.1
0.23
110.5
11.4
100.0
4.7
1,512.0
--
--
16.0
587.8
F
--
<0.1
22.8
2.2
5.35
0.69
--
<0.1
760
--
2.8
5.6
Sb
<0.05
2.0
<0.2
2.5
41.0
1.5
--
10.8
--
54.5
12.0
200
-- Indicates not analyzed.
                               645

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




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-------
Plant ID //
  06097
  13924

  18538
  30172
  36048
  Mean
         Table VII-10
MULTIMEDIA FILTER PERFORMANCE

      TSS Effluent Concentration, mg/1
   0.0, 0.0, 0.5
   1.8, 2.2, 5.6, 4.0, 4.0, 3.0, 2.2, 2.8
   3.0, 2.0, 5.6, 3.6, 2.4, 3.4
   1.0
   1.4, 7.0, 1.0
   2.1, 2.6, 1.5
   2.61
                        650

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                           SECTION VII]

             COST OF WASTEWATER TREATME
This section presents estimates of the
major wastewater treatment and control
Section VII.  These cost estimates, tog
pollutant reduction performance for eac
option presented in Sections IX, X, XI,
for evaluating the options presented an
best practicable technology currently
available technology economically achie
tional technology (BCT), best demonstra
the appropriate technology for
also provide the basis for determining
impact on the nonferrous metals forming
different pollutant discharge levels.
addresses nonwater quality environmenta
treatment and control alternatives, inc
solid waste generation, and energy requ
pretreatnent
The cost analysis performed for proposa
standards used compliance costs derived
the total subcategory and category cost
conduct a plant-by-plant cost analysis
tion of these guidelines and standards.

The first part of this section describe
used to estimate compliance costs inclu
sentative plants and the projection of
the representative plants to each subca
nonferrous metals forming category.  Th
the methodology used to estimate costs
plants.  This part includes sources of
cost, cost update factors, a descriptio
used to estimate costs, and the methodo
ual treatment technologies.  Finally, e
nonwater quality aspects of the regulat

GENERAL APPROACH

To estimate the costs of the selected t
nonferrous metals forming category, the
plants in the category discharging proc
         T AND CONTROL
 osts  of  implementing the
 echnologies  described in
 ther  with  the  estimated
T. treatment and control
 and XII, provide  a basis
  identification of the
Bailable  (BPT),  best
/able  (BAT),  best  conven-
 ed  technology  (BDT),  and
       The  cost estimates
 he  probable  economic
 industry of  regulation at
 n addition,  this  section
  impacts of  wastewater
 uding air  pollution,
 .rements.
          of these guidelines and
         for 23 plants to estimate
            The Agency intends to
         rior to final promulga-
          the general methodology
         ing selection of repre-
         he costs estimated for
         egory and to the entire
         ; second part describes
         or the representative
         ost data, components of
          of the computer model
         ogy for costing individ-
         ergy requirements and
         on are considered.
         eatment options for the
         total population of
         ss wastewater was divided
         or a representative plant
into costing groups.  Compliance costs
from each or these costing groups were calculated using a com-
puter model.  These calculated costs were used to estimate total
category and subcategory compliance costs.  This procedure is
described in detail below.
                               651

-------
Selection of Representative Plants

A total of 146 plants in the nonferrous metals forming category
discharge process wastewater.  -For cost estimation, 23 of these
plants were selected to represent 140 of the plants in the cate-
gory.  Information from one plant was not received in time to be
included in cost estimation.  Five plants would incur no costs
from compliance with these guidelines because all of their
nonferrous metals forming operations are also covered by the
recently promulgated battery manufacturing guideline and there-
fore, costs for compliance were considered under the battery
manufacturing guideline.

Division of the Category Into Costing Groups.  The nonferrous
metals forming category was divided Into 22 homogeneous costing
groups (see Table VIII-1) to adequately account for the varia-
tions within the category which affect treatment costs.  The
division of 140 of the 146 discharging plants into costing groups
was based on the factors which significantly affect compliance
costs:

     1.  Wastewater pollutant characteristics,
     2.  Wastewater flow, and
     3.  Wastewater treatment currently in-place.

Wastewater pollutant characteristics affect treatment costs
because they dictate the choice and sequence of required treat-
ment.  Removal of dissolved metals from any nonferrous metals
forming wastewater requires chemical precipitation of the metals
with lime followed by gravity settling to separate the solid from
liquid phase.  Preliminary treatment required for a particular
waste stream prior to lime and settle, however, can vary widely.
For example, emulsified oily waste streams will typically require
chemical emulsion breaking and oil/water separation, since oil is
not effectively removed by lime and settle technology.  Also,
waste streams containing treatable levels of hexavalent chromium
require treatment to reduce the chrome to trivalent chromium
before precipitation as a hydroxide (with lime) can occur.
Extensive pretreatment will result in significantly higher costs
compared to lime and settle alone.

Plant wastewater flow affects both annual and capital treatment
costs.  Capital costs depend on equipment size, which is based on
hydraulic flow.  Annual costs include cost of treatment chemicals
and wastewater pumping, both of which are affected by total plant
wastewater flow.  However, because of economies of scale, the
relationship between flow and cost is not linear and the dis-
charging plants were grouped to represent the range of flows
found in the category.
                               652

-------
Wastewater treatment in-place, when equivalent to that required
by a treatment option, will reduce a plant's annual and capital
cost for that option.  Therefore, treatment in-place was
considered in the selection of costing groups.

The selected costing groups did not always correspond to the
subcategories described in Section IV.  This is because the 11
nonferrous metals forming subcategories correspond to industry
segments with different wastewater characteristics which, because
of different pollutants present, will require distinct effluent
limitations.  In contrast, costing groups correspond to industry
segments with different wastewater characteristics which result
in different capital and annual costs of treatment.

Because both subcategories and costing groups are divisions based
on wastewater characteristics and because it was necessary to
estimate compliance costs for each subcategory, the subcategori-
zation scheme developed in Section IV was followed in selecting
costing groups, where appropriate.  Adaptation of the subcate-
gorization scheme for division into costing groups was necessary
for several subcategories:

        The lead/tin/bismuth forming subcategory covers the manu-
        facture of three distinct types of products - bullets;
        solder; and pipe, sheet and other products.  Each of
        these types of products is manufactured with a distinct
        mix of lead/tin/bismuth forming operations.  The plants
        within each costing group will generate waste streams
        with similar flows and requiring similar types of pre-
        liminary treatment.  For this reason, the lead/tin/
        bismuth subcategory was divided into three costing groups
        based on product manufactured.

        Similarly, the iron and steel/copper/aluminum metal
        powder production and powder metallurgy subcategory
        covers the manufacture of two distinct types of
        products - metal powders and parts pressed from metal
        powder.  Although the operations used to manufacture
        these products generate wastewater with similar char-
        acteristics, the operations have different water uses.
        Water is used to atomize molten metal and as a grinding
        slurry in the production of metal powders.  No flow
        reduction technology has been identified for these
        operations.  Therefore, costs of implementing some
        in-process wastewater control technology options will
        be different for metal powder production operations and
        powder metallurgy operations.  For this reason the
        subcategory was divided into two costing groups based on
        product manufactured.
                               653

-------
        Zirconium/hafnium forming, nickel/cobalt  forming,
        titanium forming and refractory metal forming are
        distinct subcategories.  However, these metals have
        similar properties, are formed by similar processes and
        thus generate wastewaters requiring the same types of
        treatment.  Furthermore, a single plant will often form
        metals from more than  one of these subcategories,
        commingling and co-treating the wastewater from the
        forming operations.  Therefore, these subcategories were
        grouped together.

Adaptation of the beryllium, uranium, magnesium, and zinc forming
subcategories, based on wastewater characteristics, was not
necessary, because one plant generates the majority of wastewater
discharged in each subcategory.  Therefore, they were retained as
separate costing groups.  Adaptation of the precious metals
subcategory based on wastewater characteristics was also not
necessary.

Nine of the eleven groupings described above could be adequately
represented by an average plant and required no further subdivi-
sion for use as costing groups.  However, as shown on Table
VIII-1, two of these groupings, precious metals forming and the
zirconium/hafnium, nickel/ cobalt, refractory metals, titanium
forming grouping required further subdivision.  This subdivision
was based on the two other factors, described above, which signi-
ficantly affect compliance costs--treatment in place and waste-
water flow.

The zirconium/hafnium,  nickel/cobalt, refractory metals, and
titanium grouping was split into two groups - plants with
treatment in-place and plants without.   Both of these groups were
further divided into groups of extra small, small, medium, large,
and extra large dischargers based on total nonferrous metals
forming process wastewater flow.

Subdivision of the precious metals forming grouping was based on
total nonferrous metals forming process wastewater flow.  Three
precious metals costing groups were created:   small, medium, and
large dischargers.

Each discharging j^lant was assigned to one of these costing
groups, based on its subcategory, flow, and treatment-in-place.
If a plant formed metals in more than one subcategory, it was
assigned to the costing group based on the subcategory contribut-
ing the greatest proportion of wastewater flow.   It was assumed
that all wastewater generated by processes in the nonferrous
metals forming category would be treated together.  Therefore,
when costing groups were based on flow, plants were assigned to a
group based on total annual nonferrous metal forming process
                               654

-------
wastewater flow.  For example, if a plant discharged 10,000
 fallons of wastewater per year from nickel forming operations and
 0,000 gallons of wastewater per year from precious metals form-
ing operations, it was assigned to a precious metals forming cost
group.  However, it was assigned to the small, medium, or large
precious metals costing group based on its total nonferrous
forming wastewater flow, 40,000 gallons per year.

No information on nonferrous metals forming wastewater flow was
available for some plants.  If the plant formed a metal whose
costing groups were based on wastewater flow, the plant was
assigned to a costing group with plants of similar productions
(pounds of product).  Based on information obtained from
follow-up telephone calls, most plants that did not adequately
complete the dcp are believed to have small wastewater flows.
Therefore, if no production information was available, the plant
was assigned to the extra-small flow costing group.

Selection of Representative Plants.  One plant representing each
costing group was selected for compliance cost estimation using
the computer model described below.  Two plants were selected to
represent the powder metallurgy group because of the large number
of plants in this group.  Based on the combined treatment assump-
tion described above, the arithmetic average of total annual non-
ferrous metals forming process wastewater flow wa?s calculated for
each costing group.  Plants were selected for costing which had
flow close to the group average.  Treatment in place and manufac-
turing process were also considered in selecting a representative
plant when they had not been used to define the group.

If several plants in a costing group had flows close to average,
a plant that had been visited and sampled was preferentially
selected for costing to take advantage of the detailed informa-
tion obtained during the visit.  However, several sampled plants
had wastewater flows much larger than average and so were not
selected for costing.

Costing the Representative Plants

Costs were estimated for each of the representative plants using
the methodology described in the second part of this section.
The computer model used for estimating costs requires pollutant
concentrations for each treated waste stream.  Pollutant concen-
trations used in estimating costs were based on sampling data
obtained during visits to 17 nonferrous metal forming plants.
See "Costing Input Data," below, for more details on the use of
the sampling data.

The pollutant parameters in list B of Table VIII-2 were used to
estimate the costs of the plant representing costing groups 6,
                               655

-------
14, 17, 18, 22, and 23 (see Table VIII-1).  The parameters  in
list A were used to estimate the costs of the plants representing
the remaining cost groups.

Estimation of Subcategory and Total Category Costs

The plants assigned to a given costing group had operations  in up
to five nonferrous metals forming subcategories.  In order  to
estimate subcategory compliance costs, the costs calculated  for
each costing group were apportioned to the subcategories present
in that group based on mass of finished product produced.

Treatment costs would be most accurately apportioned based  on
wastewater flow generated by the nonferrous metals forming
operations in each subcategory.  However, in the limited time
available between the receipt of the dcp s and the Court Ordered
deadline for proposal of these guidelines this detailed informa-
tion could not be determined for many of the plants known to
discharge wastewater.  Therefore, to apportion costing group
costs to subcategories in a consistent manner, costs were
apportioned based on mass of finished product produced.

Subcategory Costs.  Compliance costs for each subcategory were
determined by summing the estimated costs for direct dischargers
in a subcategory and the estimated costs for indirect dischargers
in that subcategory.   These estimates were made using the
following procedure:

        First, for a single costing group, the number of pounds
        of metal formed in each subcategory by each plant in the
        group was determined.  It was also determined if the
        wastewaters associated with this production were directly
        or indirectly discharged.

        Second, the total pounds of metal formed in the costing
        group were calculated.

        Third, for each subcategory present in the costing  group,
        the pounds of metal associated with direct dischargers
        and the pounds of metal associated with indirect
        dischargers were calculated.

        Fourth, the total group cost was calculated by multiply-
        ing the estimated compliance cost of the representative
        plant by the number of plants in the costing group.

        Fifth, the total group cost was apportioned to the
        direct and indirect discharges in each subcategory
        present in the group by production weighting the total
        group cost.
                               656

-------
For example:

     [pounds of Ni, wastewater directly discharged, group n] x
                   total pounds metal, group n

     [total cost, group n] = cost from group n attributable to
                             directly discharged nickel  forming
                             wastewater

These five steps were repeated for each of the 22 costing groups
except group 7.

Costing group 7 consisted of two zinc forming plants.  One plant
is much larger than the other, has most of the equipment required
by the treatment options in-place and discharges its wastewater
directly into surface water.  The plant with smaller production
has no treatment in-place, discharges its wastewater to  a POTW,
and did not supply wastewater flow information in its dcp.

The compliance cost for the larger plant was estimated using the
computer cost model.  Required capital costs at each treatment
option were determined by first calculating the total capital
cost required by the option and then subtracting out the capital
cost of equipment currently in-place at the plant.  Required
annual costs were determined by first calculating the total
annual cost required by the treatment option and then subtracting
out the annual costs currently incurred by the plant.  Because of
the large differences in production and treatment in-place
between the cos ted plant and the other plant in the costing
group, these estimates were not believed to represent the costs
for both plants in the group.  Therefore, a separate cost esti-
mate was made for the smaller plant.  This estimate was based on
the total capital and annual costs estimated for the larger plant
with the computer cost model (that is, making no allowance for
treatment in-place).  These costs were adjusted to more  accu-
rately represent the costs that would be incurred by the smaller
plant by multiplying them by the ratio of the plant productions.

The estimates for the compliance costs for the two plants in
costing group 7 were then used to estimate the total zinc forming
subcategory compliance costs.

The compliance costs for direct discharges in one subcategory
were determined by adding the production weighted costs  from each
costing group.  The same procedure was used to determine compli-
ance costs for indirect dischargers in the subcategory.  Total
compliance costs for the subcategory were simply the sum of the
costs for direct and indirect dischargers.

The compliance costs for each of the 11 subcategories were deter-
mined in the same way.
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Total Category Costs.  The compliance costs of the nonferrous
metals terming category were estimated by adding together the
compliance costs for each of the 11 subcategories, estimated as
described above.

Economic Impact Assessment.  The Agency's assessment of the eco-
nomic impact of these guidelines and standards is set forth in
Economic Analysis of Proposed Effluent Limitations and Standards
for the Nonferrous Metals Forming Industry (EPA 4-4U/2-»4-UU5) .
Part of this study involved assessing the impact of the. various
treatment options on each plant in the category.  To perform this
assessment the compliance costs estimated by the computer model
for the 23 representative plants were extrapolated to the other
plants in each costing group.  Even though a specific plant might
have operations in more than one subcategory, it was not neces-
sary to apportion the costs to perform the plant-by-plant eco-
nomic impact analysis.  Therefore, the costs estimated for the 23
representative plants in the respective costing group were
extrapolated to each of the remaining plants in the respective
costing group based on the plant's total annual nonferrous metals
forming wastewater flow.  When this information was not: availa-
ble, costs were extrapolated based on plant annual production
volume.  The total category compliance costs calculated by this
procedure are different from those calculated by apportioning
costs to each subcategory based on mass of finished product
produced.

Drawbacks of This Cost Estimation Methodology

The general approach outlined above was used to estimate costs
because of the limited time between receipt of completed dcp's
and the court-ordered date for proposal of these guidelines and
standards.  However, the Agency recognizes that this methodology
has some drawbacks and will, therefore, evaluate the costs of the
technology options on a plant-by-plant basis before promulgating
these guidelines and standards.  Some of the drawbacks of this
method of cost estimation are discussed below.

Representative Plants.  The average of the costs of the plants in
a costing group was assumed to be equal to the compliance costs
of the plant selected to represent that group.  This will only be
true to the extent that the costed plant represents the average
of the factors which significantly affect compliance costs.  The
costed plant should have average wastewater characteristics,
wastewater flow and treatment in-place.  However, because of the
small number of plants in each costing group_ and the heterogene-
ity of the category, it was not always possible to select such an
average plant.  When necessary, a plant believed to have slightly
higher than average costs was chosen to represent the costing
group.
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Apportionment of Subcategory Costs.  Treatment  costs  for  each
costing group were apportioned to subcategories based on  mass  of
finished product produced.  Since treatment  costs  depend  on
volume of water treated, apportioning costs  by  mass of  finished
product produced assumes that the total volume  of  wastewater
generated by all of the operations at a plant per  mass  of final
product will be constant from plant  to plant.   This is  clearly
not the case.  As detailed in Section IX, the volume  of waste-
water generated by a particular plant depends upon the  operations
present and the mass of metal processed by those operations.
Apportioning costs by production instead of  wastewater  flow will
sometimes under- and sometimes overestimate  the actual  cost at a
plant attributable to each subcategory.  It  is  not clear  if this
will result in a net over- or underestimate  of  a subcategory
compliance cost.

Treatment of Wastewater Other Than Nonferrous Metals Forming Pro-
cess Wastewater.  Plants which form  nonferrous  metals can gener-
ate three types of wastewater:  (a)  wastewater  from nonferrous
metals forming processes; (b) wastewater from manufacturing
activities other than nonferrous metals forming; and  (c)  nonpro-
cess wastewater (e.g., noncontact cooling water, plant  site
runoff, sanitary wastewater).  Only  treatment of nonferrous
metals forming process wastewater was considered in the estima-
tion of treatment technology costs in this category.

Approximately 56 percent of the discharging  plants in the cate-
gory and 12 of 23 plants for which costs were estimated discharge
process water from manufacturing activities  other  than  nonferrous
metals forming.  Most of these activities are covered by  other
effluent guidelines.  However, the development  of  separate guide-
lines is not meant to imply that separate treatment systems are
required, if the wastewater from one category is amenable to the
same treatment as the wastewater from another category  (that is,
if the wastewai_°rs are co-treatable).  Since wastewater from the
industrial categories most commonly  associated with nonferrous
metals forming (i.e., aluminum forming, copper  forming, metal
finishing, iron and steel manufacturing, and nonferrous metals
manufacturing) is effectively treated by the same  technology as
that from nonferrous metals forming, in practice,  separate
treatment systems would usually not  be required.

The questionnaires distributed to obtain information on the
nonferrous metals forming operations did not specifically ask  for
information on wastewater flows from operations not in  the
category.   However,  some respondents volunteered this
information.

For some of the plants which supplied such information, the
nonferrous metals forming wastewater flow is a  small part of
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total wastewater flow.  For these plants, compliance with  the
nonferrous metals forming guideline would require a small
increase in the capacity of an existing treatment system or  a
treatment system required to comply with other newly promulgated
regulations.  The compliance cost for these plants is the  cost of
that increment of treatment capacity.  Because of economies  of
scale, this cost is usually much smaller than the cost of  two
separate systems.  Since treatment of nonscope wastewaters was
not considered in the estimation of compliance costs for the
nonferrous metals forming category, the compliance costs
described in this section may overstate the actual costs for
plants in which co-treatable nonscope wastewaters are present.

The wastewater generated from nonferrous metals forming opera-
tions at some plants may require significantly more treatment
than the other wastewater generated at the plant.  These waste-
waters could be either from other manufacturing activities or
nonprocess wastewater.  If these waste streams are currently com-
mingled with nonferrous metals forming process wastewater, the
plants would incur the cost of segregating the nonferrous  metals
forming process wastewater from the commingled streams.  No
segregation costs were included in the estimation of treatment
technology costs in this category.  This omission might lead to
an underestimate of costs in some cases.

Re-estimation of Costs for Promulgation of These Guidelines  and
Standards.  Because of the issues described above, the Agency
plans to re-evaluate the costs of the technology options consid-
ered for these guidelines on a plant-by-plant basis.  To do  this
will require additional information on (a) the extent to which
co-treatment is currently practiced in the industry, (b) the
extent to which co-treatment is projected to be practiced  in the
future, (c) the costs of co-treatment currently experienced  or
projected, (d) method(s) of allocating costs for co-treatment to
individual product lines, and (e) the effectiveness of
co-treatment in reducing pollutant discharges.

Benefits.   The total mass of pollutants removed by each treatment
technology option (benefits) considered for this regulation  was
estimated as described in Section X.  This estimate depends  on
the same assumptions as the cost estimates and so may have some
of the same drawbacks.  In addition to re-evaluating costs for
these guidelines on a plant-by-plant basis, the Agency plans to
re-evaluate benefits on a plant-by-plant basis prior to promulga-
tion of these guidelines and standards.
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COST ESTIMATION METHODOLOGY

Sources of Cost Data

Capital and annual cost data for the selected treatment processes
were obtained from three sources:   (1) equipment manufacturers,
(2) literature data, and (3) cost data from existing plants.  The
major source of equipment costs was contacts with equipment ven-
dors, while the majority of annual  cost information was obtained
from the literature.  Additional cost and design data were
obtained from data collection portfolios when possible.

Components of Costs

Capital Costs.  Capital costs consist of two components:  equip-
ment capital costs and system capital costs.  Equipment costs
include:  (1) the purchase price of the manufactured equipment
and any accessories assumed to be necessary; (2) delivery
charges, which account for the cost of shipping the purchased
equipment a distance of 500 miles (considered an average delivery
distance, given the geographical distribution of plants in this
category); and (3) installation, which includes labor, excava-
tion, site work, and materials.  The correlating equations used
to generate equipment costs are shown in Table VIII-3.

Capital system costs include contingency, engineering, and con-
tractor's fees.  These system costs, each expressed as a percen-
tage of the total installed equipment cost, are combined into a
factor which is multiplied by the total equipment cost to yield
the total capital investment.  The components of the total
capital investment are listed in Table VIII-4.

Annual Costs.  The total annualized costs also consist of a
direct and a system component as in the case of total capital
costs.  The components of the total annualized costs are listed
in Table VIII-5.  Direct annual costs include the following:

     o  Raw materials - These costs are for chemicals used in
        the treatment processes, which include lime, ferrous
        sulfate, sulfuric acid, alum, polyelectrolyte, and sulfur
        dioxide.

     o  Operating labor and materials - These costs account for
        the labor and materials directly associated with opera-
        tion of the process equipment.  Labor requirements are
        estimated in terms of labor hours per year.  A labor rate
        of 21 dollars per labor hour was used to convert the
        labor hour requirements into an annual cost.  This
        composite labor rate included a base labor rate of nine
        dollars per hour for skilled labor, 15 percent of the
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        base  labor  rate  for  supervision  and plant overhead  at  100
        percent of  the total labor rate.  Nine dollars per  hour
        is  the Bureau of Labor Statistics national wage rate for
        skilled labor during 1982  (National Bureau of Labor
        Statistics, Monthly Labor Review, March 1982).

     o  Maintenance Labor  and Materials  - These costs account  for
        the labor and materials required for repair and routine
        maintenance of the equipment.  The maintenance labor rate
        was also 21 dollars per labor hour, and maintenance mate-
        rials were  usually assumed as a  percentage of capital
        costs.

     o  Energy - Energy, or power, costs are calculated based
        on  total energy requirements in kw-hrs, an electricity
        charge of $.0483/kilowatt-hour and an operating schedule
        of 24 hours/day, 250 days/year unless otherwise speci-
        fied.  The  cost of electricity (March 1982) is based on
        the industrial cost derived from the Department of
        Energy's Monthly Energy Review.

System annual costs include monitoring, taxes and insurance, and
amortization.  Monitoring refers to the periodic sampling and
analysis of wastewater to ensure that discharge limitations are
being met.  The annual cost of monitoring was calculated using an
analytical lab fee  of $120 per wastewater sample and a sampling
frequency based on  the wastewater discharge rate, as shown  in
Table VIII-6.

Taxes and insurance cost is assumed to be one percent of the
total depreciable capital investment (see Item 23 of Table
VIII-5).

Amortization costs, which account for depreciation and the  cost
of financing, were  calculated using a capital recovery factor
(CRF).   A CRF value of 0.177 was used,  which is based on an
interest rate of 12 percent, and a taxable lifetime of 10 years.
The CRF is multiplied by the total depreciable investment to
obtain the annual amortization costs (see Item 24 of Table
VIII-5).

Cost Update Factors

All costs are standardized by adjusting to the first quarter of
1982.  The cost indices used for particular components of costs
are described below.

Capital Investment  - Investment costs were adjusted using the
EPA-Sewage Treatment Plant Construction Cost Index.   The value of
this index for March 1982 is 414.0.
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Operation and Maintenance Labor - The Engineering News-Record
Skilled Labor Wage index is used to adjust the portion of Oper-
ation and Maintenance costs attributable to  labor.  The March
1982 value is 325.0.

Maintenance Materials - The producer price index published by the
Department of Labor, Bureau of Statistics is used.  The March
1982 value of this index is 276.5.

Chemicals - The Chemical Engineering Producer Price Index for
industrial chemicals is used.  This index is published biweekly
in Chemical Engineering magazine.  The March 1982 value of this
index is 362.6.

Energy - Power costs are adjusted by using the price of electric-
ity on the desired date and multiplying it by the energy require-
ments for the treatment module in kwhr equivalents.

Cost Estimation Model

Cost estimation was accomplished using a computer model which
accepts inputs specifying the required treatment system, chemical
characteristics of the raw waste streams, flow rates and treat-
ment system entry points of these streams, and operating sched-
ules.  This model utilizes a computer-aided design of a waste-
water treatment system containing modules that are configured to
reflect the appropriate equipment at an individual plant.  The
model designs each treatment module and then executes a costing
routine that contains the cost data for each module.  The capital
and annual costs from the costing routine are combined with
capital and annual costs for the other modules to yield the total
costs for that regulatory option.  The process is repeated for
each regulatory option.

Each module was developed by coupling theoretical design informa-
tion from the technical literature with actual design data from
operating plants.  This permits the most representative design
approach possible to be used, which is an important element in
accurately estimating costs.  The fundamental units for design
and costing are not the modules themselves but the components
within each module, e.g., the lime feed system within the chemi-
cal precipitation module.  This is a significant aspect of this
model for two reasons.  First, it does not limit the model to
certain fixed relationships between various components of each
module.  For instance, cost data for chemical precipitation sys-
tems are typically presented graphically as a family of curves
with lime (or other alkali) dosage as a parametric function.  The
model, however, sizes the lime feed system as a funtion of the
required mass addition rate (kg/hr) of lime.  The model thus
selects a feed system specifically designed for that plant.
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Second, this approach more closely reflects the way a plant would
actually design and purchase its equipment.  The resulting costs
are thus closer to the actual costs that would be incurred by the
facility.

Overall Structure.  The cost estimation model consists of two
main parts:  a design portion and a costing portion.  The design
portion uses input provided by the user to calculate design
parameters for each module included in the treatment system.  The
design parameters are then used as input to the costing routine,
which contains cost equations for each discrete component in the
system.  The structure of the program is such that the entire
system is designed before any costs are estimated.

An overall logic diagram of the computer programs is depicted in
Figure VIII-1.  First, constants are initialized and certain var-
iables such as the modules to be included, the system configura-
tion, plant and wastewater flows, compositions, and entry points
are specified by the user.  Each module is designed utilizing the
flow and composition data for influent streams.  The design
values are transmitted to the cost routine.  The appropriate cost
equations are applied, and the module costs and system costs are
computed.  Figures VIII-2 and VIII-3 depict the logic flow dia-
grams in more detail for the two major segments of the program.

Input Data Requirements.  Several data inputs are required to run
the computer model.  First, the treatment modules to be included
and their sequence must be specified.  Next, information on hours
of operation per day and number of days of operation per year for
the particular plant under consideration is required.  The flow
values and characteristics must be specified for each wastewater
stream entering the treatment system, as well as each stream's
point of entry into the wastewater treatment system.  These
values will dictate the size and other parameters of equipment to
be cos ted.  The derivation of each of these inputs will be
discussed in turn.

Choice of the appropriate end-of-pipe and preliminary treatment
modules and their sequence for a plant are determined by applying
the treatment technology for each option (see Figures X-l and
X-2).  These option diagrams were adjusted to accurately reflect
the treatment system that the plant would actually require.  For
example, if it were determined by examining a plant's dcp that
emulsified oils are not used in the plant's forming operations,
then a chemical emulsion breaking module would not be included in
the treatment required for that plant.  Flow reduction modules
were not included for plants whose waste stream flow rates were
already lower than the regulatory flows for flow reduced treat-
ment options.  The hours of operation per day and days of opera-
tion per year were estimated from information supplied in the
data collection portfolio.
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The flows used to  size the  treatment  equipment  were  derived as
follows:  production  (kkg/yr) and  flow  (1/yr) information  was
obtained from the  plant's dcp, or  from  sampling data where possi-
ble, and a production normalized flow in  liters  per  kkg was cal-
culated for each waste stream.  This  flow was compared  to  the
regulatory flow, also in liters per kkg,  and the lower  of  the two
flows was used to  size the  treatment  equipment.   Regulatory flow
was also assigned  to any stream for which production or flow data
was not reported in the dcp.

The raw waste concentrations of each  influent waste  stream were
derived from available sampling data.   The actual values of the
concentrations used as input into  the cost model were based on
two different assumptions;  either  a constant concentration or a
constant mass assumption was used.  Assuming constant concentra-
tion signifies that the same concentrations of  pertinent pollu-
tants were assumed for each waste  stream  regardless  of  plant,
except where the actual flow was lower  than the  regulatory flow
or where a waste stream is  flow reduced.   In these cases,  the
concentrations were adjusted to maintain  the same mass  of  pollu-
tant found at the  regulatory or unreduced flow  level.   This was
calculated by multiplying the concentrations by  the  ratio  of the
regulatory to the  lower actual flow or  unreduced to  the reduced
flow, whichever the case may be, to obtain concentrations  at the
lower flow.  For example, a waste  stream  whose  actual reported
flow is half the value of the regulatory  flow will have double
the concentrations associated with the  higher regulatory flow in
order to maintain  a constant pollutant  mass loading  for both
flows.  In other words, pollutant  concentrations were assumed to
be constant from plant to plant for a particular waste  stream if
the flow used for  costing is at the regulatory  level.  From
option to option (i.e., within a plant) however,  pollutant mass
loadings (mg/hr) were assumed to be constant.

Assuming constant  mass signifies that the pollutant  mass loadings
(mg/hr) were constant for each waste  stream.  The mass  loading  is
calculated as being directly proportional to the production rate
(kkg/hr) associated with a  particular waste stream and  is  inde-
pendent of the flow (although the  concentration derived from the
mass loading will  be a function of flow).  The  procedure used for
determining the pollutant concentrations  (mg/1)  to be used as
input to the cost  model was as follows:   for a  given input waste
stream to the model during  actual  costing,  the  average  production
normalized raw waste values (mg/kkg)  are  divided by  the produc-
tion normalized costing flow (1/kkg)  (actual or  regulatory based,
whichever is lower) to obtain the  pollutant concentration  for
costing.  The underlying assumption is  that the  amount  of  pollu-
tant generated by  any process operation corresponds  directly with
the amount of product produced by  that  operation.  A significant
result of this assumption is that  the total pollutant loading
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 (mg/hr) remains constant when in-process flow reduction tech-
niques are used (e.g., for a stream that is reduced by a factor
of two via a flow reduction measure, the pollutant concentrations
will increase correspondingly by a factor of two).

Model Results.  For a given plant, the model will generate
comprehensive material balances for each parameter tracked at any
point in the system.  It will also summarize design values for
key equipment in each treatment module, and provide a tabulation
of costs for each piece of equipment in each module, module
subtotals, total equipment costs, and system capital and annual
costs.

Cost Estimates for Individual Treatment Technologies

Introduction.  Treatment technologies have been selected from
among the larger set of available alternatives discussed in
Section VII after considering such factors as raw waste charac-
teristics, typical plant characteristics (e.g., location, produc-
tion schedules,  product mix,  and land availability), and present
treatment practices.  Specific rationale for selection is
addressed in Sections IX, X,  XI, and XII.   Cost estimates for
each technology addressed in this section include investment
costs and annual costs for depreciation, capital recovery,
operation and maintenance, and energy.

The specific assumptions for each wastewater treatment module are
listed under the subheadings  below.  Costs are presented as a
function of influent wastewater flow rate except where noted in
the unit process assumptions.

Costs are presented for the following control and treatment
technologies:

      1.  Flow Equalization,
      2.  Lime Precipitation  and Gravity Settling,
      3.  Vacuum Filtration,
      4.  Multimedia Filtration,
      5.  Contract Hauling,
      6.  Chemical Emulsion Breaking,
      7.  Oil Skimming,
      8.  Ammonia Steam Stripping,
      9.  Chromium Reduction,
     10.  Recycling of Cooling Water, and
     11.  Countercurrent Cascade/Spray Rinsing.

Flow Equalization.  Flow equalization is accomplished through
steel equalization tanks which are sized based on a retention
time of eight hours and an excess capacity factor of 1.2.  Cost
data were available for steel equalization tanks up to a capacity
                               666

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of 500,000 gallons; multiple units were  required  for  volumes
greater than 500,000 gallons.  The tanks are  fitted with  agita-
tors with a horsepower requirement of 0.006 kw/1,000  liters
(0.03 hp/1,000 gallons) of capacity  to prevent sedimentation.
An influent transfer pump is also included  in the equalization
system.

Lime Precipitation and Gravity Settling.  Precipitation using
lime followed by gravity settling is a fundamental technology for
metals removal.  In practice, either quicklime (CaO)  or hydrated
lime (Ca(OH)2) can be used to precipitate toxic and other
metals.  Hydrated lime is more economical for low lime require-
ments since the use of slakers, which are necesary for quicklime
usage, are practical only for large-volume  application of lime.

Lime is used to adjust the pH of the influent waste stream to a
value of approximately 9, at which optimum  precipitation  of the
metals is assumed to occur, and to react with the metals  to form
metal hydroxides.  The lime dosage is calculated  as a theoretical
stoichiometric requirement based on the  influent  metals concen-
trations and pH.  The actual lime dosage requirement  is obtained
by assuming an excess of 10 percent of the  theoretical lime
dosage.  The effluent concentrations are based on the Agency's
combined metals data base lime precipitation  treatment
effectiveness concentrations.

The costs of lime precipitation and gravity settling  were based
on one of three operation modes, depending  on the1 influent flow-
rate:  continuous, normal batch, and "low flow" batch.  The use
of a particular mode for costing purposes was determined  on a
least (total annualized) cost basis  for  a given flowrate.  The
economic breakpoint between continuous and  normal batch was esti-
mated to be 11,800 liters/hour (3,117 gal/hour).  Below 2,000
liters/hour (528 gal/hour), it was found that the "low flow"
batch system was most economical.

For a continuous operation, the following equipment was included
in the determination of capital and annual  costs:

        Lime feed system (continuous)

        1.   Storage units (sized for 30-day storage)
        2.   Slurry mix tank (5-minute retention time)
        3.   Feed pumps
        4.   Instrumentation (pH control)

        Polymer feed system

        1.   Storage hopper
        2.   Chemical mix tank
        3.   Agitator
        4.   Chemical metering pump
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        pH adjustment system

        1.  Rapid mix tank, fiberglass  (5-minute retention  time)
        2.  Agitator (velocity gradient is 300/second)
        3.  Control system

        Gravity settling system

        1.  Clarifier, circular, steel  (overflow rate  is 0.347
            gpm/sq. ft. (0.849 m3/m2hr), underflow solids is
            3 percent)
        2.  Sludge pumps (1), (to transfer recycle sludge stream
            flow from clarifier to pH adjustment tank  and to
            transfer sludge to dewatering)

Ten percent of the clarifier underflow stream is recycled to the
pH adjustment tank to serve as seed material for the incoming
equalized raw wastewater.

The direct capital costs of the lime and polymer feed  systems
were based on the respective chemical feed rates (dry  Ibs/hour),
which are dependent on the influent waste stream characteristics.
The flexibility of this feature (i.e.. costs are independent of
other module components) was previously noted in the description
of the cost estimation model.  The remaining equipment costs
(e.g., for tanks, agitators, pumps) were developed as  a function
of the influent flowrate (either directly or indirectly, when
coupled with the design assumptions).

Direct annual costs for the continuous system include  operating
and maintenance labor for the feed systems and the clarifier, the
cost o£ lime and polymer,  maintenance materials and energy  costs
required to run the agitators and pumps.

The normal batch treatment system (used for influent flows
greater than 2,000 1/hr but less than 11,800 1/hr) consists of
the following equipment:

        Lime feed system (batch)

        1.  Slurry tank (5-minute retention time)
        2.  Agitator
        3.  Feed pump

        Polymer feed system

        1.  Chemical mix tank
        2.  Agitator
        3.  Chemical metering pump
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        pH adjustment system

        1.  Reaction tanks  (2),  (8-hour retention time each)
        2.  Agitators (2),  (velocity gradient is 300/second)
        3.  Sludge pump (1), (to transfer sludge to dewatering)
        4.  pH control system

The reaction tanks used in pH adjustment are sized to hold the
wastewater volume accumulated for one batch period (assumed to be
8 hours).  The tanks are arranged in a parallel setup so that
treatment occurs in one tank while wastewater is accumulating in
the other tank.  A separate gravity settler is not necessary
since settling will occur in the reaction tank after precipita-
tion has taken place.  The settled sludge is then pumped to the
dewatering stage.

If additional tank capacity is required in the pH adjustment sys-
tem in excess of 25,000 gallons  (largest single fiberglass tank
capacity for which cost data were compiled), additional tanks are
added in pairs.  A sludge pump and agitator are costed for each
tank.

The cost of operating labor is the major component of the direct
annual costs for the normal batch system.  For operation of the
batch lime feed system, labor requirements range from 15 to 60
minutes per batch, depending on the lime feed rate (5 to 1,000
pounds/batch).  This labor  is associated with the manual addi-
tion of lime (stored in 50-pound bags).  For pH adjustment,
required labor is assumed to be one hour per batch (for pH con-
trol, sampling, valve operation, etc.).  Both the pH adjustment
tank and the lime feed system are assumed to require 52 hours per
year (one hour/week) of maintenance labor.  Labor requirements
for the polymer feed system are approximately one hour/day, which
accounts for manual addition of dry polymer and maintenance asso-
ciated with the chemical feed pump and agitator.

Direct annual costs also include the cost of chemicals (lime,
polymer) and energy required for the pumps and agitators.  The
costs of lime and polymer used in the model are $47.30/kkg of
lime ($43/ton) and $4.96/kg of polymer ($2.25/pound), based on
rates obtained from the Chemical Weekly Reporter (lime) and
quotations from vendors (polymer).

For small influent flowrates (less than 2,000 liters/hour) it is
more economical on a total annualized cost basis to select the
"low flow" batch treatment system.  The lower flowrates allow an
assumption of five days for the batch duration, or holdup, as
opposed to eight hours for the normal batch system.  However,
whenever the total batch volume  (based on a five-day holdup)
exceeds 25,000 gallons, the maximum single batch tank capacity,
                               669

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the holdup is decreased accordingly to maintain the batch volume
under this level.  Capital and annual costs for the low flow
system are based on the following equipment:

        pH adjustment system

        1.  Rapid mix/holdup tank (5 days or less retention time)
        2.  Agitator
        3.  Transfer pump

Only one  tank is required for both holdup and treatment: because
treatment is assumed to be accomplished during non-operating
hours (since the holdup time is much greater than the time
required  for treatment).  A lime feed system is not costed since
lime addition at low application rates can be assumed to be done
manually by the operator.   A common pump is used for transfer of
both the  supernatant and sludge through an appropriate valving
arrangement.  Addition of polymer was assumed to be unnecessary
due to the extended settling time available.

As in the normal batch case, annual costs consist mainly of labor
costs for the low flow batch system.  Labor requirements are
constant  at 1.0 hour per batch for operation (e.g., pH control,
sampling, etc.) and 52 hours per year (one hour per week) for
maintenance.  Labor is also required for the manual addition of
lime directly to the batch tank, ranging from 0.25 to 1.5 hours
per batch depending on the lime requirement (1 to 500 pounds per
batch).   Annual costs also include energy costs associated with
the pump  and agitator.

Vacuum Filtration.  The underflow from the clarifier is routed to
a rotary precoat vacuum filter  which dewaters the hydroxide
sludge (it may also include calcium sulfate and precipitated
fluoride) to a cake of 20 percent dry solids.  The dewatered
sludge is disposed of by contract hauling and the filtrate is
recycled  to the rapid mix tank as seed material for sludge
formation.

The capacity of the vacuum filter, expressed as square feet of
filtration area, is based on a yield value of 14.6 kg of dry
solids/hr per square meter of filter area (3 Ibs/hr/ft2), with
a solids capture of 95 percent.  It was assumed that the filter
was operated 8 hours/day.

Cost data were compiled for vacuum filters ranging from 0.9 to
69.7 m2 (9.4 to 750 ft2) in filter surface area.  Based on a
total annualized cost comparison, it was assumed that it was more
economical to directly contract haul clarifier underflow streams
which were less than 42 1/hr (0.185 gpm), rather than dewater by
vacuum filtration before hauling.
                               670

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The capital costs for vacuum filtration  include  the  following:

        Vacuum filter with precoat but no  sludge  conditioning,
        Housing, and
        Influent transfer pump.

Operating labor cost is the major component of annual  costs,
which also include maintenance and energy  costs.

Multimedia Filtration.  Multimedia filtration is  used  as  a
wastewater treatment polishing device to remove  suspended solids
not removed in previous treatment processes.  The filter  beds
consist of graded layers of gravel, coarse anthracite  coal,  and
fine sand.  The equipment used to determine capital  and annual
costs are as follows:

        Influent storage tank sized for one backwash volume;
        Gravity flow, vertical steel cylindrical  filters  with
        media (anthracite, sand, and garnet);
        Backwash tank sized for one backwash volume;
        Backwash pump to provide necessary flow  and  head  for
        backwash operations;
        Influent transfer pump; and
        Piping, valves, and a control system.

The hydraulic loading rate is 7,335 Iph/m2 (180 gph/ft2)  and
the backwash loading rate is 29,340 lph/m2 (720 gph/ft2).
The filter is backwashed once per 24 hours for lU minutes.  The
backwash volume is provided from the stored filtrate.

Effluent pollutant concentrations are based on the Agency's com-
bined metals data base for treatability of pollutants  by  filtra-
tion technology.

Cartridge-type filters are used to treat small flows (less than
800 liters/hour) since they are more economical compared  to
multimedia filters (based on a least total annualized  cost
comparison) at these flows.  It was assumed that  the effluent
quality achieved by cartridge-type filters was at least the  level
attained by multimedia filters.  The costs for cartridge-type
filters are based on a two-stage filter unit, a holding tank
(capacity is equal to the total batch volume of preceding batch
chemical precipitation tank) and an influent transfer  pump.

The majority of the annual cost is attributable  to replacement of
the spent cartridges which depends upon the amount of  solids
removed.  The maximum loading for each cartridge  is  assumed to be
0.225 kg of suspended solids.  The annual  energy  and maintenance
costs associated with the pump are also included  in  the total
annual costs.
                               671

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Contract Hauling.  Concentrated sludge and waste oils are removed
on a contract basis for off-site disposal.  The cost of contract
hauling depends on the classification of the waste as being
either hazardous or nonhazardous.  For nonhazardous wastes, a
rate of $0.106/liter ($0.40/gallon) was used in determining con-
tract hauling costs.  This value is based on reviewing informa-
tion from several sources, including a paint industry survey,
comments from the aluminum forming industry, and the literature.
The contract hauling cost for nonhazardous waste was used in this
cost estimation because the Agency believes that the wastes
generated from nonferrous metals forming plants are not hazardous
as defined under 40 CFR 261.   The capital cost associated with
contract hauling is assumed to be zero.

Chemical Emulsion Breaking.  Chemical emulsion breaking involves
the separation of relatively stable oil-water mixtures by chemi-
cal addition.  Alum, polymer, and sulfuric acid are commonly used
to destabilize oil-water mixtures.  In the determination of capi-
tal and annual costs based on continuous operation, 400 mg/1 of
alum and 2 mg/1 of polymer are added to waste streams containing
emulsified oil.  The equipment included in the capital and annual
costs for continuous chemical emulsion breaking are as follows:

        Alum and polymer feed systems:

        1.  Storage units
        2.  Dilution tanks
        3.  Conveyors and chemical feed lines
        4.  Chemical feed pumps

        Rapid mix tank (retention time of 15 minutes; mixer
        velocity gradient is 300/sec)

        Flocculatiori tank (retention time of 45 minutes;
        mixer velocity gradient is 100/sec)

        Pump

Following the flocculation tank, the destabilized oil-water mix-
ture enters the oil skimming module.  In the determination of
capital and annual costs based on batch operation, sulfuric acid
is added to waste streams containing emulsified oil until a pH of
3 is reached.  The following equipment is included in the deter-
mination of capital and annual costs based on batch operation:

        Sulfuric acid feed systems

        1.  Storage tanks or drums
        2.  Chemical feed lines
        3.  Chemical feed pumps
                               672

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        Two tanks equipped with  agitators  (retention  time  of
        8 hrs., mixer velocity gradient is 300/sec)

        Two belt oil skimmers

        Two waste oil pumps

        Two effluent water pumps

        One waste oil storage tank  (sized  to retain the waste
        oil from ten batches)

The capital and annual costs for  continuous and batch chemical
emulsion breaking were determined by summing the costs from the
above equipment.  Alum, polymer  and sulfuric acid  costs were
assumed to be $.257 per kg ($.118 per pound), $4.95 per kg ($2.25
per pound) and $0.08 per kg of 93 percent  acid  ($.037 per pound
of 93 percent acid), respectively.  (See Chemical Weekly
Reporter, March, 1982).

Operation and maintenance and energy costs for  the different
types of equipment which comprise the batch and continuous
systems were drawn from various  literature sources and are
included in the annual costs.

The cutoff flow for determining the operation mode (batch or con-
tinuous) is 5,000 liters per hour (1,321 gal/hr),  above which the
continuous system is costed; at lower flows, the batch system is
costed.

For annual influent flows to the  chemical  emulsion breaking sys-
tem of 91,200 liters/year (24,000 gallons/year) or less, it is
more economical to directly contract haul  rather than treat the
waste stream.  The breakpoint flow is based on a total annualized
cost comparison and a contract hauling rate of $.40/gallon (no
credit was given for oil resale).

Oil Skimming.  Oil skimming costs apply to the separation of oil-
water mixtures using a coalescent plate-type separator (which is
essentially an enhanced API-type oil-water separator).  Coales-
cent plate separators were not required following batch chemical
emulsion breaking since the batch tank, in conjunction with a
belt type oil skimmer, served as  the oil-water  separation tank.
The cost of the belt skimmer in this case was included as part of
the chemical emulsion breaking costs.

Although the required separator capacity is dependent on many
factors, the sizing was based primarily on the influent waste-
water flow rate, with the following design values assumed for the
remaining parameters of importance:
                               673

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     Parameter                          Nominal Design Value

     Specific gravity of oil                      0.85
     Operating temperature (°F)                  68
     Influent oil concentration (mg/1)       30,000

Extreme operating conditions, such as influent oil concentrations
greater than 30,000 mg/1, or temperatures lower than 68°F were
accounted for in the sizing of the separator.

The capital and annual costs of oil skimming included the follow-
ing equipment:

        Coalescent plate separator with automatic shutoff
        valve and level sensor
        Oily waste storage tanks (2-week retention time)
        Oily waste discharge pump
        Effluent discharge pump

Influent flow rates up to 159,100 1/hr (700 gpm) are costed for a
single unit; flows greater than 700 gpm require multiple units.

The direct annual costs for oil skimming include the cost of
operating and maintenance labor and replacement parts.  Annual
costs for the coalescent separators alone are minimal and involve
only periodic clean out and replacement of the coalescent plates.

Ammonia Steam Stripping.  This technology is used as a pretreat-
ment step to remove free ammonia (NH3) down to a treatability
level of 32.2 mg/1 by stripping with steam in a packed column.
The treatability concentration is based on actual performance
data at an iron and steel plant and verified by data from a
zirconium/hafnium metal manufacturing plant.  In the process, the
ammonia-laden wastewater is adjusted to a pH of 11.5 using lime
and contacted countercurrently in a packed column with steam.

The capital costs for ammonia steam stripping are based on the
following equipment:

        Column (hydraulic loading based on 2 gpm/ft^),

        pH adjustment system using lime

        1.  Rapid mix tank with agitator (5-minute retention
            time)
        2.  Lime feed system
        3.  Transfer pump

        Steam generation system

        1.  Reboiler (direct fired heat exchanger)
                               674

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        Heat exchangers  (influent preheat)

        Acid cleaning system

        1.  Surge tank
        2.  Agitator
        3.  Transfer pump

The direct annual costs  for ammonia steam stripping consist
mainly of chemical costs (for lime and sulfuric acid), energy
costs (for the reboiler, pumps, and agitators), and operating and
maintenance labor costs.

Chromium Reduction.  Chromium reduction refers to the reduction
of hexavalent chromium to the trivalent form.  Chromium in the
hexavalent state will not precipitate as a hydroxide until it has
been reduced to trivalent chromium.  For large flows (greater
than 2,000 1/hr) which undergo continuous treatment, the waste
stream is treated by addition of acid (to lower pH to 2.5) and
gaseous sulfur dioxide (SC^) dissolved in water in an agitated
reaction vessel.  The S02 is oxidized to sulfate (864) while
it reduces the chromium.  For smaller flows  (less than 2,000
1/hr), for which batch treatment is more appropriate, the waste
stream is treated by manual addition of sodium metabisulfite in
the same reaction vessel used for chemical precipitation.  The
chemistry of this operation is similar to that for S02 addi-
tion.

The equipment required for the continuous stream includes a S02
feed system (sulfonator), a H2S04 feed system, a reactor
vessel and agitator, and a pump.  The reaction pH is 2.5 and the
SO? dosage is a function of the influent loading of hexa-
valent chromium.  A conventional sulfonator  is used to meter
SO? to the reaction vessel.  The mixer velocity gradient is
100/sec.

Annual costs are as follows:

        S02 feed system

        1.  S02 cost at $0.55/kg ($0.25/lb),
        2.  Operation and maintenance labor requirements vary
            from 437 hrs/yr at 4.5 kg S02/day (10 Ibs S02/
            day) to 5,440 hrs/yr at 4,540 kg SC>2/day (10,000
            Ibs S02/day),
        3.  Energy requirements vary from 570 kwh/yr at 4.5 kg
            SOo/day (10 Ibs SOo/day) to 31,000 kwh/yr at
            4,540 kg S02/day (10,000 Ibs S02/day).
                               675

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     -  H2S04 feed system

        1.  Operating and maintenance labor at 72 hrs/yr at
            37.8 Ipd (10 gpd) of 93 percent H2S04 to 200
            hrs/yr at 3,780 Ipd (1,000 gpd), of 93 percent
            H2S04,
        2.  Maintenance materials at 3 percent of the equip-
            ment cost,
        3.  Energy requirements for metering pump and storage
            heating and lighting.

        Reactor vessel and agitator

        1.  Operation and maintenance labor at 120 hrs/yr,
        2.  Electrical requirements for agitator.

For batch treatment of hexavalent chromium with sodium metabisul-
fite, no equipment in addition to that required for chemical pre-
cipitation is assumed to be necessary.  Annual costs are based on
1/2 hour of labor per batch for chemical addition and testing.

Recycle of Cooling Water.  Cooling towers are used to recycle
casting and heat treatment contact cooling waters for recirculat-
ing flow rates above 3,400 1/hr (15 gpm).  The minimum flowrate
represents the smallest cooling tower commercially available from
the vendors contacted.  Conventional holding tanks are used to
recycle flowrates less than 15 gpm.

The cooling tower capacity is sized based on the amount of heat
removed, which takes into account both the flowrate and tempera-
ture range (or decrease in water temperature across the cooling
tower).  The amount of water recycled is equal to the difference
between the recirculation flowrate and the regulatory reduced
flow (discharge allowance).  The recirculation flow is equal to
the flow prior to recycling, i.e., the unreduced flow.  For cases
in which the actual flow is less than the regulatory reduced
flow, a cooling tower is not costed since flow reduction is not
required.

The range was based on a cold water temperature of 85°F and an
average hot water temperature for each particular waste stream
calculated from sampling data.  When the hot water temperature
was not available from sampling data, or found to be below 95°F,
a value of 95°F was assumed, resulting in a range of 10°F
(95-85°F).  The remaining significant design parameters, the wet
bulb temperature (ambient temperature at 100 percent relative
humidity) and the approach (of cold water temperature to the wet
bulb temp) are assumed to be constant at 75°F and 8 F,
respectively.
                               676

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The capital costs of cooling tower systems include the following
equipment:

        Cooling tower (crossflow, mechanically-induced) and
        typical accessories
        Piping and valves (305 meters (1000 ft.) carbon steel)
        Cold water storage tank  (1 hour retention time)
        Recirculation pump, centrifugal
        Chemical treatment system (for pH, slime and corrosion
        control)

For nominal recirculation flow rates greater than 159,100 1/hr
(700 gpm), multiple cooling towers are assumed to be required.

A holding tank system would consist of a holding tank and a
recirculation pump.

The direct capital costs include purchased equipment cost,
installation and delivery.  Installation costs for cooling towers
were assumed to be 200 percent of the cooling tower cost based on
information supplied by vendors.

Direct annual costs included raw chemicals for water treatment
and fan energy requirements.  Maintenance and operating labor was
assumed to be constant at 60 hours per year.  The water treatment
chemical cost was based on a rate of $5/gpm of recirculated
water.

Countercurrent Cascade/Spray Rinsing.   This technology is used
to reduce water use in rinsing operations.  It involves
multiple-stage rinsing, with product and rinse water moving in
opposite directions (see Section VII for more details on theory).
This allows for a significant reduction in flow over single stage
rinsing, while achieving the same product cleanliness by using
the most contaminated rinse water to rinse the incoming product.

The costs for Countercurrent cascade/spray rinsing apply to a
two-stage rinse system, each consisting of the following
equipment:

     o  Two fiberglass rectangular tanks (Existing source costs
        include only one tank since the other tank was assumed
        to be already in place).

     o  One spray rinsing system (nozzles, piping,
        instrumentation, etc.) if not in place,

     o  One centrifugal, transfer pump,

     o  One sparger (air diffuser) for agitation, and
                               677

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      o  One blower  (including motor)  for  supplying  air  to  the
        sparger.

Information reported in dcp's was used to estimate  the  volume  of
countercurrent rinse tanks.  If no  information was  available,
tank  volume was assumed to be 3,600 gallons, a typical  value.
When  it was determined from a plant's dcp that two-stage counter-
current cascade rinsing could be achieved by converting two
existing  adjacent rinse tanks, only piping, pump, and spray  rins-
ing costs were accounted for.  A constant value of  $1,000  was
estimated for the piping costs.

NONWATER QUALITY ASPECTS

The elimination or  reduction of one form  of pollution may  aggra-
vate  other environmental problems.  Therefore, Sections 304(b)
and 306 of the Act  require EPA to consider the nonwater quality
environmental impacts (including energy requirements) of certain
regulations.  In compliance with these provisions,  EPA  has con-
sidered the effect  of this regulation on air pollution, solid
waste generation, water scarcity, and energy consumption.  This
regulation was circulated to and reviewed by EPA personnel
responsible for nonwater quality environmental programs.   While
it is difficult to balance pollution problems against each other
and against energy utilization, the Administrator has determined
that  the impacts identified below are justified by  the  benefits
associated with compliance with the limitations and standards  in
this  guideline.  The following are the nonwater quality environ-
mental impacts (including energy requirements) associated with
compliance with the nonferrous metals forming regulation.

Air Pollution

Imposition of BPT, BAT,  BCT, NSPS, PSES, and PSNS will  not create
any substantial air pollution problems because the  wastewater
treatment technologies required to meet these limitations  and
standards do not cause air pollution.

Solid Waste

EPA estimates that  nonferrous metals  forming facilities generated
14,000 kkg (15,400 tons) of solid wastes  (wet basis) in 1981 as a
result of wastewater treatment-in-place.  These wastes  were  com-
posed of treatment system sludges containing toxic  metals,
including antimony, cadmium, chromium, copper, lead, nickel, and
zinc.

EPA estimates that the proposed BPT will generate an additional
3,900 kkg (4,300 tons) per year of solid wastes.  The proposed
BAT will increase these wastes by approximately 5.9 kkg (6.5
                               678

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tons) per year beyond BPT levels.  PSES will  increase these
wastes by approximately 9,900 kkg  (10,900 tons) per year beyond
current levels.  New nonferrous metals forming plants subject to
PSNS/NSPS would also generate treatment system sludges.  These
sludges will necessarily contain additional quantities  (and  con-
centrations) of toxic metal pollutants.

Wastes generated by nonferrous metal formers  are subject to  regu-
lation under Subtitle C of the Resource Conservation and Recovery
Act  (RCRA) if they are hazardous.  However, the Agency  examined
solid wastes similar to those that would be generated at nonfer-
rous metals forming plants by the suggested treatment technol-
ogies (that is, the sludges from lime and settle treatment)  and
believes they are not hazardous wastes under  the Agency's regula-
tions implementing Subtitle C of RCRA.  None  of these wastes are
specifically listed as hazardous, nor are they likely to exhibit
one  of the four characteristics of hazardous  waste (see 40 CFR
Part 261) based on the recommended technology of chemical pre-
cipitation and sedimentation, preceded where  necessary  by hexa-
valent chromium reduction.  By the addition of a small  excess of
lime during treatment, similar sludges, specifically toxic metal
bearing sludges generated by other industries such as the iron
and  steel industry passed the Extraction Procedure (EP) toxicity
test (see 40 CFR 261.24).  Thus, the Agency believes that nonfer-
rous metals forming wastewater treatment sludges will similarly
not be EP toxic if the recommended technology is applied.

The Agency is not proposing an allowance for  discharge  of spent
solvents from the solvent degreasing operations at nonferrous
metals forming plants.  Disposal of the spent solvent may be sub-
ject to regulation under RCRA.  However, no plant in the nonfer-
rous metals forming industry is known to currently discharge the
spent solvents.  Therefore, the cost of disposal of the spent
solvents has not been included in estimating  the cost of this
proposed regulation because all plants which  use solvent degreas-
ing have already incurred those costs.

The Agency is proposing a no discharge requirement for  tube-
reducing spent lubricants because, based on analytical  data  for
that waste stream at one plant sampled, the waste stream contains
treatable levels of N-nitrosodiphenylamine.   That waste stream
would have to be disposed of as a solid waste.  The Agency has
not  estimated the cost of that disposal but expects it  to be
quite small because the waste stream flow is  quite small.

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 262.10).  The Agency also may list these wastes  as
hazardous under 40 CFR 261.11.
                               679

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If these wastes are hazardous, as  defined by RCRA, they will  come
within the scope of RCRA's "cradle to grave" hazardous waste  man-
agement program, requiring regulation from the point of genera-
tion to point of final disposition.  EPA's generator standards
require generators of hazardous nonferrous metals  forming wastes
to meet containerization, labelling, recordkeeping, and reporting
requirements; if plants dispose of hazardous wastes off-site,
they 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).
The transporter regulations require transporters of hazardous
wastes to comply with the manifest system to assure that the
wastes are delivered to a permitted facility (see  40 CFR 263.20).
Finally, RCRA regulations establish standards for  hazardous waste
treatment, storage, and disposal facilities allowed to receive
such wastes (see 40 CFR Part 264).

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 Section 4004 of RCRA (see 44 FR
53438, September 13, 1979).  The Agency has calculated as part of
the costs for wastewater treatment the cost of hauling and dis-
posing of these wastes.

Consumptive Water Loss

Treatment and control technologies that require extensive recy-
cling and reuse of water may require cooling mechanisms.  Evapo-
rative cooling mechanisms can cause water loss and contribute to
water scarcity problems--a primary concern in arid and semi-arid
regions.  While this regulation assumes water reuse, the overall
amount of reuse through evaporative cooling mechanisms is low and
the quantity of water involved is not significant.  In addition,
most nonferrous metals forming plants are located  east of the
Mississippi where water scarcity is not a problem.  The Agency
has concluded that consumptive water loss is insignificant and
that the pollution reduction benefits of recycle technologies
outweigh their impact on consumptive water loss.

Energy Requirements

EPA estimates that the achievement of BPT effluent limitations
will result in a net increase in electrial energy  consumption of
approximately 3.9 million kilowatt-hours per year.  The addi-
tional electricity would be used for extra pumps or agitators.
The BAT effluent technology should not substantially increase the
energy requirements of BPT because reducing the flow reduces  the
pumping requirements, the agitation requirement for mixing waste-
water, and other volume-related energy requirements.  Therefore,
                               680

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the BAT limitations are assumed to require an equivalent energy
consumption to that of the BPT limitations.  To achieve the BPT
and BAT effluent limitations, a typical direct discharger will
increase total energy consumption by 110,000 kilowatt-hours per
year.

The Agency estimates that PSES will result in a net increase in
electrical energy consumption of approximately 6.0 million
kilowatt-hours per year.  To achieve PSES, a typical existing
indirect discharger will increase energy consumption by 50,000
kilowatt-hours per year.
                               681

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           Input
        User-Specified
         Variables
                  Figure  VIII-1
GENERAL LOGIC  DIAGRAM OF COMPUTER COST  MODEL
                       682

-------
                        FLOW AND
                      CONCENTRATIONS
                      FROM PREVIOUS
                         MODULE
    DATA FROM
    PREVIOUSLY
    UNTREATED
   WASTEWATER
                         SPECIFY
                       CONSTANTS.
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                         STREAMS
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                         DESIGN
                         VALUES
                          HAS
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                          OYO
                       WANT DESIGN
                        VALUES TO
                          PRINT?
                      PRINT MATERIAL
                      BALANCES AND
                      DESIGN VALUES
                        GO TO NEXT
                         MODULE
                   Figure  VIII-2
LOGIC  DIAGRAM  OF  MODULE  DESIGN PROCEDURE
                         683

-------
                        DESIGN VALUES
                      AND CONFIGURATION
                        FROM MATERIAL
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                             I
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 MODULE 1
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 MODULE 2
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                                                      1
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                       Figure  VIII-3
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                             684

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                           Table VIII-2

                COST PROGRAM POLLUTANT PARAMETERS
       List A
Pollutant Parameters

Flowrate
pH
Temperature
Total Suspended Solids
Acidity (as CaC03>
Aluminum
Ammonia
Antimony
Arsenic

Cadmium
Chromium (trivalent)
Chromium (hexavalent)
Cobalt
Copper
Cyanide (free)
Cyanide (total)
Fluoride
Iron
Lead

Manganese

Nickel
Oil and Grease
Phosphorus
Selenium
Silver

Thallium
Zinc
      List B
Pollutant Parameters

Flowrate
PH
Temperature
Total Suspended Solids
Acidity (as CaC03)
Aluminum
Ammonia
Antimony
Arsenic
Beryllium
Cadmium
Chromium (trivalent)
Chromium (hexavalent)

Copper
Cyanide (free)
Cyanide (total)
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Iron
Lead
Magnesium

Misc. Metals*
Nickel
Oil and Grease

Selenium
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Sulfate
Thallium
Zinc
Units

liters/hour
pH units
*F
mg/1
mg/1
mg/1
mg/1
mg/1
mg/1
mg/1
mg/1
mg/1
mg/1
mg/1
mg/1
mg/1
mg/1
mg/1
mg/1
mg/1
mg/1
mg/1
mg/1
mg/1
mg/1
mg/1
mg/1
mg/1
mg/1
mg/1
mg/1
Note:  List A pollutant parameters used to cost plants in all
       groups except 6, 14, 17, 18, 22, and 23.

Note:  List B pollutant parameters used to cost plants in groups
       6, 14, 17, 18, 22, and 23.

* Includes bismuth, cobalt, columbium, hafnium, molybdenum,
  tantalum, tin, titanium, tungsten, uranium, and vanadium.
                               687

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-------
                Table VIII-6

       WASTEWATER SAMPLING FREQUENCY
Wastewater Discharge
  (Liters Per Day)

       0  -  37,850

  37,851  - 189,250

 189,251  - 378,500

 378,501  - 946,250

 946,250+
Sampling Frequency

Once per month

Twice per month

Once per week

Twice per week

Three times per week
                    694

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                            SECTION IX

                BEST PRACTICABLE CONTROL TECHNOLOGY
                        CURRENTLY AVAILABLE


This section defines the effluent characteristics attainable
through the application of best practicable control technology
currently available (BPT), Section 301(b)(1)(A).  BPT represents
the average of the best existing performance by plants of various
sizes, ages, and manufacturing processes within the nonferrous
metals forming category.  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 employed, nonwater
quality environmental impacts (including energy requirements),
and other factors the Administrator considers appropriate.  In
general, the BPT level represents the average of the best exist-
ing performances of plants of various ages, sizes, processes, or
other common characteristics.  Where existing performance is uni-
formly inadequate, BPT may be transferred from a different sub-
category or category.  Limitations based on transfer of technol-
ogy 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.
Ty7b).  BPT focuses on end-of-pipe treatment rather than process
changes or internal controls, except where such practices are
common industry practice.

TECHNICAL APPROACH TO BPT

The objective of BPT effluent limitations is to reduce the total
quantity of pollutants discharged into surface waters.  Because
olants could meet a concentration-based standard by dilution
rather than treatment, mass limitations have been developed for
the nonferrous metals forming industry.   In order for regulations
to be equitable for plants with large productions and small pro-
ductions, the mass limitations must be normalized by an appropri-
ate unit of production called a production normalizing parameter
(PNP).  As discussed in Section IV, the PNP for the nonferrous
metals forming category is off-metric ton (the metric tons of
metal removed from a forming operation or associated operation at
the end of a process cycle).  Pollutant discharge limitations for
this category are written as mass loadings, allowable mass of
pollutant discharge per off-metric ton of production (mg/kkg).
                               695

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Mass loadings were calculated for each operation within each sub-
category.  This calculation was made on an operation-by-operation
basis because plants in this category may perform one or more
operations in one or more subcategories.

The pollutant discharge limitation for each operation was calcu-
lated by multiplying the production normalized wastewater flow
(1/kkg or gal/ton) for that operation by the effluent concentra-
tion achievable by the BPT treatment technology (mg/1).

Effluent Limitations

EPA conducted a screen sampling program to determine which pollu-
tants are found in wastewaters generated by the nonferrous metals
forming category.  This program and its results are described in
Section V of this document.

Oil and grease, suspended solids,  toxic metals, and nonconven-
tional pollutants are present in significant concentrations in
wastewater produced by the major forming operations (rolling,
drawing, extruding, and forging),  minor forming operations (clad-
ding, tube reducing, metal powder production and powder metal-
lurgy) and by operations associated with metal forming (casting,
heat treatment, surface treatment, alkaline cleaning, solvent
degreasing, sawing, grinding, tumbling, burnishing, and product
testing).  Although the specific toxic metals present will vary
from subcategory to subcategory, the Agency believes that one
treatment technology with preliminary treatment, where necessary,
is an appropriate basis for BPT effluent limitations for all
subcategories.

Treatment Train

The Agency evaluated several end-of-pipe and in-process tech-
nologies to determine how suitable they are for controlling the
pollutants detected in the sampling program (see Section VII).
One of these treatment trains was selected as BPT:  lime precipi-
tation and sedimentation (L&S), with preliminary treatment, where
necessary (see Figure IX-1).  This treatment will remove toxic
metals, cyanide, nonconventional pollutants, oil and grease, and
TSS.  Currently, this technology is in place at 24 of the 39
direct dischargers in the category.

Preliminary treatment is required when lime precipitation and
sedimentation alone will not adequately remove regulated pollu-
tants.  The preliminary treatments required in this category
(chemical emulsion breaking, oil skimming, chromium reduction,
cyanide precipitation, and ammonia steam stripping) are described
in Section VII.  Preliminary treatments potentially required by
each regulated waste stream are listed in Tables IX-1 through
IX-11.
                               696

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Whether preliminary treatment is required at  a particular plant
will be decided by each NPDES permitting authority on a  case-by-
case basis.  Preliminary treatment of wastewater  is  only required
when the pollutant controlled by the preliminary  treatment is
present above the treatment effectiveness concentration  given  in
Section VII.  Specifically:

        Oil skimming is required when oil and grease is  present
        in  a concentration greater than the treatment effective-
        ness (L&S technology) given in Table VII-9.

        Chemical emulsion breaking is always  followed by oil
        skimming.  It is required when oil and grease in an
        emulsified form is present in a concentration greater
        than the treatment effectiveness (L&S technology) given
        in Table VII-9.

        Ammonia steam stripping is required when  ammonia-nitrogen
        is present in a concentration greater than the treatment
        effectiveness given in Table VII-9.

        Cyanide precipitation is required when cyanide is present
        in a concentration greater than the treatment effective-
        ness given in Table VII-9.

        Chromium reduction is required when hexavalent chromium
        is present in a concentration greater than the treatment
        effectiveness (LScS technology) given in Table VII-9.   If
        chromium is already in the trivalent oxidation state,
        further chromium reduction is not required.

Effluent Concentrations

Table VII-9 presents the effluent concentrations  achievable by
the BPT treatment train for the pollutants regulated in  each sub-
category.   These concentrations are based on the  performance of
chemical precipitation and sedimentation (lime and settle) when
applied to a broad range of metal-bearing wastewaters.   The deri-
vation of these achievable effluent concentrations is discussed
in substantial detail in Section VII.

Discharge Flows

EPA used the dcp data for each process within each subcategory to
determine (1) whether or not the process generated wastewater,
(2) the specific flow rate generated, and (3) the specific pro-
duction normalized flows for the process.

The normalized flows were then analyzed to determine which flow
was to be used as part of the basis for BPT mass  limitations.
                              697

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The  selected  flow  (referred  to  as  the BPT regulatory  flow  or BPT
flow) reflects the water use controls which are  common  practices
within the  industry.  The overall  effectiveness  of  end-of-pipe
treatment for the removal of wastewater pollutants  is improved  by
the  application of water flow controls within  the process  to
limit the volume of wastewater  requiring treatment.  However, the
controls or in-process technologies recommended  under BPT  include
only those measures which are commonly practiced within  the cate-
gory or subcategory.  Except for recycle of lubricating  emul-
sions, most plants in this category do not have  flow reduction
in-place.  Therefore, flow reduction is not generally included  as
part of the BPT technology.

The BPT normalized flow is based on the average  of  all  applicable
data.  Plants with existing  flows  above the average may  have to
implement some method of flow reduction to achieve  the BPT limi-
tations.  In  most cases, this will involve improving housekeeping
practices, better maintenance to limit water leakage, or reducing
excess flow by turning down  a flow valve.  It  is not believed
that these modifications would  generate any significant  costs for
the plants.   In fact, these  plants would save  money by  reducing
water consumption.

Although BPT  limitations apply  only to plants  which discharge
wastewater directly, direct  and indirect dischargers have  been
considered as a single group in making technical assessments of
data, reviewing manufacturing processes, and evaluating waste-
water treatment technology options.  An examination of plants and
processes did not indicate any  process differences  based on the
type of discharge, whether it be direct or indirect.  Conse-
quently, the  calculation of  the BPT regulatory flow included
normalized flows from both direct and indirect dischargers.

Regulated Pollutant Parameters

Pollutant parameters were selected for regulation in the nonfer-
rous metals forming subcategories because of their  frequent pres-
ence at treatable concentrations in raw wastewaters.  Total sus-
pended solids, oil and grease,  and pH were selected for  regula-
tion in each subcategory.  Toxic metals are also regulated in
every subcategory, though the specific metals  regulated  vary.
The pollutants selected for regulation under BPT in each subcate-
gory and the  reasons for their  selection are described  in  Section
VI.

Total suspended solids, in addition to being present at: high con-
centrations in raw wastewater from nonferrous  metals  forming
operations, is an important control parameter  for metals removal
in chemical precipitation and settling treatment systems.  Metals
are precipitated as insoluble metal hydroxides,  and effective
                               698

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solids removal is required in order to ensure reduced  levels  of
regulated toxic metals in the treatment system effluent.  There-
fore, total suspended solids are regulated  as a  conventional  pol-
lutant to be removed from the wastewater prior to discharge.

Oil and grease is regulated under BPT since a number of nonfer-
rous metals forming operations  (i.e., rolling, sawing/grinding,
drawing, and extrusion) generate emulsified wastewater streams
which may be discharged.

The importance of pH control is documented  in Section VII and its
importance in metals removal technology cannot be overemphasized.
Even small excursions from the  optimum pH level  can result  in
less than optimum functioning of the treatment system and inabil-
ity to achieve specified results.  The optimum operating  level
for removal of most metals is usually pH 8.8 to  9.3.  However,
nickel, cadmium, and silver require higher pH for optimal
removal.  To allow a reasonable operating margin and to preclude
the need for final pH adjustment, the effluent pH is specified to
be within the range of 7.5 to 10.

The remainder of this section describes the development of BPT
mass loadings for each subcategory.  The development of BPT regu-
latory flow for each operation  in each subcategory is presented
in detail.  The pollutants regulated and the cost and benefit of
their regulation at BPT are also listed.

LEAD/TIN/BISMUTH FORMING SUBCATEGORY

Production Operations and Discharge Flows

Rolling

The following information was reported on rolling operations  in
this subcategory:

Number of plants:  25
Number of operations:  25
Number of operations using emulsion lubricant:   7
Number of operations using soap solution lubricant-coolant:   1
Number of operations using no lubricant:  17.

Rolling Spent Emulsions.  All of the operations  using rolling
emulsions completely recycle the emulsions and periodically bat*.'h
dump them when they become spent.  The spent emulsion  from  one
operation is incinerated; the spent emulsion from one operation
is applied to land; and the spent emulsion  from  five operations
is contract hauled.  Spent emulsions which are contract hauled
off-site typically receive some type of emulsion breaking  (chemi-
cal or thermal) and oil skimming treatment.  After this treatment
                               699

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the water  fraction is discharged and the oil  fraction  is  either
sent to a  reclaiming operation or  landfilled  directly.  Since  the
spent emulsions could be treated on-site and  the water  discharged
(with the  oil fraction contract hauled), the BPT discharge  allow-
ance is 23.3 1/kkg (5.60 gal/ton), the average of  the  six
reported values.

Rolling Spent Soap Solutions.  The one operation using  rolling
soap solutions applies and discharges 43.0 1/kkg (10.3  gal/ton).
Therefore, the BPT discharge allowance is 43.0 1/kkg (10.3
gal/ton).

Drawing

The following information was reported on drawing  operations in
this subcategory:

Number of  plants:   18
Number of  operations:  20
Number of  operations using neat oil lubricant:  3
Number of  operations using emulsion lubricant:  7
Number of  operations using soap solution lubricant-coolant:  2
Number of  operations using no lubricant:  8.

Drawing Spent Neat Oils.  None of  the three operations  using neat
oils discharge any of the lubricant.   Two achieve  zero  discharge
through recirculation with drag-out on the product and  one  con-
tract hauls batches of the spent neat oils periodically.  Since
neat oils  are pure oil streams, with no water fraction, it  is
better to  remove the oil directly and not to discharge  the  stream
than to commingle the oil with water streams and then remove it
later.  Therefore, the BPT discharge allowance is  zero.

Drawing Spent Emulsions.  Six of the seven operations using an
emulsion asa lubricant achieve zero discharge.  One operation
discharges periodically to a POTW.   Four of the six operations
reporting  zero discharge achieve 100 percent recycle of the
emulsions with drag-out on the product surface being the  only
loss, while two operations report  contract hauling the  spent
emulsions  after periodic batch dumps.  Spent emulsions  which are
contract hauled off-site typically receive some type of emulsion
breaking (chemical or thermal) and oil skimming treatmemt.  After
this treatment, the water fraction is discharged and the  oil
fraction is either sent to a reclaiming operation or landfilled
directly.  Since the spent emulsions could be treated on-site  and
the water  discharged (with the oil fraction contract hauled),  the
BPT discharge allowance is 16.7 1/kkg (4.00 gal/ton), the only
reported non-zero discharge value.

Drawing Spent Soap Solutions.  One of the two operations  using
soap solutions as a drawing lubricant periodically discharges  the
                              700

-------
solution.  The other operation achieves zero discharge through
recirculation with drag-out on the product.  The BPT discharge
allowance is 7.46 1/kkg  (1.79 gal/ton), the one reported non-zero
discharge value.

Extrusion

The following information was reported on extrusion operations in
this subcategory:

Number of plants:  43
Number of operations:  50
Number of operations using contact cooling water:  18
Number of dry operations:  32.

Extrusion Press and Solution Heat Treatment Contact Cooling
Water.  As discussed in Section III, contact water is used in
extrusion operations to accomplish a heat treatment effect,
either by spraying water onto the metal as it emerges from the
die or press, or by direct quenching in a contact water bath.
Three operations achieve zero discharge by 100 percent recycle;
one operation achieves zero discharge by evaporation; and one
operation achieves zero discharge by contract hauling the contact
cooling water.  A discharge with no recycle is reported for 13
extrusion operations.  No water use data were reported for one of
the operations.  The BPT discharge allowance is the average of
the 12 reported non-zero discharge values, 1,750 1/kkg (419
gal/ton).

Extrusion Press Hydraulic Fluid Leakage.  One of the 43 plants
with extrusion operations discharges Hydraulic fluid leakage from
an extrusion press.  However, the Agency believes that other
plants in the lead/tin/bismuth forming subcategory use similar
extrusion presses and have leakage.  The BPT discharge allowance
is based on the one reported value, 49.3 1/kkg (11.8 gal/ton).

Casting

The following information was reported on casting operations in
this subcategory:

Total number of plants:  34
Total number of operations:  43

Number of plants and operations with continuous strip casting:  6
     Number using contact cooling water:  5
     Number dry:  1
                               701

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Number of plants and operations with semi-continuous ingot
casting:  2
     Number using contact cooling water:  2

Number of plants and operations with shot casting:  3
     Number using contact cooling water:  3

Number of plants and operations with continuous wheel casting:  1
     Number dry:  1

Number of plants and operations with continuous sheet casting:  1
     Number dry:  1

Number of plants and operations with stationary casting  (also
referred to as chill casting and mold casting):  26 plants,
28 operations
     Number dry:  28

Number of plants and operations with shot pressing:  2
     Number dry:  2.

Continuous Strip Casting Contact Cooling_ Water.  In five of the
six operations the cooling water is completely recycled  and peri-
odically batch dumped.   One operation uses only noncontact cool-
ing water.  The BPT discharge allowance is the average of the
five reported values, 1.00 1/kkg (0.240 gal/ton).

Semi-Continuous Ingot Casting Contact Cooling Water.  Water use
and discharge data were reported for only one operation.  Based
on the one reported value, the BPT discharge allowance is 29.4
1/kkg (7.04 gal/ton).

Shot Casting Contact Cooling Water.  In all three operations, the
wastewater is periodically dumped.   The average of the two
reported discharge values is the BPT discharge allowance, or 42.0
1/kkg (10.1 gal/ton).

Shot-Forming Wet Air Pollution Control Blowdown.   One plant
reported having a wet scrubber with no recycle to control air
pollution from the lead polishing and drying unit operations of a
shot-forming line.  The BPT discharge allowance is the reported
value by that one plant, 0.086 1/kkg (0.021 gal/ton).

Alkaline Cleaning

Four plants provided information on six alkaline cleaning opera-
tions.  Five of the operations consist of a bath followed by a
single stage rinse; one of the operations is a single stage
bath/rinse which is periodically batch dumped.
                               702

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Alkaline Cleaning Spent Baths.  Spent baths are discharged  from
six alkaline cleaning operations.  No water use data were
reported for one of the operations.  The BPT discharge allowance
is 606 1/kkg (145 gal/ton), the average of the five reported
values.

Alkaline Cleaning Rinsewater.  Five alkaline cleaning operations
discharge rinsewater with no recycle.  The BPT discharge allow-
ance is 6,460 1/kkg (1,550 gal/ton), the average of the five
values.

Swaging

The following information was reported on swaging operations in
this subcategory:

Number of plants:  5
Number of operations:   6
Number of operations using emulsion lubricant:  4
Number of operations using no lubricant:  2.

Swaging Spent Emulsions.  Three of the four swaging operations
which use lubricants achieve zero discharge by 100 percent  recy-
cle, with evaporation and drag-out on the product surface being
the only losses.  Spent emulsion is batch discharged from the
other operation.  Spent emulsions which are contract hauled off-
site typically receive some type of emulsion breaking (chemical
or thermal) and oil skimming treatment.  After this treatment the
water fraction is discharged and the oil fraction is either sent
to a reclaiming operation or landfilled directly.  Since the
spent emulsions could be treated on-site and the water discharged
(with the oil fraction contract hauled), the BPT discharge  allow-
ance is 1.77 1/kkg (0.424 gal/ton), the only reported non-zero
discharge value.

Degreasing

A small number of surveyed plants with solvent degreasing opera-
tions have process wastewater streams associated with the opera-
tion.  These facilities may use a water rinse after solvent
degreasing, or discharge solvent recovery sludge to the facil-
ity's oil treatment system.  Because most plants practice solvent
degreasing without wastewater discharge, the Agency believes zero
discharge of wastewater is an appropriate discharge limitation.

Miscellaneous Nondescript Wastewater

Several low volume sources of wastewater were reported in dcp s
and observed during the site and sampling visits.  Because  these
sources generally represent low volume periodic discharges  appli-
cable to most plants,  the Agency has combined these individual
                               703

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wastewater sources under the term  "miscellaneous nondescript
wastewater".  The wastewater included in this allowance  is  from
maintenance  and cleanup, autoclave contact cooling water, and
final product lubrication.  The BPT discharge allowance  for
wastewater from these  sources is the sum of the three reported
values  for these sources, 58.4 1/kkg (14.0 gal/ton).

Calculation  of BPT Effluent Mass Limitations

The pollutants regulated in the lead/tin/bismuth forming subcate-
gory are antimony, lead, oil and grease, TSS, and pH.  The BPT
mass limitations for these pollutants are listed in Section II,
Part 2, Subpart B.  These limitations were calculated by multi-
plying  the BPT normalized flow (1/kkg,  summarized in Table IX-12)
by the  one-day maximum and 10-day  average effluent concentration
(mg/1)  for each pollutant achievable using the BPT treatment
system  (Table VTI-9).  The 10-day  average is used to calculate
the maximum  monthly average because, as discussed in Section VII,
it provides  a reasonable basis for a monthly average and is typi-
cal of  the sampling frequency required by discharge permits.

Costs andBenefits

In establishing BPT, EPA must consider the cost of treatment and
control in relation to the incremental increase in mass  of pollu-
tants removed from wastewater (benefits).  The application of BPT
to direct dischargers will remove  approximately 5,222.3 kg/yr
(11,513.2 Ib/yr) of pollutants from estimated current discharge
levels.  The corresponding capital and annual costs (1982 dol-
lars) for this removal are $21,100 and $30,300 per year, respec-
tively.  The Agency concludes that these pollutant removals jus-
tify the costs incurred by plants  in the lead/tin/bismuth forming
subcategory.

NICKEL/COBALT FORMING  SUBCATEGORY

Production Operations  and Discharge Flows

Rolling

The following information was reported on rolling operations in
this subcategory:

Number of plants:   26
Number  of operations:  43
Number  of operations using neat oil lubricant:  6
Number  of operations using emulsion lubricant:  11
Number of operations using soap solution lubricant-coolant:  7
Number  of operations using no lubricant:  19.
                               704

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Rolling Spent Neat Oils.  The neat oils in five of the operations
are consumed during the rolling operation, while the neat oils in
the other operation are contract hauled.  Since neat oils are
pure oil streams, with no water fraction, it is better to remove
the oil directly and not to discharge the stream than to com-
mingle the oil with water streams and then remove it later.
Consequently, the BPT discharge allowance is zero.

Rolling Spent Emulsions.  No discharge data are available for
seven of the 11 operations.  As discussed previously for rolling
spent emulsions in the lead/tin/bismuth forming subcategory, the
spent emulsions could be treated on-site and the water discharged
(with the oil fraction contract hauled).  Therefore, the average
of the four reported discharge values is the BPT discharge allow-
ance, 1,490 1/kkg (357 gal/ton).

Rolling Contact Lubricant-Coolant Water.  Complete recirculation
of this water was reported for five o£ the operations.  The aver-
age of the two reported discharge values is the BPT discharge
allowance, 13,400 1/kkg (3,210 gal/ton).

Rolling Solution Heat Treatment Contact Cooling Water.  One plant
reported using contact cooling water for heat treatment purposes
in one rolling operation.   The BPT discharge allowance, based on
this one reported value, is 0.271 1/kkg (0.065 gal/ton).
       ^

Tube Reducing

Two plants reported information on two tube reducing (also
referred to as pilgering)  operations.  Lubricants are used in
both operations.

Tube Reducing Spent Lubricants.  Tube reducing spent lubricants
were sampled at one plant.  Analysis of this stream showed treat-
able concentrations of N-nitrosodiphenylamine, a toxic organic
pollutant.  The most economical handling of this stream is to
intercept it before mixing with other process wastewaters and
transport it to off-site treatment or disposal.  Because this is
the only waste stream in the category with a significant concen-
tration of an organic pollutant, treatment of this stream (with
activated carbon) after mixing with other process wastewaters
would be much more expensive.  For this reason, and because the
Agency believes the potentially carcinogenic properties of
nitrosamines justify prohibiting its discharge, the BPT discharge
allowance for tube reducing spent lubricants is zero.

Drawing

The following information was reported on drawing operations in
this subcategory:
                               705

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Number of plants:  23
Number of operations:  29
Number of operations using neat oil lubricant:  9
Number of operations using emulsion lubricant:  4
Number of operations using no lubricant:  16.

Drawing Spent Neat Oils.  The neat oils in three of the opera-
tionsare consumed during the drawing process while the neat oils
in the remaining six operations are contract hauled or lost in
drag-out.  As discussed previously for drawing spent neat oils in
the lead/tin/bismuth forming subcategory, it is better to remove
the neat oils directly and not to discharge the stream.  There-
fore, the BPT discharge allowance is zero.

Drawing^ Spent Emulsions.  No specific information was reported on
recycle practices or batch dumping frequencies for drawing spent
emulsions in this subcategory.  As discussed previously for draw-
ing spent emulsions in the lead/tin/bismuth forming subcategory,
the spent emulsions could be treated on-site and the water dis-
charged (with the oil fraction contract hauled).  Therefore, the
BPT discharge allowance is the average of the three reported
discharge values, 95.4 1/kkg (22.9 gal/ton).

Extrusion

The following information was reported on extrusion operations in
this subcategory:

Number of plants:  7
Number of operations:  7
Number of operations using a lubricant:  3*
Number of operations using contact cooling water:  2*
Number of dry operations:  3.

*0ne operation uses a lubricant and contact cooling water.

Extrusion Spent Lubricants.  Lubricants are completely recycled
in two operations, with the only loss occurring through drag-out;
one operation discharges to a septic tank.  The extrusion lubri-
cants which are used are typically neat oils.  Since neat oils
are pure oil streams, with no water fraction, it is better to
remove the oil directly and not to discharge the stream than to
commingle the oil with water streams and then remove it later.
Therefore, the BPT discharge allowance is zero.

Extrusion Press and Solution Heat Treatment Contact Cooling
Water.As discussed in Section III,contact water is used in
extrusion operations to accomplish a heat treatment effect,
either by spraying water onto the metal as it emerges from the
die or press, or by direct quenching in a contact water bath.
                               706

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Contact cooling water in one of the operations is completely
recycled and periodically batch dumped; the other operation
discharges with no recycle.  The average of the two reported
values is the BPT discharge allowance, 83.2 1/kkg (20.0 gal/ton).

Forging, Extrusion, and Isostatic Press Hydraulic Fluid Leakage.
Hydraulic pressesin the nickel/cobalt forming subcategory are
used in forging, extrusion, and isostatic pressing operations.
Discharge of hydraulic fluid leakage was reported from presses
for all three of these operations.  The Agency has combined these
discharges under the term "forging, extrusion, and isostatic
press hydraulic fluid leakage".  The average of the two reported
values is the BPT discharge allowance, 124 1/kkg (29.7 gal/ton).

Forging

The following information was reported on forging operations  in
this subcategory:

Number of plants:   25
Number of operations:  31
Number of operations using neat oil lubricant:  3
Number of operations using die contact cooling water:  3
Number of dry operations:  25.

Forging and Swaging Spent Neat Oils.  The neat oils from all
three operations are contract hauled.  Since neat oils are pure
oil streams, with no water fraction, it is better to remove the
oil directly and not to discharge the stream than to commingle
the oil with water streams and then remove it later.   Therefore,
the BPT discharge allowance is zero.

Forging Die Contact Cooling Water.  In all three operations,  no
water is recycled.  The average of the three reported values  is
the BPT discharge allowance, 1,260 1/kkg (302 gal/ton).

Forging Equipment Cleaning Wastewater.  One plant reported using
water to clean the equipmentin itsForging operation.  The BPT
discharge allowance, based on the one reported value, is 1,630
1/kkg (390 gal/ton).

Casting

The following information was reported on casting operations  in
this subcategory:

Total number of plants:  11
Total number of operations:   16
                               707

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Number of plants and operations with stationary and direct chill
casting:  10 plants, 12 operations
  Number using contact cooling water:  2
  Number dry:  10

Number of plants and operations with vacuum melting and cast-
ing:  2
  Number of plants with vacuum melting steam condensate:  1
  Number dry:  1

Number of plants and operations with electroflux remelting:  2
  Number dry:  2.

Stationary and Direct Chill Casting Contact Cooling Water.
Complete recirculation occurs in both operations and the cooling
water is periodically batch dumped.  The BPT discharge allowance,
based on the one reported value, is 17,800 1/kkg (4,280 gal/ton).

Vacuum Melting Steam Condensate.  Information was reported on one
vacuum melting operation which generates a waste stream from
steam condensate.  The water is completely recycled with a small
periodic bleed.  The BPT discharge allowance, based on the one
reported value, is 168 1/kkg (40.4 gal/ton).

Metal Powder Production

The following information was reported on metal powder production
in this subcategory:

Number of plants:  5
Number of operations:  6
Number of wet atomization operations:  3
Number of dry atomization operations:  3.

Metal Powder Production Atomization Wastewater.  One operation
has no available discharge data.The BPT discharge allowance is
the average of the two reported values, 2,840 1/kkg (680
gal/ton).

Solution Heat Treatment

The following information was reported on solution heat treatment
operations in this subcategory:

Number of plants:  29
Number of operations:  48
Number of operations using contact cooling water:  20
Number of dry operations:  28.
                               708

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Solution Heat Treatment Contact Cooling Water.  Five operations
achieve zero discharge by complete recirculation; one operation
achieves zero discharge by evaporation.  No discharge data are
available for eight of the operations.  The BPT discharge allow-
ance is the average of the six reported discharge values, 4,570
1/kkg (1,100 gal/ton).

Wet Air Pollution Control

Wet Air Pollution Control Slowdown.  Seven plants provided infor-
mation on seven operations that have an air pollution control
scrubber.  No water use data were provided for three of the oper-
ations.  Three of the wet APC devices are operated at greater
than 90 percent recycle.  The BPT discharge allowance, based on
90 percent reduction of the four reported water use values, is
251 1/kkg (60.2 gal/ton).

Surface Treatment

Twenty-four plants provided information on surface treatment
operations in the nickel/cobalt subcategory.  Spent baths are
discharged from 33 operations, rinsewater from 28.

Surface Treatment Spent Baths.  Water discharge data are unavail-
able for 10 of these operations.  The spent baths from one opera-
tion are contract hauled.  The average of 22 reported non-zero
discharge values is the BPT discharge allowance, 861 1/kkg (206
gal/ton).

Surface Treatment Rinsewater.  No discharge data were provided
for 11 of the rinses.The FPT discharge allowance is the average
of the 17 reported discharge values, 10,600 1/kkg (2,535
gal/ton).

Alkaline Cleaning

Six plants provided information on alkaline cleaning operations
in the nickel/cobalt subcategory.  The reported operations
include 16 baths and nine rinses.

Alkaline Cleaning Spent Baths.  No discharge data were available
for six baths.  One bath is not discharged and loses water only
by evaporation.  The average of the nine available non-zero
values is the BPT discharge allowance, 30.6 1/kkg (7.34 gal/ton).

Alkaline Cleaning Rinsewater.  No discharge data were available
for two rinses.  The BPT discharge allowance is the average of
the seven reported values, 4,970 1/kkg (1,190 gal/ton).

Molten Salt Treatment

The following information was reported on molten salt treatment
in this subcategory:
                               709

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Number of plants:  6
Number of operations:  7.

Molten Salt Rinsewater.  No water discharge data were supplied
for two operations.  The BPT discharge allowance, based on the
five reported values, is 1,280 1/kkg (307 gal/ton).

Ammonia Rinse Treatment

The following information was reported on ammonia rinse treatment
in this subcategory:

Number of plants:  2
Number of operations:  3.

Ammonia Rinsewater.  No discharge data were available for one
operation.  The average of the two reported values is the BPT
discharge allowance, 15.7 1/kkg (3.77 gal/ton).

Sawing/Grinding

The following information was reported on sawing/grinding
operations in this subcategory:

Number of plants:  17
Number of operations:  46
Number of operations using lubricants:   29
Number of dry operations:  17.

Sawing/Grinding SpentLubricants.   For 17 operations no water
discharge data are available.  Lubricants are completely recir-
culated in four operations.  Sawing/grinding lubricants are
typically emulsions which could be treated on-site and the water
discharged (with the oil fraction contract hauled).  The BPT
discharge allowance is the average of the eight reported non-zero
values, 1,000 1/kkg (240 gal/ton).

Steam Cleaning

Steam Cleaning Condensate.   Two plants  reported the discharge of
contact steam condensate from product cleaning operations.
Neither plant recycles any of this condensate.  The BPT discharge
allowance is the average of the two reported discharge values,
23.2 1/kkg (5.56 gal/ton).

Hydrostatic Tube Testing

Hydrostatic Tube Testing Wastewater.   One plant provided water
discharge information on a hydrostatic tube testing operation.
The BPT discharge allowance is  the one reported discharge value,
1,350 1/kkg (324 gal/ton).
                               710

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Degreasing

Only a small number of surveyed plants with solvent degreasing
operations indicated having process wastewater streams associated
with the operation.  These facilities may use a water rinse after
solvent degreasing, or discharge solvent recovery sludge to the
facility's oil treatment system.  Because most plants practice
solvent degreasing without wastewater discharge, the Agency
believes zero discharge of wastewater is an appropriate discharge
limitation.

Miscellaneous Nondescript Wastewater.  Several low volume sources
of wastewater were reported in dcp's and observed during the site
and sampling visits.  Because these sources generally represent
low volume periodic discharges applicable to most plants, the
Agency has combined these individual wastewater sources under the
term  miscellaneous nondescript wastewater".  Because limited
information was available on the volume of these discharges in
the nickel/cobalt subcategory, the BPT discharge allowance was
transferred from the lead/tin/bismuth subcategory.  This allow-
ance ,is 58.4 1/kkg (14.0 gal/ton).

Calculation of BPT Effluent Mass Limitations

The pollutants regulated in the nickel/cobalt forming subcategory
are chromium, nickel, fluoride, oil and grease, TSS, and pH.  The
BPT mass limitations for these pollutants are listed in Section
II, Part 2, Subpart D.  These limitations were calculated by
multiplying the BPT normalized flow (1/kkg, summarized in Table
IX-13) by the one-day maximum and 10-day average effluent concen-
tration (mg/1) for each pollutant achievable using the BPT treat-
ment system (Table VII-9).  The 10-day average is used to calcu-
late the maximum monthly average because, as discussed in Section
VII, it provides a reasonable basis for a monthly average and is
typical of the sampling frequency required by discharge permits.

Cost and Benefits

In establishing BPT, EPA must consider the cost of treatment and
control in relation to the incremental increase in mass of pollu-
tants removed from wastewater (benefits).  The application of BPT
to direct dischargers will remove approximately 19,579.2 kg/yr
(43,165 Ib/yr) of pollutants from estimated current discharge
levels.  The corresponding capital and annual costs (1982 dol-
lars) for this removal are $141,200 and $119,700 per year,
respectively.  The Agency concludes that these pollutant removals
justify the costs incurred by plants in the nickel/cobalt forming
subcategory.
                               711

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ZINC FORMING SUBCATEGORY
     s
Production Operations and Discharge Flows

Rolling

The following information was reported on rolling operations  in
this subcategory:

Number of plants:  5
Number of operations:  8
Number of operations using neat oil lubricant:  1
Number of operations using emulsion lubricant:  3
Number of operations using contact lubricant-coolant water:   2
Number of operations using no lubricant:  2.

Rolling Spent Neat Oils.  The one rolling operation that uses a
neat oillubricantdoes not discharge any of the lubricant.
Drag-out on the product surface accounts for the only losses.  As
discussed previously for rolling spent neat oils in the nickel/
cobalt forming subcategory, it is better to remove the neat oils
directly and not to discharge the stream.  Therefore, the BPT
discharge allowance is zero.

Rolling Spent Emulsions.  The spent emulsion from one of the
three operations is applied to land; the spent emulsion from  one
operation is contract hauled; and the spent emulsion from one
operation is treated on-site and the water fraction is completely
reused.  As discussed previously for rolling spent emulsions  in
the lead/tin/bismuth forming subcategory, the spent emulsions
could be treated on-site and the water discharged (with the oil
fraction contract hauled).  Therefore, the BPT discharge allow-
ance is 1.39 1/kkg (0.334 gal/ton), the only reported value.

Rolling Contact Lubricant-Coolant Water.  In both operations  the
lubricant-coolant water is not recycled.  The BPT discharge
allowance is the average of the two reported values, 347 1/kkg
(83.2 1/kkg).

Drawing

The following information was reported on drawing operations  in
this subcategory:

Number of plants:  7
Number of operations:  7
Number of operations using emulsion lubricant:  4
Number of operations using no lubricant:  3.
                               712

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Drawing Spent Emulsions.  The spent emulsion  from two of the  four
operations is contract hauled and the spent emulsion from two
operations is treated on-site and the water fraction is dis-
charged.  As discussed previously for drawing spent emulsions in
the lead/tin/bismuth forming subcategory, the spent emulsions can
be treated on-site and the water discharged (with the oil frac-
tion contract hauled).  Therefore, the average of the three
reported discharge values is used as the BPT discharge allowance,
8.01 1/kkg (1.92 gal/ton).

Casting

The following information was reported on casting in this sub-
category:

Total number of plants:  7
Total number of operations:  7

Number of plants and operations with direct chill casting:  2
  Number using contact cooling water:  2

Number of plants and operations with stationary casting:  3
  Number using contact cooling water:  1
  Number dry:  2

Number of plants and operations with continuous casting:  2
  Number dry:  2.

Direct Chill Casting Contact Cooling Water.  The contact cooling
waterfrom one operation is completely recycled with no dis-
charge; the contact cooling water from the other operation is
discharged with no recycle.  The BPT discharge allowance is 503
1/kkg (121 gal/ton), which is the one reported non-zero value.

Stationary Casting Contact Cooling Water.  The contact cooling
water in the one operation is completely evaporated.  Therefore,
the BPT discharge allowance is zero.

Heat Treatment

The following information was reported on heat treatment opera-
tions in this subcategory:

Number of plants:  1
Number of operations:  1
Number of operations using contact cooling water:  1.

Solution Heat Treatment Contact Cooling Water.  The contact cool-
ing water in the one operation is batch dumped daily.  The BPT
discharge allowance is 761 1/kkg (183 gal/ton), the reported
value.
                               713

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Surface Treatment

Two plants provided information on five zinc surface treatment
operations.  Four of the surface treatment operations consist of
a bath followed by a single-stage spray rinse and one operation
consists of a coating bath not followed by a rinse.

Surface Treatment Spent Baths.  Spent baths are discharged from
all five surface treatment operations.  The BPT discharge allow-
ance is 9.50 1/kkg (2.28 gal/ton), the average of the four
reported values.

Surface Treatment Rinsewater.  Four surface treatment operations
have a discharge from single-stage spray rinses with no recycle.
The BPT discharge allowance is 4,860 1/kkg (1,170 gal/ton), the
average of the two reported values.

Alkaline Cleaning

One plant supplied information on an alkaline cleaning operation.
That operation consists of a bath followed by a two-stage coun-
tercurrent cascade rinse.

Alkaline CleaningSpent Baths.  The BPT discharge allowance is
0.715 T/kkgTO. 171 gal/ton) ,~ the one reported value.

Alkaline Cleaning Rinsewater.  The BPT discharge allowance is
5,720 1/kkg (1,3/0 gal/ton),  the one reported value.

Sawing/Grinding

One plant provided information on grinding zinc.  An emulsion is
used as a lubricant in the operation.

Sawing/Grinding Spent Lubricants.  The emulsion is completely
Fecirculated and batch dumped periodically.  The BPT discharge
allowance is 54.9 1/kkg (13.2 gal/ton), the one reported value.

Degreasing

Only a small number Q£ surveyed plants with solvent degreasing
operations have process wastewater streams associated with the
operation.  These facilities may use a water rinse after solvent
degreasing, or discharge solvent recovery sludge to the facil-
ity's oil treatment system.  Because most plants practice solvent
degreasing without wastewater discharge, the Agency believes zero
discharge of wastewater is an appropriate discharge limitation.
                               714

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Calculation of BPT Effluent Mass Limitations

The pollutants regulated  in the zinc  forming  subcategory  are
chromium, cyanide, zinc,  oil and grease, TSS, and pH.  The BPT
mass limitations  for these pollutants are  listed in Section II,
Part 2, Subpart I.  These limitations were calculated by  multi-
plying  the BPT normalized flow  (1/kkg,  summarized in Table IX-14)
by the  one-day maximum and 10-day average  effluent concentration
(mg/1)  for each pollutant achievable using the BPT treatment
system  (Table VII-9).  The 10-day average  is  used to calculate
the maximum monthly average because,  as discussed in Section VII,
it provides a reasonable basis for a monthly  average and  is
typical of the sampling frequency required by discharge permits.

Cost and Benefits

In establishing BPT, EPA  must consider  the cost of treatment and
control in relation to the incremental  increase in mass of pollu-
tants removed from wastewater (benefits).  The application of BPT
to the  one direct discharger will have  no net benefits or costs
because that plant currently meets or exceeds proposed BPT
effluent mass limitations.

BERYLLIUM FORMING SUBCATEGORY

Production Operations and Discharge Flows

Because there is only one plant in the  beryllium forming  subcate-
gory, the BPT discharge allowances are  based  on the discharge
values  reported from this plant.

Area Cleaning Wastewater.  The plant reported four operation
areas that require cleaning by hose spraying.  The BPT discharge
allowance is the average of the four values,  or 21,300 1/kkg
(5,110  gal/ton).

Billet  Washing Wastewater.  The plant reported two billet washing
operations with no recirculation of wastewater.  One washing
operation follows vacuum casting and the other follows beryllium
sintering.  The average of the two discharge  values is the BPT
allowance, 38.2 1/kkg (9.17 gal/ton).

Surface Treatment

The plant has one surface treatment operation which consists of a
bath followed by a single-stage overflow rinse.

Surface Treatment Spent Bathg.   The surface treatment operation
hasa dischargefrom a spent bath which is dumped once every
week.   The BPT discharge allowance is based on the reported dis-
charge  value which is 2,670 1/kkg (640  gal/ton).
                               715

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Surface Treatment Rinsevater.  The surface treatment rinsewater
is not recycled.  The BPT discharge allowance is the reported
discharge value, 2,670 1/kkg (640 gal/ton).

Sawing/Grinding Spent Lubricants.  Two sawing/grinding operations
were reported.  The plantdid not report any use of lubricant in
one of the operations.  The lubricants from the other operation
are discharged periodically.  The BPT discharge allowance is 424
1/kkg (102 gal/ton), the only reported discharge value.

Inspection/Testing Wastewater.   One inspection/testing operation
was reported by the plant.  The operation includes a stagnant
bath which is not discharged.  Therefore, the BPT discharge
allowance is zero.

Degreasing

Only a small number of surveyed plants with solvent degreasing
operations have process wastewater streams associated with the
operation.  These facilities may use a water rinse after solvent
degreasing, or discharge solvent recovery sludge to the facil-
ity's oil treatment system.   Because most plants practice solvent
degreasing without wastewater discharge, the Agency believes zero
discharge of wastewater is an appropriate discharge limitation.

Calculation of BPT Effluent Mass Limitations

The pollutants regulated in the beryllium forming subcategory are
beryllium, copper,  cyanide,  fluoride, oil and grease, TSS, and
pH.  The BPT mass limitations for these pollutants are listed in
Section II, Part 2, Subpart A.   These limitations were calculated
by multiplying the BPT normalized flow (1/kkg, summarized in
Table IX-15) by the one-day maximum and 10-day average effluent
concentration (mg/1) for each pollutant achievable using the BPT
treatment system (Table VII-9).  The 10-day average is used to
calculate the maximum monthly average because, as discussed in
Section VII, it provides a reasonable basis for a monthly average
and is typical of the sampling frequency required by discharge
permits.

Ghosts and Benefits

In establishing BPT, EPA must consider the cost of treatment and
control in relation to the incremental increase in mass of pollu-
tants removed from wastewater (benefits).  The application of BPT
will have no net costs or benefits because the one plant in this
subcategory currently meets or exceeds the proposed BPT effluent
mass limitations.
                               716

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PRECIOUS METALS FORMING SUBCATEGORY

Production Operations dnd Discharge Flows

Rolling

The following information was reported on rolling operations in
this subcategory:

Number of plants:  24
Number of operations:  29
Number of operations using emulsion lubricant:  8
Number of operations using no lubricant:  21.

Rolling Spent Emulsions.  The spent emulsions from two operations
are contract hauled and one operation has 60 percent recycle of
spent emulsions.  Five operations discharge spent emulsions with
no recycle.  The BPT discharge allowance, the average of the five
non-recycled discharge values, is 360 1/kkg (86.0 gal/ton).

Rolling Solution Heat Treatment Contact Cooling Water.  Contact
cooling water with no recirculation is used in three rolling
operations.  The BPT discharge allowance is the average of the
three reported discharge values, 7,000 1/kkg  (1,680 gal/ton).

Draw in:'
The following information was reported on drawing operations in
this subcategory:

Number of plants:  18
Number of operations:  22
Number of operations using neat oil lubricant:  2
Number of operations using emulsion lubricant:  7
Number of operations using soap solution lubricant-coolant:  2
Number of operations using an unspecified lubricant:  2
Number of operations using no lubricant:  9.

Drawing Spent Neat Oils.  Neat oils are completely recycled in
one operation and the neat oil in the other operation is entirely
consumed in the drawing process.  As discussed previously  for
drawing spent neat oils in the lead/tin/bismuth forming subcate-
gory, it is better to remove the neat oils directly and not to
discharge the stream.  Therefore, the BPT discharge allowance is
zero.

Drawing Spent Emulsions.  One operation has complete recycle of
spent emulsions and another operation has 99 percent recircula-
tion with periodic contract hauling of spent emulsions.  Spent
emulsions from three operations are contract hauled.  The  average
                               717

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of the two reported non-zero discharge values  is the BPT
discharge allowance, 213 1/kkg  (51.0 gal/ton).

Drawing Spent Soap Solutions.  No discharge data were provided on
one operation and one operation was reported to discharge  spent
soap solution.  The BPT discharge allowance is the one reported
non-zero value, 6.93 1/kkg  (1.66 gal/ton).

Extrusion

The following information was reported on extrusion operations in
this subcategory:

Number of plants:  6
Number of operations:  7
Number of operations using contact cooling water:   2
Number of dry operations:  5.

Extrusion Solution Heat Treatment Contact Cooling Water.   Contact
cooling water is not recycled in either operation.  The "BPT dis-
charge allowance is the average of the two reported values,
13,700 1/kkg (3,290 gal/ton).

Casting

The following information was reported on casting operations in
this subcategory:

Total number of plants:   24
Total number of operations:   37

Number of dry operations (casting type unspecified):   21

Number of plants and operations with semi-continuous and
continuous casting using contact cooing water:   6 plants,  11
operations

Number of plants and operations with shot casting using contact
cooling water:   1

Number of plants and operations with stationary casting using
contact cooling water:   2
  Number dry:  1

Number of plants and operations with direct chill casting  using
contact cooling water:   1.

Semi-Continuous and Continuous Casting Contact Cooling water.
Zero discharge is achieved in five operations by complete  recycle
of the contact cooling water.  One of the operations with  a
                               718

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discharge did not report water use information.  The average of
the five reported water discharge values is the BPT discharge
allowance, 11,200 1/kkg (2,680 gal/ton).

Shot Casting Contact Cooling Water.  The BPT discharge allowance
is the value reported for the one shot casting operation, 892
1/kkg  (214 gal/ton).

Stationary Casting Contact Cooling Water.  A water discharge
value was reported for only one of the two operations.  That
value  is the BPT discharge allowance, 4.17 1/kkg (1 gal/ton).

Direct Chill Casting Contact Cooling Water.  The one reported
directchill casting operation hasgreater than 99 percent
recirculation of the contact cooling water.  The reported water
discharge value is the BPT discharge allowance, 818 1/kkg (196
gal/ton).

Casting Wet Air Pollution Control Blowdown.  Two plants use wet
scrubbers to control air pollution from their casting operations.
One of the plants completely recirculates the scrubber water.
The BPT discharge allowance is the non-zero discharge value, 58.6
1/kkg  (14.0 gal/ton).

Metal Powder Production

The following information was reported on metal powder production
in this subcategory:

Number of plants:  5
Number of operations:  10
Number of wet atomization operations:  1
Number of wet powder milling operations:  1
Number of dry atomization operations:  8.

Metal Powder Production Atomization Wastewater.  The BPT
discharge allowance, based on the one reported value, is 6,670
1/kkg  (1,600 gal/ton).

Metal Powder Production Milling Wastewater.  The BPT discharge
allowance, based on the one reported value, is 21,700 1/kkg
(5,200 gal/ton).

Pressure Bonding

Pressure Bonding Contact Cooling Water.  One plant reported using
contact cooling water after a pressure bonding operation.  The
reported value is the BPT discharge allowance, 83.5 1/kkg (20.0
gal/ton).
                              719

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Heat Treatment

The following information was reported on heat treatment
operations in this subcategory:

Number of plants:  23
Number of operations:  45
Number of operations using contact cooling water:  18
Number of dry operations:  27.

Annealing Heat Treatment Contact Cooling Water.  Zero discharge
is achieved in two operationsby complete recycle of the contact
cooling water.  No discharge data were reported  for six of  the
operations.  The average of the 10 reported values is the BPT
discharge allowance, 10,000 1/kkg (2,400 gal/ton).

Surface Treatment

Twenty-two plants supplied information on surface treatment
operations.  Some of these operations are associated with the
cladding of precious metals to other metals.  Wastewater is
generated and discharged from these operations as follows:

Number of baths discharged:  17
Number of baths contract hauled:  3
Number of baths never discharged:  2
Number of rinses discharged:  14
Number of rinses treated and completely recycled:  1.

Surface Treatment Spent Baths.  No water discharge data were
reported for 13 of the operations.  The BPT discharge allowance
is the average of the four reported discharge values, 155 1/kkg
(37.2 gal/ton).

Surface Treatment Rinsewater.  Three of the 14 rinsing operations
use two-stage countercurrent cascade rinsing.  No water use data
were reported for four of the operations.  The BPT discharge
allowance is the average of the 10 reported values, 2,840 1/kkg
(681 gal/ton).

Alkaline Cleaning

Five plants supplied information on five precious metals alkaline
cleaning operations, five discharge spent baths and two discharge
rinsewater.  Eight plants reported information on 11 prebonding
cleaning operations.

Alkaline Cleaning Spent Baths.  Bath discharge data were not
reported for three of the operations.  The BPT discharge allow-
ance is the average of the two reported discharge values, 3.67
1/kkg (0.88 gal/ton).
                              720

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Alkaline Cleaning Rinsewater.  Discharge  data were  not  reported
for one of the operations.The BPT discharge allowance  is  the
one reported discharge value, 6,920 1/kkg  (1,660 gal/ton).

Prebonding Cleaning Wastewater.  Discharge data were not  reported
for two or the operations.The BPT discharge allowance  is  the
average of the nine reported discharge values, 3,400 1/kkg  (817
gal/ton).

Tumbling/Burnishing

Tumbling Wastewater.  One plant reported a tumbling operation
using water.  The BPT discharge allowance, based on the  one
reported value, is 1,150 1/kkg (277 gal/ton).

Burnishing Wastewater.  Two plants reported information on  two
burnishing operations using water.  The BPT discharge allowance,
based on the average of the two reported values, is 25,700  1/kkg
(6,170 gal/ton).

Sawing/Grinding

The following information was reported on sawing/grinding opera-
tions in this subcategory:

Number of plants:   9
Number of operations:   15
Number of operations using emulsion lubricant:  5
Number of operations using no lubricant:  10.

Sawing/Grinding Spent Emulsions.   Zero discharge is achieved in
one operation by complete recycle of the lubricant, the lubricant
is completely consumed in another.  Discharge information was not
reported for one operation.  The BPT discharge allowance is the
average of the two reported discharge values, 6.05 1/kkg  (1.45
gal/ton).

Degreasing

Only a small number of surveyed plants with solvent degreasing
operations have process wastewater streams associated with  the
operation.  These facilities may use a water rinse after solvent
degreasing, or discharge solvent recovery sludge to the facil-
ity's oil treatment system.  Because most plants practice solvent
degreasing without wastewater discharge, the Agency believes zero
discharge of wastewater is an appropriate discharge limitation.
                              721

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Calculation of BPT Effluent Mass Limitations

The pollutants regulated in the precious metals forming subcate-
gory are cadmium, copper, cyanide, silver, oil and grease, TSS,
and pH.  The BPT mass limitations for these pollutants are listed
in Section II, Part 2, Subpart E.  These limitations were calcu-
lated by multiplying the BPT normalized flow (1/kkg, summarized
in Table IX-16) by the one-day maximum and 10-day average efflu-
ent concentration (mg/1) for each pollutant achievable using the
BPT treatment system (Table VII-9).  The 10-day average is used
to calculate the maximum monthly average because, as discussed in
Section VII, it provides a reasonable basis for a monthly average
and is typical of the sampling frequency required by discharge
permits.

Costs and Benefits

In establishing BPT, EPA must consider the cost of treatment and
control in relation to the incremental increase in mass of pollu-
tants removed from wastewater (benefits).  The application of BPT
to direct dischargers will remove approximately 2,194.7 kg/yr
(4,838.5 Ib/yr) of pollutants from estimated current discharge
levels.  The corresponding capital and annual costs (1982 dol-
lars) for this removal are $173,400 and $114,000 per year,
respectively.  The Agency concludes that these pollutant removals
justify the costs incurred by plants in the precious metals
forming subcategory.
                      \
IRON AND STEEL/COPPER/ALUMINUM METAL POWDER PRODUCTION AND POWDER
METALLURGY SUBCATEGORY

Production Operations and Discharge Flows^

Metal Powder Production

The following information was reported on metal powder production
in this subcategory:

Number of plants:  14
Number of operations:   19
Number of wet atomization operations:  6
Number of wet milling operations:  1
Number of dry atomization operations:  10
Number of dry milling operations:  2.

Metal Powder Production Atomization Wastewater.  No recycle was
reported for any of the six operations.  From an examination of
the available data,  it is not apparent that there is any signi-
ficant difference in water use and discharge among the different
metals.  Therefore,  the BPT discharge allowance is the average of
the six reported values, 5,040 1/kkg (1,210 gal/ton).
                               722

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Metal Powder Production Milling Wastewater.  No recycle was
reported for the one wet powder milling operation.  The BPT
discharge allowance is based on the one reported value, 1,670
1/kkg (400 gal/ton).

Metal Powder Production Wet Air Pollution Control Slowdown.  Two
plantsreportedthe useof wetscrubbers associated withmetal
powder production.  One plant reported a discharge and 85 percent
recycle; the other reported complete recycle.  The BPT discharge
allowance is based on 90 percent recycle of the scrubber water to
achieve a discharge allowance of 2,640 1/kkg (632 gal/ton).

Sizing

Sizing Spent Lubricant.  One plant reported information on two
operations using lubricants in sizing operations associated with
powder metallurgy parts production.  However, because all of the
lubricant is consumed during processing there is no resulting
discharge.  Therefore, the BPT flow allowance is zero.

Oil-Resin Impregnation

Oil-Rejin Impregnation Wastewater.  Three plants reported impreg-
nation of powder metallurgy parts with oils and resins.  Only one
of the plants reported water use and discharge values.  The BPT
discharge allowance is based on the single reported value, 74.5
1/kkg (17.9 gal/ton).

Steam Treatment

Steam Treatment Scrubber Blowdown.  One plant operates a wet
scrubber to control air pollution from its steam treatment pro-
cess.  The BPT discharge allowance, based on the one reported
discharge value, is 2,840 1/kkg (681 gal/ton).

Tumbling,  Burnishing,  and Cleaning

Tumbling,  Burnishing,  and Gleaning Wastewater.   Eighteen plants
reported information on 26 tumbling, burnishing, and other
physical-chemical cleaning operations associated with powder
metallurgy parts production.  There appears to be no significant
difference in the water use and discharge practices among these
operations for iron, steel, copper, or aluminum parts.  No water
discharge information was reported for 12 of the 26 operations.
The BPT discharge allowance is the average of the 14 reported
values or 7,150 1/kkg (1,710 gal/ton).
                               723

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Sawing/Grinding

Rawing/Grinding Spent Lubricants.  Two plants reported informa-
tion on four operations using lubricants for sawing and grinding
of powder metallurgy parts.  None of the plants reported lubri-
cant use or discharge values.  Because simlar operations are used
in the nickel/cobalt forming subcategory, the BPT discharge
allowance for these operations is the same as the allowance in
the other subcategory, 1,000 1/kkg (240 gal/ton).

Degreasing

Only a small number of surveyed plants with solvent degreasing
operations have process wastewater streams associated with the
operation.  These facilities may use a water rinse after solvent
degreasing, or discharge solvent recovery sludge to the facil-
ity's oil treatment system.  Because most plants practice solvent
degreasing without wastewater discharge, the Agency believes zero
discharge of wastewater is an appropriate discharge limitation.

Calculation of BPT Effluent Mass Limitations

The pollutants regulated in the iron and steel/copper/ai.luminum
metal powder prodxiction and powder metallurgy subcategory are
copper, cyanide, lead, aluminum, iron, oil and grease, TSS, and
pH.  The BPT mass limitations for these pollutants are listed in
Section II, Part 2, Subpart K.  These limitations were calculated
by multiplying the BPT normalized flow (1/kkg, summarized in
Table IX-17) by the one-day maximum and 10-day average effluent
concentration (mg/1) for each pollutant achievable using the BPT
treatment system (Table VII-9).  The 10-day average is used to
calculate the maximum monthly average because, as discussed in
Section VII, it provides a reasonable basis for a monthly average
and is typical of the sampling frequency required by discharge
permits.

Costs and Benefits

In establishing BPT, EPA must consider the cost of treatment and
control in relation to the incremental increase in mass of pollu-
tants removed from wastewater (benefits).  The application of BPT
to direct dischargers will remove approximately 8,995.6 kg/yr
(19,831.9 Ib/yr) of pollutants from estimated current discharge
levels.  The corresponding capital and annual costs (1982 dol-
lars) for this removal are $122,000 and $77,500 per year,
respectively.  The Agency concludes that these pollutant removals
justify the costs incurred by plants in the iron and steel/
copper/aluminum metal powder production and powder metallurgy
subcategory.
                               724

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TITANIUM FORMING SUBCATEGORY

Production Operations and Discharge Flows

Rolling

The following information was reported on rolling operations  in
this subcategory:

Number of plants:  9
Number of cold rolling operations:  6
Number of hot rolling operations:  6
Number of cold rolling operations using  lubricants:  4
Number of hot rolling operations using contact lubricant-coolant
water:  3
Number of cold rolling operations using  no lubricant:  2
Number of hot rolling operations using no lubricant:  3.

Cold Rolling Spent Lubricants.  Two of the four operations have
no water discharge because all water loss is through drag-out.
The BPT discharge allowance is the average of the two reported
discharge values, 3,340 1/kkg (800 gal/ton).

Hot Rolling Contact Lubricant-Coolant Water.  No recycle was
reported for any of the three operations.  One operation has  no
available water usage or discharge data.  The BPT discharge
allowance is the average of the two reported discharge values,
4,300 1/kkg (1,030 gal/ton).

Extrusion

The following information was reported on extrusion operations in
this subcategory:

Number of plants:  9
Number of operations:  10
Number of operations using lubricants:   3
Number of dry operations:   7.

Extrusion Spent Lubricants.  The lubricant used in one of the
operations is consumed during the extrusion.  The BPT discharge
allowance is the average of the two reported non-zero discharge
values, 274 1/kkg (65.7 gal/ton).

Forging

The following information was reported on forging operations  in
this subcategory:

Number of plants:  26
Number of operations:  37
                               725

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Number of operations using lubricants:  6
Number of operations using contact cooling water:  5
Number of dry operations:  26.

Forging Spent Lubricants.  The lubricants in five of the six
operations are consumed during forging and the lubricants from
the other operation are contract hauled.  The forging lubricants
are typically neat oils.  As discussed previously for forging and
swaging spent neat oils in the nickel/cobalt forming subcategory,
it is better to remove the neat oils directly and not to dis-
charge the stream.  Therefore, the BPT discharge allowance is
zero.

Forging Contact Cooling Water.  No discharge data were available
for one of the five operations.  Consequently, the BPT allowance
is the average of the four reported non-zero values, 3,000 1/kkg
(72.1 gal/ton).

Forging Wet Air Pollution Control Blowdown.  Two plants use wet
air pollution control scrubbers to control air pollution from
forging operations.  The BPT discharge allowance is the average
of the two reported values, 2,020 1/kkg (485 gal/ton).

Heat Treatment

The following information was reported on heat treatment: opera-
tions in this subcategory:

Number of plants:  17
Number of operations:  23
Number of operations using contact cooling water:  10
Number of dry operations:  13.

Heat Treatment Contact Cooling Water.  Contact cooling water in
two of the 10 operationsis 100 percent recycled.  No discharge
data were supplied for four of the 10 operations.  The BPT dis-
charge allowance is the average of the four reported non-zero
values or 4,510 1/kkg (1,080 gal/ton).

Surface Treatment

Seventeen plants reported information on 21 surface treatment
operations.

Surface Treatment Spent Baths.  No discharge data were supplied
for 14 of the operations.The BPT discharge allowance is the
average of six of the seven reported values.  One value was
omitted from the average because it was much higher than the
values for spent surface treatment baths in other metal forming
categories and subcategories and, therefore, not believed to be
typical of current best practice.  The BPT discharge allowance is
160 1/kkg (38.5 gal/ton).
                               726

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Surface Treatment Rinsewater.  No water  is  recycled  in any  of the
operations.  Water usage  and  discharge data were  not  supplied for
eight  of  the operations.   The BPT discharge allowance is  the
average of 10 reported non-zero  values.  Three  of the reported
values were omitted  from  the  average  because  they were much
higher than the average of the other  10  and therefore,  not
believed  to be typical of current best practice.   The BPT
discharge allowance  is 21,100 1/kkg  (5,050  gal/ton).

Surface Treatment Wet Air Pollution Control Blowdown.   Three
plants reported using wet scrubbers to control  air pollution from
surface treatment operations.  All of the plants  supplied infor-
mation for continuous discharges from the scrubbers.   However,
only two  supplied enough  information  to  determine the percent
recycle of scrubber  liquor.   One of the  plants, which recycles
scrubber  liquor, had a much greater production  normalized dis-
charge of air pollution control  blowdown than plants  in other
metal  forming categories  and  subcategories.   Therefore, the PNF
from that plant was  not believed to be typical  of current best
practice.  The other reported value,  on  a scrubber with 96
percent recycle, is  the BPT discharge allowance,  170  1/kkg  (40.8
gal/ton).

Alkaline Cleaning

Five plants supplied information on alkaline  cleaning operations.
All five  plants discharge spent  cleaning baths  and four plants
discharge rinsewater.

Alkaline Cleaning Spent Baths.  Water usage and discharge data
were notreported for two of  the five operations.  The BPT  dis-
charge allowance is  the average  of the three  reported discharge
values, 2,550 1/kkg  (612  gal/ton).

Alkaline Cleaning Rinsewater.  No water  is  recycled  in any  of the
operations.  No water discharge  information was reported  for  one
of the operations.   One reported value is much  higher than  the
other two reported values  and much higher than  the values for
alkaline  cleaning rinsewater  in  other metal forming  categories
and subcategories.  This  value was not included in the  calcula-
tion of the BPT flow because  it  is not believed to be typical of
current best practice.  The BPT  discharge allowance  is  the  aver-
age of two of the three reported values, 2,760  1/kkg  (663
gal/ton).

Sawing/Grinding

The following information  was reported on sawing/grinding opera-
tions in this subcategory:

Number of plants:   12
Number of operations:  14
Number of operations using lubricants:   10
Number of operations using no lubricant:   4.
                              727

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Sawing/Grinding Spent Lubricants.  The  lubricants used  in  two  of
the 10 operations are completely recycled; the lubricants  in two
other operations are completely consumed.  No discharge  informa-
tion was reported for two of the operations.  Two of the remain-
ing four reported discharge values are  much higher than  the other
two values, and much higher than the values for sawing/grinding
spent lubricants in other metal forming categories and subcatego-
ries.  These two values were not included in the calculation of
the BPT discharge allowance because they are not believed  to be
typical of current best practice.  The BPT discharge allowance is
the average of the other two of the four reported values,  49.7
1/kkg (11.9 gal/ton).

Tumbling

Tumbling Wastewater.  One plant reported information on  a  titan-
ium tumbling operation.  The BPT discharge allowance is  based  on
the value for this operation, 790 1/kkg (189 gal/ton).

Degreasing

Only a small number of surveyed plants with solvent degreasing
operations have process wastewater streams associated with the
operation.  These facilities may use a water rinse after solvent
degreasing, or discharge solvent recovery sludge to the  facil-
ity's oil treatment system.  Because most plants practice  solvent
degreasing without wastewater discharge, the Agency believes zero
discharge of wastewater is an appropriate discharge limitation.

Calculation of BPT Effluent Mass Limitations

The pollutants regulated in the titanium forming subcategory are
cyanide, lead, zinc, ammonia, fluoride, titanium, oil and  grease,
TSS, and pH.  The BPT mass limitations  for these pollutants are
listed in Section II, Part 2, Subpart F.  These limitations were
calculated by multiplying the BPT normalized flow (l/kkg,  summa-
rized in Table IX-18) by the one-day maximum and 10-day  average
effluent concentration (mg/1) for each pollutant achievable using
the BPT treatment system (Table VII-9).  The 10-day average is
used to calculate the maximum monthly average because, as  dis-
cussed in Section VII, it provides a reasonable basis for  a
monthly average and is typical of the sampling frequency required
by discharge permits.

gosts and Benefits

In establishing BPT, EPA must consider  the cost of treatment and
control in relation to the incremental  increase in mass  of pollu-
tants removed from wastewater (benefits).  The application of  BPT
to direct dischargers will remove approximately 379,217.2  kg/yr
                               728

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(836,030.8 Ib/yr) of pollutants from estimated current discharge
levels.  The corresponding capital and annual costs  (1982 dol-
lars) for this removal are $1,164,700 and $858,300 per year,
respectively.  The Agency concludes that these pollutant removals
justify the costs incurred by plants in the titanium forming sub-
category.

REFRACTORY METALS FORMING SUBCATEGORY

Production Operations and Discharge Flows

Rolling

The following information was reported on rolling operations in
this subcategory:

Number of plants:  14
Number of operations:  20
Number of operations using neat oil lubricant:  1
Number of operations using emulsion lubricant:  1
Number of operations using no lubricant:  18.

Rolling Spent Neat Oils.  No discharge information was reported
for the one operation which uses a neat oil rolling  lubricant.
As discussed previously for rolling spent neat oils  in the
nickel/cobalt forming subcategory, it is better to remove the
neat oils directly and not to discharge the stream.  Therefore,
the BPT discharge allowance is zero.

Rolling Spent Emulsions.  Spent emulsions in the one rolling
operation which uses emulsified lubricants are batch dumped annu-
ally and contract hauled.  As discussed previously for rolling
spent emulsions in the lead/tin/bismuth forming subcategory, the
spent emulsions could be treated on-site and the water discharged
(with the oil fraction contract hauled).  Therefore, the reported
value is the BPT discharge allowance, 1,200 1/kkg (288 gal/ton).

Drawing

The following information was reported on drawing operations in
this subcategory:

Number of plants:  13
Number of operations:  16
Number of operations using lubricants:  5
Number of operations using no lubricant:  11.

Drawing Spent Lubricants.  The lubricants in three operations are
completely consumed.  Lubricant loss in one operation occurs only
                                729

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through drag-out.  One operation has no available water  discharge
data.  The drawing lubricants used are typically neat oils.  As
discussed previously for drawing spent neat oils in the  lead/tin/
bismuth forming subcategory, it is better to remove the  neat oils
directly and not to discharge the stream.  Therefore, the BPT
discharge allowance is zero.

Extrusion

The following information was reported on extrusion operations in
this subcategory:

Number of plants:  3
Number of operations:   3
Number of operations using contact cooling water:  1
Number of dry operations: '  2.

Extrusion Heat Treatment Contact Cooling Water.  Contact cooling
water is used with no recycle in a post-extrusion operation.  The
BPT discharge allowance is the one reported discharge value,
3,460 1/kkg (830 gal/ton).

Extrusion Press Leakage.  Leakage of extrusion press hydraulic
Tluid was observed at one sampled plant.  The BPT discharge
allowance is based on the one value for this operation,  1,190
1/kkg (285 gal/ton).

Forging

The following information was reported on forging operations in
this subcategory:

Number of plants:  13
Number of operations:   15
Number of operations using lubricants:  3*
Number of operations using contact cooling water:  2*
Number of operations that generate equipment cleaning waste-
water:   3*
Number of dry operations:  11.

*Two operations use a lubricant, contact cooling water,  and
 generate equipment cleaning wastewater.

Forging Spent Lubricants.  The lubricants in two of the  opera-
tions are consumed in the forging processes and lost through
drag-out in the other operation.  The forging lubricants used are
typically neat oils.  As discussed previously for forging spent
neat oils in the nickel/cobalt forming subcategory, it is better
to remove the neat oils directly and not to discharge the stream.
Therefore, the BPT discharge allowance is zero.
                               730

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Forging Solution Heat Treatment Contact Cooling Water.  None  of
the contact cooling water in either ot the two operations is
recycled.  The BPT discharge allowance is the average of the  two
reported values, 5,790 1/kkg (1,390 gal/ton).

Extrusion and Forging Equipment Cleaning Wastewater.  Two plants
use cleaning water that is not recycled to clean  forging and
extrusion equipment in three operations.  The BPT discharge
allowance is the average of the two reported values, 417 1/kkg
(100 gal/ton).

Metal Powder Pressing

The following information was reported on metal powder pressing
operations in this subcategory:

Number of plants:  22
Number of operations:  44
Number of operations using a lubricant:  1
Number of dry operations:   43.

Metal. Powder Pressing Spent Lubricants.  The lubricants used  in
one operation are neat oils which are completely recirculated.
Since neat oils are pure oil streams, with no water fraction, it
is better to remove the oil directly and not to discharge the
stream than to commingle the oil with water streams and then
remove it later.  Therefore, the BPT discharge allowance is zero.

Casting

The following information was reported on casting operations  in
this subcategory:

Number of plants:  4
Number of operations:  4
Number of operations using contact cooling water:   1
Number of operations using post-casting washwater:  1
Number of dry operations:   3.

Casting Contact Cooling Water.   One operation loses water only
through evaporation.Therefore, the  BPT discharge allowance is
zero.

Post-Casting Washwater.  One plant reported a water discharge
from a post-casting wash operation.  The BPT discharge allowance
is the one reported value, 29.8 1/kkg (7.14 gal/ton).
                              731

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Metal Powder Production

The following information was reported on metal powder production
in this subcategory:

Number of plants:  11
Number of operations:  20
Number of wet operations:  4
Number of dry operations:  16.

Metal Powder Production Wastewater.  No water discharge data were
provided for one operation.  The BPT discharge allowance, based
on the average of the three reported values of metal powder
production wastewater, is 1,640 1/kkg (393 gal/ton).

Metal Powder Production Wet Air Pollution Control Scrubber Blow-
down.The one plant that reported using a wet scrubber to con-
trol air pollution from its metal powder production operation
recirculates all of the scrubber liquor to achieve zero dis-
charge.  Because no water is discharged, the BPT allowance is
zero.

Surface Treatment

Twelve plants supplied information on refractory metals surface
treatment operations.

Surface Treatment Spent Baths.  No discharge values were supplied
for spent bathsfrom 13 surface treatment operations.  One of the
two reported values was much higher than values reported in other
metal forming categories and subcategories.  This value was not
used to calculate the BPT flow because it was not believed to be
typical of current best practice.  The BPT discharge allowance,
based on the other reported value, is 12.7 1/kkg (3.04 gal/ton).

Surface Treatment Rinsewater.  Rinsewater is discharged from 16
surface treatment operations.  No discharge data were provided
for five operations', no recycle of rinsewater was reported for
any of the 16 operations.  The BPT discharge allowance is the
average of 10 of 11 reported values.  One reported value was much
higher than the average of the other 10 and, therefore, not
believed to be typical of current best practice.  The allowance
is 121,000 1/kkg (29,100 gal/ton).

Surface Treatment Wet Air Pollution Control Scrubber Blowdpwn.
Two plants reported using wet scrubbers to control air pollution
from their surface treatment operations.  Water discharge data
were supplied for only one of the two operations.  The BPT dis-
charge allowance, based on the one reported value, is 11,800
1/kkg (2,480 gal/ton).
                              732

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Coating Wet Air Pollution Control Scrubber Slowdown.  One plant
reported using a wetscrubber to control air pollution from its
coating operation.  The BPT discharge allowance, based on the one
reported value, is 1,080 1/kkg  (258 gal/ton).

Alkaline Cleaning

Thirteen plants supplied information on 14 alkaline cleaning
operations.

Alkaline Cleaning Spent Baths.  No discharge values were provided
for any of the 14 operations.  Consequently, the BPT discharge
allowance  for alkaline cleaning spent baths in the nickel/cobalt
forming subcategory was transferred to this subcategory.  The BPT
discharge  allowance is 30.6 1/kkg (7.34 gal/ton).

Alkaline Cleaning Rinsewater.  Eight of the operations have no
available water discharge data.  No water is recirculated in any
of the 14  operations.  The average of the six reported values is
the BPT discharge allowance, 140,000 1/kkg (33,500 gal/ton).

Molten Salt

Molten Salt Rinsewater.  Rinsewater is discharged from five
molten salt operations.  Because no information on rinsewater
discharge was provided for one operation, the BPT discharge
allowance  is the average of the four reported values, 90,200
1/kkg (21,600 gal/ton).

Tumbling/Mil ling/Burnishing

Tumbling/Milling/Burnishing Wastewater.  Five plants provided
information on 14 operationsinvolving tumbling, milling, or
burnishing.  One operation is dry.  One of the reported values is
much higher than the other 12 and therefore, is not believed to
be typical of current best practice.  Consequently, the BPT dis-
charge allowance is the average of 12 of the 13 reported values,
22,100 1/kkg (5,300 gal/ton).

Sawing/Grinding

The following information was reported on sawing/grinding opera-
tions in this subcategory:

Number of plants:  10
Number of operations:   31
Number of  operations using neat oil lubricant:  1
Number of operations using emulsion lubricant:  17
Number of  operations using lubricant-coolant water:  6
Number of operations using no lubricant:  7.
                               733

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Sawing/Grinding Spent Neat Oils.  No discharge  information was
reportedtor tne one operation.  Since neat oils are pure oil
streams, with no water fraction, it is better to remove  the  oil
directly and not to discharge the stream than to commingle the
oil with water streams and then remove it later.  Therefore, the
BPT discharge allowance is zero.

Sawing/Grinding Spent Emulsions.  The spent emulsions from six
operations are contract hauled; emulsions are completely recycled
in one operation; and, emulsions are lost only  through drag-out
in three operations.  Water discharge data were not provided for
five operations.  The average of the two reported discharge
values is the BPT discharge allowance, 217 1/kkg (52.1 gal/ton).

Sawing/Grinding Lubricant-Coolant Water.  Discharge data were not
provided for one operation.  One hundred percent recycle of
lubricant-coolant water was achieved in three operations.  The
two reported discharge values were much higher  than values typi-
cal of similar operations in other metal forming subcategories
and categories and were not believed to be typical of current
best practice.  For this reason, the BPT discharge allowance is
10 percent of the lower reported value, achievable through 90
percent recycle.  The Agency believes this value reflects cur-
rently established use of sawing/grinding lubricant-coolant water
in the nonferrous metals forming and other metal forming catego-
ries.   The BPT discharge allowance is 812 1/kkg (195 gal/ton).

Sawing/Grinding Wet Air Pollution Control Scrubber Blowdowri.  One
plant reported using a wet scrubber to control  air pollution from
a grinding operation.   Since the quantity of wastewater dis-
charged was not reported, the BPT discharge allowance for coating
wet air pollution control blowdown was used as  an allowance  for
this waste stream.   Thus, the BPT discharge allowance is 1,080
1/kkg (258 gal/ton).

Post-Sawing/Grinding Rinsewater.  One plant supplied information
on a post-sawing/grinding operation.  The BPT discharge allowance
is the one reported value, 513 1/kkg (123 gal/ton).

Product Testing

Product Testing Wastewater.  Wastewater from a  product testing
operation was observed at one sampled plant.  The BPT discharge
allowance is the value for this operation, 77.6 1/kkg (18.6
gal/ton).

Degreasing

Only a small number of surveyed plants with solvent degreasing
operations have process wastewater streams associated with the
                               734

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operation.  These facilities may use a water rinse after  solvent
degreasing, or discharge solvent recovery sludge to the facil-
ity's oil treatment system.  Because most plants practice  solvent
degreasing without wastewater discharge, the Agency believes zero
discharge of wastewater is an appropriate discharge limitation.

Calculation of BPT Effluent Mass Limitations

The pollutants regulated in the refractory metals forming  sub-
category are copper, nickel, columbium, fluoride, molybdenum,
tantalum, tungsten, vanadium, oil and grease, TSS, and pH.  The
BPT mass limitations for these pollutants are listed in Section
II, Part 2, Subpart G.  These limitations were calculated  by
multiplying the BPT normalized flow (1/kkg, summarized in  Table
IX-8) by the one-day maximum and 10-day average effluent  concen-
tration (mg/1) for each pollutant achievable using the BPT treat-
ment system (Table VII-9).  The 10-day average is used to  calcu-
late the maximum monthly average because, as discussed in  Section
VII, it provides a reasonable basis for a monthly average  and  is
typical of the sampling frequency required by discharge permits.

Costs and Benefits

In establishing BPT, EPA must consider the cost of treatment and
control in relation to the incremental increase in mass of pollu-
tants removed from wastewater (benefits).  The application of BPT
to direct dischargers will remove approximately 6,903.9 kg/yr
(15,220.5 Ib/yr) of pollutants from estimated current discharge
levels.  The corresponding capital and annual costs (1982  dol-
lars) for this removal are $35,800 and $70,400 per year, respec-
tively.  The Agency concludes that these pollutant removals
justify the costs incurred by plants in the refractory metals
forming subcategory.

ZIRCONIUM/HAFNIUM FORMING SUBCATEGORY

Production Operations and Discharge Flows

Drawing

The following information was reported on drawing operations in
this subcategory:

Number of plants:  3
Number of operations:  3
Number of operations using lubricants:  3.

Drawing Spent Lubricants^  The lubricant in two of the three
operations is completely recycled; no discharge information was
reported for the other operation.  The drawing lubricants  are
                               735

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typically neat oils.  As discussed previously for drawing spent
neat oils in the lead/tin/bismuth forming subcategory, it is
better to remove the neat oils directly and not to discharge the
stream.  Therefore, the BPT discharge allowance is zero.

Extrusion

The following information was reported on extrusion operations in
this subcategory:

Number of plants:  5
Number of operations:   5
Number of operations using emulsion lubricant:  2*
Number of operations using contact cooling water:   1*
Number of dry operations:  3.

*0ne operation uses a lubricant and contact cooling water.

Extrusion Spent Emulsions.  The emulsion in one of the operations
is consumed; the spent emulsion in the other operation is dis-
charged without recycle.  The BPT discharge allowance, based on
the one reported value,  is 74.1 1/kkg (17.8 gal/ton).

Extrusion Heat Treatment Contact Cooling Water.   The BPT dis-
charge allowance is based on the single reported value, 285 1/kkg
(68.4 gal/ton).

Extrusion Press Hydraulic Fluid Leakage.  Two plants reported the
discharge of leakage from extrusion presses.  Hydraulic fluid
leaks from moving part connection points in high pressure extru-
sion presses.  Neither plant recirculates the leakage.  Discharge
information was not reported for one of the operations.  The BPT
discharge allowance is based on the one reported value, 370 1/kkg
(88.8 gal/ton).

Forging

Forging Solution Heat Treatment Contact Cooling Water.  Two
plants reported using heat treatment quench baths following
forging, but only one reported water use and discharge values.
The BPT discharge allowance is based on the single reported
value, 34.9 1/kkg (8.36 gal/ton).

Tube Reducing

Tube Reducing Spent Lubricants.  Tube reducing spent lubricants
were sampled at one plantin the nickel/cobalt forming subcate-
gory.  Analysis of this stream showed treatable concentrations of
N-nitrosodiphenylamine, a toxic organic pollutant.  The Agency
believes that tube reducing operations are similar and use the
                               736

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same lubricants in the two subcategories.  The most economic
handling of this stream is to intercept  it before mixing with
other process wastewaters and transport  it to off-site treatment
or disposal.  Because this is the only waste stream in the cate-
gory with a significant concentration of an organic pollutant,
treatment of this stream  (with activated carbon) after mixing
with other process wastewaters would be  much more expensive.  For
this reason, and because  the Agency believes the potentially
carcinogenic properties of nitrosamines  justify prohibiting its
discharge, the BPT discharge allowance for tube reducing spent
lubricants is zero.

Surface Treatment

Seven plants supplied information on surface treatment opera-
tions in the zirconium/hafnium subcategory.

Surface Treatment Spent Baths.  Spent surface treatment baths are
discharged from 13 operations.  Three of these baths are contract
hauled.  No data on water usage or water discharge was provided
for seven operations.  Even though the spent baths from three of
the operations are contract hauled, the BPT discharge allowance
is the average of the six reported values, 399 1/kkg (95.8
gal/ton).

Surface Treatment Rinsewater.  Rinsewater is discharged from 10
surface treatment operations.  No information on water usage or
discharge was provided for four of the 10 operations.  The
reported water usage and  discharge from  one plant were omitted in
determining the regulatory flow because they were far outside the
range of values of the other plants and  therefore not believed to
be typical of best current practice.   The BPT discharge allowance
was based on the average  of the five reported values, 15,300
1/kkg (3,680 gal/ton).

Alkaline Cleaning

Alkaline Cleaning Spent Baths.  Six plants reported information
on the discharge of alkaline cleaning baths from 11 operations.
Even though the wastewater from two of these operations is con-
tract hauled, the BPT discharge allowance is based on the average
of all 11 reported values.  The allowance is 2,130 1/kkg (511
gal/ton).

Alkaline Cleaning Rinsewater.  Rinsewater is discharged from 10
operations.   No data on water discharge were provided for two of
the operations.  The BPT  discharge allowance is the average of
the eight reported values, 55,300 1/kkg  (13,300 gal/ton).
                               737

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Sawing/Grinding

Saving/Grinding Spent Lubricants.  Four plants reported nine
operations using lubricants in sawing and grinding.  Plants gen-
erally recirculate the lubricants in these operations but period-
ically draw off a portion to prevent the excessive buildup of
contaminants in the lubricant and to prevent it from becoming
rancid.  The amount discharged is generally very small relative
to waste streams from other forming operations.  A discharge
value was reported for only one of the nine operations.  The BPT
discharge allowance, based on the one reported value, is 9.01
1/kkg (2.16 gal/ton).

Sawing/Grinding Wet Air Pollution Control Slowdown.  Because the
one plant reporting use of an air pollution control unit operates
it with 100 percent recycle, the BPT discharge allowance is zero.

Degreasing

Degreasing Rinsewater.  One plant reported the discharge of
degreasing nnsewater from two operations.  The BPT discharge
allowance is the average of the two reported values, 2,030 1/kkg
(486 gal/ton).

Calculation of BPT Effluent Mass Limitations

The pollutants regulated in the zirconium/hafnium forming subcat-
egory are chromium, cyanide, nickel, ammonia,  fluoride, hafnium,
zirconium, oil and grease, TSS, and pH.  The BPT mass limitations
for these pollutants are listed in Section II, Part 2, Sxabpart J.
These limitations were calculated by multiplying the BPT normal-
ized flow (1/kkg, summarized in Table IX-20) by the one-day
maximum and 10-day average effluent concentration (mg/1) for each
pollutant achievable using the BPT treatment system (Table
VII-9).  The 10-day average is used to calculate the maximum
monthly average because, as discussed in Section VII, it provides
a reasonable basis for a monthly average and is typical of the
sampling frequency required by discharge permits.

Costs and Benefits

In establishing BPT, EPA must consider the cost of treatment and
control in relation to the incremental increase in the mass of
pollutants removed from wastewater (benefits).  The application
of BPT to direct dischargers will remove approximately 1,061.8
kg/yr (2,340.9 Ib/yr)  of pollutants from estimated current
discharge levels.  The corresponding capital and annual costs
(1982 dollars) for this removal are $172,200 and $88,500 per
year, respectively.  The Agency concludes that these pollutant
removals justify the costs incurred by plants in the
zirconium/hafnium forming subcategory.
                               738

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MAGNESIUM FORMING SUBCATEGORY

Production Operations and Discharge Flows

Rolling

The following information was reported on rolling operations in
this subcategory:

Number of plants:  1
Number of operations:  2
Number of operations using emulsion lubricant:  2.

Rolling Spent Emulsions.  The spent emulsions from both opera-
tions are batch dumped and contract hauled, therefore, the BPT
discharge allowance is zero.

Forging

The following information was reported on forging operations in
this subcategory:

Number of plants:  3
Number of operations:  4
Number of operations using lubricants:  3*
Number of operations using contact cooling water:  4*.

*Three of the operations use lubricants and contact cooling
 water.

Forging Spent Lubricants.  The only loss of lubricant from any of
the three operations is through drag-out on the product surface.
Consequently, the BPT discharge allowance for forging spent
lubricants is zero.

Forging Solution Heat Treatment Contact Cooling Water.  One
operation has no water discharge due to evaporation.  The BPT
discharge value is the average of the three reported non-zero
discharge values, 6,330 1/kkg (1,520 gal/ton).

Forging Wet Air Pollution Control Slowdown.  One plant reported
discharging water from a wet scrubber used to control air pollu-
tion from a forging operation.  Because the plant currently recy-
cles 90 percent of the scrubber water, the BPT discharge allow-
ance, based on the reported discharge value from this scrubber,
is 266,000 1/kkg (63,800 gal/ton).

Forging Equipment Cleaning Wastewater.  One plant reported using
water to clean a forging press.  The wastewater from this opera-
tion is not recycled.  The BPT discharge allowance, based on the
one reported value, is 1,620 1/kkg (388 gal/ton).
                               739

-------
Casting

Direct Chill Casting Contact Cooling Water.  One plant casts mag-
nesium by the direct chill method.  Since the cooling water used
in this operation is completely recycled, the BPT discharge
allowance is zero.

Surface Treatment

Three plants supplied information on eight magnesium surface
treatment operations.  Information was provided on the discharge
of eight surface treatment baths and on eight rinsewater
discharges.

Surface Treatment Spent Baths.  Three of the operations only lose
water by drag-out on the product surface and the wastewater from
two of the operations is contract hauled.  The BPT discharge
allowance is the average of the three reported non-zero values,
or 465 1/kkg (111 gal/ton).

Surface Treatment Rinsewater.  Rinsewater is batch dumped from
three operations on a yearly basis and from one operation on a
daily basis.  Rinsewater is continuously discharged from four
operations.  The average of the eight reported discharge values
is the BPT flow, 17,700 1/kkg (4,250 gal/ton).

Sawing/Grinding

The following information was reported on sawing/grinding
operations in this subcategory:

Number of plants:  4
Number of operations:  4
Number of operations using emulsion lubricant:  3
Number of operations using no lubricant:  1.

Sawing/Grinding Spent Lubricants.  Two of the operations have no
wastewater discharge because the spent lubricant is hauled with
the saw chips and one operation loses lubricant only through
drag-out.  Consequently, the BPT discharge allowance is zero.

Sanding and Repairing Wet Air Pollution Control Slowdown.  One
plant reported using wet scrubbers to control air pollution from
a sanding operation and a repairing operation.  At least 90 per-
cent of the scrubber liquor is recycled in both operations.  The
BPT discharge allowance is the average of the two reported dis-
charge values, 428 1/kkg (103 gal/ton).
                               740

-------
Degreasing

Only a small number of surveyed plants with solvent degreasing
operations have process wastewater streams associated with the
operation.  These facilities may use a water rinse after solvent
degreasing, or discharge solvent recovery sludge to the facil-
ity's oil treatment system.  Because most plants practice solvent
degreasing without wastewater discharge, the Agency believes zero
discharge of wastewater is an appropriate discharge limitation.

Calculation of BPT Effluent Mass Limitations

The pollutants regulated in the magnesium forming subcategory are
chromium, zinc, ammonia, fluoride, magnesium, oil and grease,
TSS, and pH.  The BPT mass limitations for these pollutants are
listed in Section II, Part 2, Subpart C.  These limitations were
calculated by multiplying the BPT normalized flow (1/kkg, summa-
rized in Table IX-21) by the one-day maximum and 10-day average
effluent concentration (mg/1) for each pollutant achievable using
the BPT treatment system OTable VII-9).  The 10-day average is
used to calculate the maximum monthly average because, as discus-
sed in Section VII, it provides a reasonable basis for a monthly
average and is typical of the sampling frequency required by
discharge permits.

Costs, and Benefits

In establishing BPT, EPA must consider the cost of treatment and
control in relation to the incremental increase in mass of pollu-
tants removed (benefits).   The application of BPT to direct dis-
chargers will remove approximately 12,772.8 kg/yr (28,159.2
Ib/yr) of pollutants from estimated current discharge levels.
The corresponding capital and annual costs (1982 dollars) for
this removal are $50,500 and $70,900 per year, respectively.  The
Agency concludes that these pollutant removals justify the costs
incurred by plants in the magnesium forming subcategory.

URANIUM FORMING SUBCATEGORY

Production Operations and Discharge Flows

Extrusion

The following information was reported on extrusion operations in
this subcategory:

Number of plants:  2
Number of operations:  5
Number of operations using lubricants:  2*
Number of operations using contact cooling water:  4*.

*0ne operation uses lubricants and contact cooling water.
                               741

-------
Extrusion Spent Lubricants.  Spent lubricants are not discharged
from either of the two operations.  The extrusion lubricants used
are typically neat oils.  As discussed previously for extrusion
spent lubricants in the nickel/cobalt forming subcategory, it is
better to remove the neat oils directly and not to discharge the
stream.  Therefore, the BPT discharge allowance is zero,,

Extrusion Solution Heat Treatment Contact Cooling Water,.  In none
of the four operations is the water recycled.  The BPT discharge
allowance is the average of the four reported values, 2,720 1/kkg
(653 gal/ton).

Extrusion Tool Contact Cooling Water.  One plant reported using
contact cooling water to quench the extrusion tools.  The water
was not recycled.  The BPT discharge allowance is the reported
value, 517 1/kkg (124 gal/ton).

Forging

The following information was reported on forging oprations in
this subcategory:

Number of plants:  1
Number of operations:   1
Number of operations using lubricants:  1*
Number of operations using contact cooling water:   1*.

*The one operation uses a lubricant and contact cooling water.

Forging Spent Lubricant.  No lubricant discharge information was
provided for the one operation.  The forging lubricants are typi-
cally neat oils.  As discussed previously for forging and swaging
spent neat oils in the nickel/cobalt subcategory,  it is better to
remove the neat oils directly and not to discharge the stream.
Therefore, the BPT discharge allowance for spent lubricants is
zero.

Forging Solution Heat Treatment Contact Cooling Water.  The BPT
discharge allowanceis the one reported value, 2,840 1/kkg (682
gal/ton).

Surface Treatment

All three uranium forming plants provided information on surface
treatment operations.   Spent baths are discharged from four
operations,  rinsewater from five.

Surface Treatment Spent Baths.   Spent baths from three of the
four operations are neutralized and contract hauled.  The BPT
discharge allowance is based on the one reported non-zero value,
35.6 1/kkg (8.52 gal/ton).
                               742

-------
Surface Treatment Rinsewater.  Rinsewater from two of the opera-
tlons Is neutralized and contract hauled; rinsewater from one of
the operations is sent to a holding pond which is not discharged.
Rinsewater from the other two operations is discharged.  The
discharge value of one of these streams was not included in the
calculation of the BPT allowance because it is much larger than
the other one and is not believed to be typical of current best
practice.  The BPT discharge allowance, based on the other
reported value, is 1,480 1/kkg (355 gal/ton).

Surface Treatment Wet Air Pollution Control.  One plant reported
using a wet scrubber to control air pollution from its surface
treatment operations.  The BPT discharge allowance, based on the
one reported value, is 74.2 1/kkg (17.8 gal/ton).

Sawing/Grinding

Sawing/Grinding Spent Emulsions.   One plant reported using lubri-
cating emulsionsin ^wo sawing/grinding operations.  However,
water usage and discharge data were reported for only one of the
operations.  The BPT discharge allowance, based on the one
reported value, is 3.10 1/kkg (0.744 gal/ton).

Post Sawing/Grinding Rinsewater.   One plant reported using a
stagnant bath to rinse uranium pieces after they are sawed or
ground.  The bath is batch dumped on a weekly basis.  The BPT
discharge allowance, based on the one reported value, is 38.1
1/kkg (9.12 gal/ton).

Degreasing

Only a small number of surveyed plants with solvent degreasing
operations have process wastewater streams associated with the
operation.  These facilities may use a water rinse after solvent
degreasing, or discharge solvent recovery sludge to the facil-
ity's oil treatment system.  Because most plants practice solvent
degreasing without wastewater discharge, the Agency believes zero
discharge of wastewater is an appropriate discharge limitation.

Calculation of BPT Effluent Masj? Limitations

The pollutants regulated in the uranium forming subcategory are
cadmium, copper, nickel, fluoride, radium, uranium, oil and
grease, TSS, and pH.  The BPT mass limitations for these pollu-
tants are listed in Section II, Part 2, Subpart H.  These limi-
tations were calculated by multiplying the BPT normalized flow
(1/kkg, summarized in Table IX-22) by the one-day maximum and
10-day average effluent concentration (mg/1) for each pollutant
achievable using the BPT treatment system (Table VII-9).  The
10-day average is used to calculate the maximum monthly average
                              743

-------
because, as discussed  in Section VII,  it provides  a  reasonable
basis for a monthly avergage and is typical of the sampling
frequency required by  discharge permits.

Benefits

In establishing BPT, EPA must consider the cost of treatment  and
control in relation to the incremental increase in mass of pollu-
tants removed from wastewater (benefits).  The application of BPT
to direct dischargers will remove approximately 1,655.0 kg/yr
(3,648.7 Ib/yr) of pollutants from estimated current discharge
levels.  The corresponding capital and annual costs  (1982 dol-
lars) for this removal are $287,900 and $148,400 per year,
respectively.  The Agency concludes that these pollutant removals
justify the costs incurred by plants in the uranium  forming
subcategory.

APPLICATION OF REGULATIONS IN PERMITS

The purpose of these limitations (and standards) is to form a
uniform basis for regulating wastewater effluent from the nonfer-
rous metals forming category.  For direct dischargers, this is
accomplished through NPDES permits.  Since the nonferrous metals
forming category is regulated on an individual waste stream
"building-block" approach, three examples of applying these
limitations to determine the allowable discharge from nonferrous
metals forming facilities are included.

Some process wastewater streams may not be covered by this regu-
lation or other effluent guidelines but are generated in the
nonferrous metals forming plant and must be dealt with either in
the permit or pretreatment context.  Whenever such wastewaters
are encountered, the permit writer or control authority should
take into account the minimum necessary water use for the process
operation and the treatment effectiveness of the model technology
using these factors to derive a mass discharge amount for the
unregulated process wastewater.

Example 1

Plant X forms tantalum strip by a hot rolling operation which
uses an emulsion as a  lubricant.  The plant produces 20 kkg
(44,000 Ibs) of final product strip per day.  In the process, a
stock billet is heated and put through the rolling mill for five
passes, then annealed  (dry annealing), brought back  to the
rolling mill for three more passes, annealed again, rolled for
four more passes, and  annealed for a final time to produce the
product.  Table IX--23  illustrates the calculation of the allow-
able BPT discharge for nickel, one of the pollutants regulated in
this subcategory.  The allowable discharge for the other regu-
lated pollutants would be calculated in the same way.
                              744

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This example illustrates  the  calculation  of  an  allowable  pollu-
tant mass discharge using  "off-kilograms".   The  term  "off-
kilogram" means the mass  of metal  or  metal alloy removed  from a
forming operation at the  end  of a  process cycle  for transfer  to  a
different machine or process.  In  this  example,  each  of the
passes through the rolling mill would not be  counted  as separate
 off-kilograms" since the  product  is  not  transferred  to a differ-
ent machine or process after  each  pass.   However,  each of the
three sets of passes would be counted as  separate "off-kilograms"
since the product is transferred to an  annealing process  after
each set of passes and would  require  additional  lubricant when
brought back to the rolling mill.  Therefore, for this plant,  the
off-kilograms to produce 20 kkg of final  product is 60 kkg.   This
is the daily production used  in the calculations presented in
Table IX-23.

Example 2

Plant Y forms lead bullets by an extrusion and  swaging process
and casts lead shot.  The plant operates  250  days  per year with  a
total annual production of 250 kkg (551,000  Ibs)  of shot  and
1,000 kkg (2,204,000 Ibs) of bullets.   Shot  is produced by cast-
ing.  Bullets are produced by casting lead into  ingots (station-
ary casting), extrusion followed by a spray  quench at the press,
and swaging.  The bullets  are washed  and  rinsed  before being
assembled into cartridges.  Table  IX-24 illustrates the
calculation of the allowable BPT discharge of TSS.

The daily shot casting production  is 250  kkg/yr  divided by 250
days/yr or 1 kkg/day.   This production  is multiplied by the shot
casting limitation (mg/kkg) to get the  daily  discharge limit  for
shot casting at Plant Y.  The daily bullet production is  1,000
kkg/yr divided by 250 days/yr or 4 kkg/day.   This  production  is
multiplied by the limitations (mg/kkg)  for extrusion press heat
treatment contact cooling water, extrusion press hydraulic fluid
leakage, alkaline cleaning spent baths  and rinsewater, and swag-
ing spent emulsions to get the daily  discharge  limits for bullet
making.  The total plant production (5 kkg/day)  is multiplied  by
the limitation for miscellaneous nondescript wastewater sources
to get the daily limit for miscellaneous  sources.  The sum of  the
daily limits for the individual operations becomes the plant
limit.

Example^ 3

Plant Z forges 125 kkg (275,000 Ibs) of nickel and 25 kkg (55,000
Ibs) of titanium per year  (250 days).   Eighty percent of  the
nickel and 10 percent of the titanium are pickled, then rinsed
with a spray. The plant has one mechanical forge and uses contact
cooling water on the dies.  The one forge and one  pickle  bath  are
                               745

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used for both nickel and titanium products.  Air emissions  from
the pickling area are controlled by a wet scrubber.  Table  IX-25
illustrates the calculation of the allowable BPT discharge  for
nickel.  Table IX-26 illustrates the calculation of the allowable
BPT discharge for TSS.

The daily nickel forging production is 125 kkg/yr divided by 250
days/yr or 0.5 kkg/day.  This production is multiplied by the
nickel forging die contact cooling water limitation (mg/kkg) to
get the daily nickel discharge limit for nickel forging at  Plant
Z.  The plant does not generate any forging equipment cleaning
wastewater so it receives no allowance for that waste stream.
Eighty percent of forged nickel or 0.4 kkg/day are pickled  and
rinsed.  This production is multiplied by the nickel surface
treatment spent bath limitation, the nickel surface treatment
rinsewater limitation, and the nickel wet air pollution control
blowdown limitation to get the daily nickel discharge limit for
nickel surface treatment at Plant Z.  The total nickel production
(0.5 kkg/day) is multiplied by the limitation for miscellaneous
nondescript wastewater sources to get the daily nickel discharge
limit for miscellaneous sources.  There is no nickel limit  for
any of the waste streams generated by titanium forming and
associated operations.  Therefore, the daily nickel discharge
limit for all titanium forming operations is zero.

The calculation of the allowable BPT discharge for TSS, shown in
Table IX-26, is similar.  However, there is a TSS limit for
wastewater generated by titanium forming operations, so nickel
and titanium operations contribute to the daily TSS discharge
limit.

The same physical water may be used to process metal in more than
one subcategory.  For example, one bath can be used to pickle
both nickel and titanium.  Because the discharge limits are based
on mass of production, the plant is allowed to discharge 35,000
mg of TSS for every kkg of nickel pickled in the bath and 6,600
mg of TSS for every kkg of titanium pickled in the bath.

Note, there is no allowance for miscellaneous nondescript waste-
water sources in the titanium forming subcategory.   For this
reason, only the nickel production was used to calculate the
daily TSS discharge limit for miscellaneous sources.
                               746

-------
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                             SECTION X

         BEST AVAILABLE TECHNOLOGY ECONOMICALLY ACHIEVABLE
The effluent limitations in this section apply to existing  direct
dischargers.  A direct discharger is a facility which  discharges
or may discharge pollutants into waters of the United  States.
These effluent limitations, which must be achieved by  July  1,
1984, are based on the best control and treatment technology
employed by a specific point source within the industrial cate-
gory or subcategory, or by another industry where it is readily
transferable.  Emphasis is placed on additional treatment tech-
niques applied at the end of the treatment systems currently
employed for BPT, as well as improvements in reagent control,
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 employed, process changes, non-
water quality environmental impacts (including energy  require-
ments), and the costs of application of such technology.  BAT
technology represents the best existing economically achievable
performance of plants of various ages, sizes, processes, or other
characteristics.  Those categories whose existing performance is
uniformly inadequate may require a transfer of BAT from a differ-
ent subcategory or category.  BAT may include process  changes or
internal controls, even when these are not common industry  prac-
tice.  This level of technology also considers those plant
processes and control and treatment technologies which at pilot
plants and other levels have demonstrated both technological per-
formance and economic viability at a level sufficient  to justify
investigation.

TECHNICAL APPROACH TO BAT

The Agency reviewed and evaluated a wide range of technology
options to ensure that the most effective technologies were used
as the basis of BAT.  To accomplish this, the Agency examined
three technology alternatives which could be applied to nonfer-
rous metals forming as BAT options and which would represent
substantial progress toward prevention of pollution of the
environment above and beyond progress achievable by BPT.  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 reasonableness of costs.
                               785

-------
EPA evaluated three levels of BAT for the category at proposal.
Option 1 is BPT treatment.  Option 2 is BPT treatment plus flow
reduction and in-plant controls.  Option 3 provides additional
levels of treatment.  Options 1, 2,  and 3 technologies are, in
general, equally applicable to all the subcategories of the
nonferrous metals forming category.   Each treatment produces
similar concentrations of pollutants in the the effluent from all
subcategories.  Mass limitations derived from these options will
vary, however, because of the impact of different production
normalized wastewater discharge flow allowances.

In summary form, the treatment technologies which were considered
for the nonferrous metals forming category are:

     Option 1 (Figure X-l):

          Lime and settle (chemical  precipitation of metals
          followed by sedimentation), and

          pH adjustment; and, where  required,

          Chemical emulsion breaking,

          Oil skimming,

          Ammonia steam stripping,

          Cyanide removal, and

          Hexavalent chromium reduction.

     (This option is the technology  on which BPT  is based).

     Option 2 (Figure X-l):

          Option 1, plus process wastewater flow  reduction by
          the following methods:

             Heat treatment contact  cooling water recycle through
             cooling towers.
             Air pollution control scrubber liquor recycle.
             Countercurrent cascade  rinsing or other water effi-
             cient methods applied to alkaline cleaning or
             surface treatment and other rinses.

     Option3 (Figure X-2):

          Option 2, plus multimedia  filtration at the end
          of the Option 2 treatment  train.
                              786

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Option 1

Option 1 is  the BPT end-of-pipe  treatment  technology.  This
treatment train depicted in Figure X-l consists  of preliminary
treatment, when necessary, consisting of emulsion breaking,  oil
skimming, ammonia steam stripping, cyanide removal, and hexava-
lent chromium reduction.  The  effluent from  preliminary treatment
is combined  with other wastewaters for combined  treatment by  lime
and settle.

Option 2

Option 2 builds upon the BPT end-of-pipe treatment technologies
by incorporating in-process flow reduction measures.  The flow
reduction measures eliminate some wastewater streams  and concen-
trate the pollutants in others.  Treatment of more concentrated
streams allows a greater net removal of pollutants.   Addition-
ally, treating a reduced flow  reduces costs.  Methods for
reducing process wastewater generation or  discharge include:

Heat Treatment Contact Cooling Water Recycle Through  Cooling
Towers.  The cooling and recycle of heat treatment contact cool-
ing water is practiced by seven plants in  this category.  The
function of heat treatment contact cooling water is to remove
heat quickly from the nonferrous metals.  Therefore,  the princi-
pal requirements of the water  are that it be cool and not contain
dissolved solids at a level that would cause water marks or  other
surface imperfections.   There  is sufficient  industry  experience
to assure the success of this  technology using cooling towers or
heat exchangers.  Although five plants have  reported  that they do
not discharge any quench water by reason of  continued recycle,
some blowdown or periodic cleaning is likely to be needed to
prevent a build-up of dissolved and suspended solids.

Scrubber Liquor Recycle.  The  recycle of scrubber liquor from wet
processes controlling air pollution from forming operations is
practiced by 11 plants in this category.  The scrubber water
picks up particulates and fumes from the air.  Scrubbers have
relatively low water quality requirements  for efficient opera-
tion, accordingly,  recycle of  scrubber liquor is appropriate for
nonferrous metals forming operations.  A blowdown or  periodic
cleaning is necessary to prevent the buildup of dissolved and
suspended solids.

Countercurrent Cascade Rinsing Applied to Gleaning or Etching
and Die Cleaning Rinses.  Countercurrent cascade rinsing is a
mechanism commonly encountered in nonferrous metals processing
operations (see Section VII).   The cleanest water is used for
final rinsing of an item, preceded by rinse  stages using water
with progressively more contaminants to partially rinse the item.
                               787

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Fresh make-up water is added to the final rinse, and contaminated
rinse water is discharged from the initial rinse stage.  The
make-up water for all but the final rinse stage is from the
following stage.

The countercurrent cascade rinsing process substantially improves
efficiencies of water use for rinsing.  For example, the use of a
two-stage countercurrent cascade rinse can reduce water usage to
approximately one-tenth of that needed for a single-stage rinse
to achieve the same level of product cleanliness.   Similarly, a
three-stage countercurrent cascade rinse would reduce water usage
to approximately one-thirtieth.   Through information supplied by
plants in dcps or obtained during sampling visits by the Agency,
countercurrent cascade rinsing is known to be practiced at three
nonferrous metals forming plants.  However, the Agency believes
that more than three plants use countercurrent cascade rinsing.
Most plants did not provide sufficient information in the dcp to
classify the type of rinsing performed in their operations.
Nonetheless, there is sufficient industry experience in counter-
current cascade rinsing to assume that a larger number of plants
use such rinsing operations.  The installation of countercurrent
cascade rinsing is applicable to existing nonferrous metals
forming plants because surface treatment and alkaline cleaning
operations are usually discrete operations and space is generally
available for additional rinse tanks following these operations.

Option 3

Option 3, depicted in Figure X-2 builds upon the technical
requirements of Option 2 by adding conventional mixed-media
filtration after the Option 2 technology treatment train.

The Agency briefly considered a fourth option, filtration without
flow reduction.   This option would have been equivalent to Option
1 with the addition of conventional mixed-media filtration after
the Option 1 technology treatment train.   However, flow reduction
greatly reduces the size of the wastewater treatment system
required, and hence its costs.   Simultaneously, the efficiency of
the treatment system is increased.  For these reasons, the Agency
concluded that filtration without flow reduction did not make
sense.  Also, greater pollutant removals could be achieved by
implementing in-process flow reduction prior to end-of-pipe
treatments, including multimedia filtration.  Furthermore, for
waste streams which cannot be flow-reduced this option was
equivalent to Option 3.

Estimation of BAT Options Costs and Benefits

The Agency estimated the costs and benefits of the implementation
of each of the options described above in order to evaluate their
economic achievability.  The capital and annual costs of each
                               738

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option were estimated for each subcategory, as described  in
detail in Section VIII.  Costs were estimated for 140 dischargers
by extrapolation of costs for 23 plants generated by the  computer
model described in Section VIII.  The benefits of implementing
each treatment option were also estimated for each subcategory,
again, based on benefits calculated for 23 plants and extrapo-
lated to the remaining dischargers in the category.

This approach was used because of the limited time between
receipt of completed dcp's and the Court Ordered date for pro-
posal of these guidelines and standards.  However, the Agency
recognizes that this methodology has some drawbacks and intends
to evaluate the costs and benefits of the technology options on a
plant-by-plant basis before promulgating these guidelines and
standards.

The cost estimates for the direct dischargers are presented in
Table X-l.  All costs are based on March 1982 dollars.

The method of estimating costs has been described in detail in
Section VIII.  Briefly, cost estimation was accomplished using a
computer model which accepts inputs specifying the required
treatment system, chemical characteristics of the raw waste
streams, flow rates and treatment system entry points of these
streams, and operating schedules.  The chemical characteristics
of the raw waste streams input to the model were based on sam-
pling data obtained during visits to 17 nonferrous forming
plants.  The model utilizes a computer-aided design of a waste-
water treatment system containing modules that are configured to
reflect the appropriate equipment at an individual plant.  The
model designs each treatment module and then executes a costing
routine that contains the cost data for each module.  The capital
and annual costs from the costing routine are combined with capi-
tal and annual costs for the other modules to yield the total
costs for that regulatory option.  The process is repeated for
each regulatory option.

Capital and annual cost data for the selected treatment processes
were obtained from three sources:  (1) equipment manufacturers,
(2) literature data, and (3) cost data from existing plants.  The
major source of equipment costs was contacts with equipment ven-
dors, while the majority of annual cost information was obtained
from the literature.  Additional cost and design data were
obtained from data collection portfolios, when possible.

Each of the 23 costed plants was selected to represent a group of
similar plants ("costing group") because the plants assigned to a
given costing group were apportioned to the subcategories present
in that group based on mass of finished product produced.  This
apportionment process is described in detail in Section VIII.
                               789

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An estimate of the total mass of pollutants removed  from waste-
water (benefits) by each option was also made for each subcate-
gory.  The benefits that the treatment options are estimated  to
achieve for direct dischargers are presented in Tables X-2
through X-14.

The first step in the calculation of the benefit estimates was to
estimate the concentration of pollutants in the raw wastewater
from each subcategory.  This was done with data from the computer
model, which generates material balances for water and each pol-
lutant at any point in the system.  Concentrations of the pollu-
tants removed by lime and settle (toxic and nonconventional
metals, and fluoride) were assumed to be the concentrations
generated by the computer model at the influent to the lime and
settle module of a cos ted plant.  Computer-generated data from a
costed plant generating wastewater from operations in any one
subcategory were used to estimate the pollutant concentration for
all raw wastewater from that subcategory.

Concentrations of pollutants removed by preliminary treatment
(oil and grease, cyanide, and ammonia) were estimated differ-
ently.  First, the total mass of the pollutant generated by a
costed plant was determined.  This was done by multiplying the
computer-generated pollutant concentration at the influent to the
applicable preliminary treatment module by the flow  into the  mod-
ule.   The total mass of pollutant was then divided by the total
volume of treated wastewater at the costed plant to yield the
average concentration of the pollutant in the raw wastewater.

The raw waste concentrations (mg/1) for pollutants in each sub-
category were multiplied by the raw waste flow (1/yr) for direct
dischargers and indirect dischargers in each subcategory.  This
produced an estimate of the raw mass (kg/yr) of each pollutant
generated in each subcategory by discharge status.  Thus, to
accurately estimate the raw mass (kg/yr) of each pollutant gen-
erated in each subcategory, the raw waste flow (1/yr) from each
operation present in each subcategory at a given plant must be
known.  However, in the limited time available between the
receipt of the dcp's and the Court Ordered deadline  for proposal
of these guidelines, it was not always possible to determine what
portion of a plant's reported wastewater discharge was attributa-
ble to which nonferrous metals forming subcategory.  Therefore,
estimates of raw waste flow for direct dischargers and indirect
dischargers in each subcategory were based on mass of finished
product produced in each subcategory.  These estimates were made
using the same strategy as was used for cost estimation,
described in detail in Section VIII, and reiterated below.
                               790

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Raw waste flows  for each  subcategory  were  determined  by  summing
the estimated flows for direct  dischargers  in  a  subcategory  and
the estimated flows for indirect  dischargers  in  that  subcategory.
These estimates were made using the following  procedure:

        First, for a single costing group,  the number of  pounds
        of metal  formed in each subcategory in each plant in the
        group was determined.  It was  also  determined if  the
        wastewaters associated with this production were
        directly  or indirectly  discharged.

        Second, the total pounds  of metal  formed in the costing
        group were calculated.

        Third, for each subcategory present in the costing
        group, the pounds of metal associated  with direct
        dischargers and the pounds of  metal associated with
        indirect  dischargers were calculated.

        Fourth, the total group wastewater  flow  was calculated
        by multiplying the wastewater  flow  of  the representative
        plant by  the number of plants  in the costing  group.

        Fifth, the total group raw waste flow  was apportioned  to
        the direct and indirect discharges  in  each subcategory
        present in the group by production  weighting  the  total
        group raw waste flow.

For example:

     [pounds of Ni, wastewater directly discharged, group n] x
                   total poundsmetal, group n

     [total raw waste flow, group n] = raw  waste flow from group
                                       n attributable to  directly
                                       discharged nickel  forming
                                       wastewater

These five steps  were repeated  for each of  the 22 costing groups.

The raw waste flows for direct dischargers  in  one subcategory
were determined by adding the production weighted flows from each
costing group.  The same procedure was used to determine  raw
waste flows for indirect dischargers in the  subcategory.   The  raw
waste flows for each of the 11 subcategories were determined in
the same way.  Discharge flows for each option for each subcate-
gory were also calculated using the procedure  described above.
                                791

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The total mass of each pollutant  (kg/yr) discharged at  each
option for each subcategory was calculated as follows:  the  total
flow  (1/yr) discharged at one option  in a subcategory was  multi-
plied by the long-term mean effluent  concentration of each pollu-
tant  (mg/1) (Table VII-9) achievable  using that option.  This was
done  for all three options in all 11  subcategories.  The total
mass  of each pollutant removed  (kg/yr) at each option for  each
subcategory was calculated by subtracting the total mass dis-
charged (kg/yr) from the total  raw mass (kg/yr).

For some regulated pollutants (in particular, cyanide,  ammonia,
and fluoride), the benefits, calculated as described above,  are
very  low or zero.  This is due  to the use of average subcategory
concentrations in the calculation.  These pollutants are not
expected to be present in all waste streams in the subcategories
in which they are regulated (see Section V).  When they are
present, they are present in concentrations significantly  above
treatable concentrations and substantial removals would be
achieved by treatment at an individual plant.

No sampling data were available for several nonconventional
pollutants regulated in some subcategories (columbium, hafnium,
tantalum,  tungsten, and zirconium).  However, for all of these
pollutants, raw wastewater concentrations were estimated using
the criteria outlined in Section V and benefits were calculated.
In addition, no estimates were  made of vanadium benefits.

As discussed in Section VIII, the Agency intends to recalculate
the costs and benefits of each  technology option on a plant-by-
plant basis prior to promulgation of these standards.  This
method of calculation will eliminate  the use of average subcate-
gory concentrations in calculating benefits and thus more  accu-
rately represent the true removals of cyanide, ammonia, and
fluoride achievable by the technology options.  The Agency also
intends to include vanadium removals  in the benefit recalcula-
tion.

The mass of pollutants currently discharged differs from the mass
of pollutants in the raw waste  because treatment is currently in
place at some plants.  The dcp  summary sheets were used to tally
the treatment systems which are currently in place at direct dis-
chargers and indirect dischargers.  It was not possible to tell
from the dcp summary sheets if  a plant is currently discharging
wastewater at the reduced flows stipulated by Option 3.  There-
fore, it was assumed that.flow  reduction is not currently  in
place at any plant.

Treatment systems that used chemical precipitation (lime,
caustic) and/or coagulant addition (lime, alum, polyelectrolyte)
followed by settling, were considered to have treatment in place
equivalent to Option 1.  That is, the mass of toxic metals
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 (except chromium) and nonconventional pollutants  (except  ammonia)
removed by these plants was considered to be equivalent to the
mass removed by Option 1 treatment technology.

Treatment systems that consisted of chemical precipitation fol-
lowed by settling and an additional solids removal step (filter,
settling basin, polishing pond or lagoon) were considered to have
treatment in place equivalent to Option 3 without in-process flow
reduction.  That is, the mass of toxic metals (except chromium)
and nonconventional pollutants (except ammonia) removed by these
plants was considered to be equivalent to the mass removed if
Option 3 treatment technology was applied without flow reduction.

Treatment systems that had a preliminary chromium reduction step
prior to chemical precipitation and settling were considered to
remove the same mass of chromium as removed by Option 1 treatment
technology.  If the chromium reduction step preceded a treatment
system consisting of chemical precipitation, settling and addi-
tional solids removal, the system was considered  to remove the
same mass of chromium as removed by Option 3 treatment technol-
ogy, applied without flow reduction.

Treatment systems that included ammonia stripping were considered
to remove the same mass of ammonia as removed by Option 1 treat-
ment technology.

Treatment systems that included oil skimming and/or emulsion
breaking were considered to remove the same mass of oil and
grease as removed by Option 1 treatment technology.

Treatment systems that included a single settling, filtration or
any other solids separation process were considered to remove the
same mass of total suspended solids as removed by Option 1 treat-
ment technology.  Treatment systems that involved a second solids
separation process after the primary step were considered to
remove the same mass of total suspended solids as removed by
Option 3 treatment technology, applied without flow reduction.

After the number of plants in each subcategory with various types
of treatment in place was tallied, the fraction of plants with
each treatment was calculated.  Separate calculations were made
for direct dischargers and indirect dischargers.  No considera-
tion was given to the volume of wastewater treated by the tallied
plants.   The mass of pollutant currently discharged was estimated
for direct and indirect dischargers for each subcategory using an
approach based upon the expression:
                               793

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     Current = (1-x) Raw + (x-y) Option 1 +  (y) Option 3

     Where x = fraction of plants currently  removing the same
               mass of the pollutant as removed by Option 1

           y = fraction of plants currently  removing the same
               mass of the pollutant as removed by Option 3,
               without flow reduction

         Raw = total mass of the pollutant in untreated waste-
               water (kg/yr)

    Option 1 = total mass of the pollutant in discharged waste-
               water treated by Option 1 technology (kg/yr)

    Option 3 = total mass of the pollutant in discharged waste-
               water treated by Option 3 technology, without flow
               reduction (kg/yr)

     Current = total mass of pollutant currently discharged
               (kg/yr)

That is, the current mass discharged is the  sum of the fraction
of plants with no treatment multiplied by the raw mass discharge,
plus the fraction of plants achieving Option 1 removals multi-
plied by the Option 1 mass discharge, plus the fraction of plants
achieving Option 3 pollutant removals (without flow reduction)
multiplied by the Option 3 without flow reduction mass discharge.

Inherent to this approach are the following  assumptions:

        A facility with wastewater treatment equipment tallied as
        equivalent to that specified by Option 1 will discharge
        wastewater with the pollutant concentrations specified
        for lime and settle technology in Table VII-9.

        A facility with wastewater treatment equipment tallied as
        equivalent to that specified by Option 3 will discharge
        wastewater with the pollutant concentrations specified
        for lime, settle, and filter technology, in Table VTI-9.

        A facility tallied as having no treatment in place
        discharges wastewater at the estimated raw waste
        pollutant concentrations.

However, an individual facility with treatment equipment in place
equivalent to that specified by Option 1 or Option 3 may dis-
charge wastewater at pollutant concentrations higher or lower
than those specified in Table VII-9.  Nevertheless, the Agency
believes that even if a plant with wastewater treatment equipment
                               794

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in place is not currently achieving  the  effluent  limitations  spe-
cified in Table VII-9, it could do so by operating its  equipment
properly.  Because  this could be  accomplished without any  addi-
tional costs, no additional benefits should be assumed.

Also, a facility with no tallied  treatment in place may, in fact,
discharge wastewater with pollutant  concentrations lower than the
estimated raw waste pollutant concentrations.  However, this  is
the only possible assumption to make without preforming a  plant-
by-plant cost analysis.

The current mass removed of each  pollutant (kg/yr) for  each
subcategory was calculated by subtracting the current mass
discharged (kg/yr)  from the total raw mass (kg/yr).

BAT OPTION SELECTION

EPA has selected Option 3 as the  basis for BAT effluent limita-
tions in 9 of the 11 subcategories.  Option 2 was selected for
the lead/tin/bismuth forming subcategory and the  iron and  steel/
copper/aluminum metal powder production  and powder metallurgy
subcategory.   These options were  selected because they  provide
protection of the environment consistent with proven operation of
in-process controls and treatment effectiveness.  The reduction
of pollutants in the effluent, especially toxic metals, is
substantial and economically achievable, thus resulting in a
minimal impact on the industry.

Option 3 builds upon the technologies established for BPT.  Flow
reduction measures and multi-media filtration are the principal
mechanisms for reducing pollutant discharges at this option.
Flow reduction measures concentrate the pollutants in wastewater
streams.  Treatment of a more concentrated stream allows a
greater net removal of pollutants.  In addition,  flow reduction
lowers the cost of  treatment by reducing the flow and hence
pumping and chemical costs and the size of treatment equipment.
In many cases, the  costs for reducing a wastewater flow and
treating the reduced flow with lime, settle, and multimedia
filtration are less than the costs of treating a non-reduced
wastewater flow by  lime and settle alone.   The application of
technologies such as countercurrent cascade rinsing to  surface
treatment and alkaline cleaning lines is not expected to cause
serious interruptions in production  since these operations tend
to be used intermittently, allowing process changes to  be  sched-
uled.  In 9 of the 11 subcategories, sufficient amounts of pollu-
tants remain in the waste streams after lime and settle treatment
to justify the use  of multi-media filtration.  The Agency
believes that the costs involved warrant selection of Option  3 as
the model BAT technology for 9 of the 11 subcategories.
                               795

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EPA has decided to select Option 2 technology for the lead/tin/
bismuth subcategory and the iron and steel/copper/aluminum metal
powder production and powder metallurgy subcategory.  Lime and
settle treatment is particularly effective for these two subcate-
gories.  When it is applied after flow reduction, the amount of
toxic metal pollutants remaining in the wastewater is not
significant.  That is, application of filters after lime and
settle would remove an estimated 322 Ibs/yr (146 kg/yr) of
additional pollutants, but only an additional 22.5 Ibs/yr (10.2
kg/yr) of toxic pollutants.

The Agency recognizes that many nonferrous metals forming plants
not only perform operations that fall under more than one nonfer-
rous metals forming subcategory, but also have discharges that
are subject to regulation under other point source categories.
Therefore, it was difficult to estimate the costs specifically
associated with treating nonferrous metals forming wastewaters.
As mentioned previously, the Agency intends to evaluate the costs
and benefits of the proposed technology options on a plant-by-
plant basis.  As part of the effort, the Agency intends to con-
duct a plant-by-plant analysis of the degree of integration in
nonferrous forming plants and the costs associated with each
technology option.  Based on this evaluation, and any data pro-
vided during the public comment period, EPA may choose to promul-
gate Option 2 as the BAT technology for one or more of these nine
subcategories for which Option 3 is the proposed technology.

In particular^ four subcategories, nickel/cobalt, refractory
metals, titanium, and zirconium/hafnium, are highly integrated
within themselves and with other industrial categories, some of
which are not subject to effluent limitations based on the addi-
tion of filtration and typically combine process wastewaters from
all operations for common treatment.  If EPA determines that it
has significantly underestimated the costs for these plants to
either segregate their nonferrous metals forming flows subject to
effluent limitations based on the addition of filtration or
cotreating their combined wastewater flows and achieve the appli-
cable effluent limitations, the Agency may choose to promulgate
BAT based on Option 2 for those four subcategories and any other
subcategories similarly situated.

The effluent limitations which would be imposed if Option 2 were
selected for any of these nine subcategories are detailed in
Section 2, Part 8, Subparts A and C through J.

The Agency is also considering promulgating Option 3 for both the
lead/tin/bismuth and the iron and steel/copper/aluminum metal
powder production and powder metallurgy subcategories, if the
plant-by-plant analysis and additional data show that filtration
does remove significant additional quantities of pollutants in
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these two subcategories and that the filtration technology is
economically achievable.  The limitations that would be imposed
if Option 3 were selected for either of these two subcategories
are detailed in Section 2, Part 8, Subparts B and K.

REGULATED POLLUTANT PARAMETERS

The raw wastewater concentrations from individual operations and
each subcategory as a whole were examined to select those pollu-
tants found at frequencies and concentrations warranting regula-
tion.  The selection process and the pollutants selected for
regulation are described in Section VI.

As discussed in Section VII, the correct pH must be maintained in
the lime and settle treatment system to assure adequate removal
of the metals regulated in each subcategory.  Clarifier effluent
pH should be maintained within the range of 7.5 to 10 at all
times to ensure optimal metals removal.

The Agency recognizes that this effluent may be subsequently com-
mingled with nonprocess wastewater not requiring treatment (i.e,
noncontact cooling water) which might effectively lower the pH to
below 7.0 prior to final discharge.  This may be accounted for in
individual NPDES permits.

APPLICATION OF FLOW REDUCTION TECHNOLOGY

Tables X-15 to X-25 list the BAT wastewater discharge flows for
the production operations and associated waste streams that
received an allowance under BPT.  In some cases, the BAT dis-
charge allowance is identical to the BPT allowance.  The Agency
could not identify applicable flow-reducing technologies for some
of these streams.  For other streams, flow-reduction technology
is currently common industry practice,  and further flow-reduction
is not required at BAT.  For many streams, the BAT discharge
allowance is substantially less than the BPT allowance.
In-process flow reduction measures considered as part of Option 3
technology were the bases for the BAT discharge allowances for
these streams.

Production Operations and Discharge Flows for Which Applicable
Flow Reduction Technology Could Not Be Identified

The Agency could not identify applicable flow reduction technol-
ogy for the following waste streams.  Therefore, the BAT dis-
charge allowance equals the BPT discharge allowance for these
waste streams.
                               797

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Lead/Tin/Bismuth Forming Subcategory

Waste Stream                     Normalized BPT and BAT Discharge

Rolling Spent Soap Solutions     43.0 1/kkg (10.3 gal/ton)
Extrusion Press Hydraulic        175 1/kkg (41.9 gal/ton)
  Fluid Leakage
Alkaline Cleaning Spent Bath     606 1/kkg (145 gal/ton)
Miscellaneous Nondescript        58.4 1/kkg (14.0 gal/ton)
  Wastewater

Nickel/Cobalt Forming Subcategory

Waste Stream                     Normalized BPT and BAT Discharge

Forging, Extrusion, and          124 1/kkg (29.7 gal/ton)
  Isostatic Press Hydraulic
  Fluid Leakage
Vacuum Melting Steam Condensate  168 1/kkg (40.4 gal/ton)
Metal Powder Production          2,840 1/kkg (680 gal/ton)
  Atomization Wastewater
Alkaline Cleaning Spent Baths    30.6 1/kkg (7.34 gal/ton)
Surface Treatment Spent Baths    861 1/kkg (206 gal/ton)
Steam Cleaning Condensate        23.2 1/kkg (5.56 gal/ton)
Miscellaneous Nondescript        58.4 1/kkg (14.0 gal/ton)
  Wastewater

Zinc Forming Subcategory

Waste Stream                     Normalized BPT and BAT Discharge

Surface Treatment Spent Baths    9.50 1/kkg (2.28 gal/ton)
Alkaline Cleaning Spent Baths    0.715 1/kkg (0.171 gal/ton)

Beryllium Forming Subcategory

Waste Stream                     Normalized BPT and BAT Discharge

Area Cleaning Wastewater         21,300 1/kkg (5,110 gal/ton)
Billet Washing Wastewater        38.2 1/kkg (9.17 gal/ton)

Precious Metals Forming Subcategory

Waste Stream                     Normalized BPT and BAT Discharge

Metal Powder Production          6,670 1/kkg
  Atomization Wastewater
Surface Treatment Spent Baths    155 1/kkg (37.2 gal/ton)
Alkaline Cleaning Spent Baths    3.67 1/kkg (0.88 gal/ton)
                               798

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Iron and Steel/Copper/Aluminum Metal Powder Production and Powder
Metallurgy Subcategory
Waste Stream

Metal Powder Production Wet
  Atomization Wastewater
Metal Powder Production
  Milling Wastewater
Oil-Resin Impregnation
  Wastewater
                                 Normalized BPT  and BAT  Discharge

                                 5,040 1/kkg (1,210 gal/ton)

                                 1,670 1/kkg (400  gal/ton)

                                 74.5  1/kkg (17.9  gal/ton)
Titanium Forming Subcategory

Waste Stream                     Normalized BPT and BAT Discharge

Surface Treatment Spent Baths    160 1/kkg (38.5 gal/ton)

Refractory Metals Forming Subcategory

Waste Stream                     Normalized BPT and BAT Discharge
Post-Casting Billet Washwater
Surface Treatment Spent Baths
Metal Powder Production
  Wastewater
Alkaline Cleaning Spent Baths
                                 29.8  1/kkg (7.14  gal/ton)
                                 12.7  1/kkg (3.04  gal/ton)
                                 1,640 1/kkg (393  gal/ton)
                                 30.6  1/kkg (7.34  gal/ton)

Zirconium/Hafnium Forming Subcategory
Waste Stream

Extrusion Press Hydraulic
  Fluid Leakage
Surface Treatment Spent Baths
Alkaline Cleaning Spent Baths

Magnesium Forming Subcategory

Waste Stream

Surface Treatment Spent Baths

Uranium Forming Subcategory

Waste Stream

Surface Treatment Spent Baths
                                 Normalized BPT  and BAT  Discharge

                                 370  1/kkg (88.8 gal/ton)

                                 399  1/kkg (95.8 gal/ton)
                                 2,130  1/kkg  (511  gal/ton)



                                 Normalized BPT  and BAT  Discharge

                                 465  1/kkg (111  gal/ton)



                                 Normalized BPT  and BAT  Discharge

                                 35.6 1/kkg (8.52  gal/ton)
                               799

-------
Waste Streams Flow Reduced at BPT
Flow reduction is not required for the following streams because
this technology is currently common industry practice.  There-
fore, the BAT and BPT discharge allowances are the same.

Lead/Tin/Bismuth Forming Subcategory
Waste Stream

Rolling Spent Emulsions
Drawing Spent Neat Oils
Drawing Spent Eimilsions
Drawing Spent Soap Solutions
Continuous Strip Casting
  Contact Cooling Water
Swaging Spent Emulsions
Degreasing Spent Solvents

Nickel/Cobalt Forming Subcategory

Waste Stream
Normalized BPT and BAT Discharge

23.3 1/kkg (5.60 gal/ton)
0
16.7 1/kkg (4.00 gal/ton)
7.46 1/kkg (1.79 gal/ton)
1.00 1/kkg (0.240 gal/ton)
1
0
,77  1/kkg  (0.424 gal/ton)
Rolling Spent Neat Oils
Tube Reducing Spent Lubricants
Drawing Spent Neat Oils
Drawing Spent Eimilsions
Extrusion Spent Lubricants
Extrusion Press and Solution
  Heat Treatment Contact
  Cooling Water
Forging and Swaging Spent
  Neat Oils
Wet Air Pollution Control
  Blowdown
Surface Treatment Spent Baths
Molten Salt Rinsewater
Ammonia Rinsewater
Sawing/Grinding Spent Emulsions
Degreasing Spent Solvents

Zinc Forming Subcategory

Waste Stream

Rolling Spent Neat Oils
Rolling Spent Emulsions
Drawing Spent Emulsions
Stationary Casting Contact
  Cooling Water
Alkaline Cleaning Rinse Water
Sawing/Grinding Spent
  Lubricants
Degreasing Spent Solvents
Normalized BPT and BAT Discharge

0
0 1/kkg (0 gal/ton)
0
95.4 1/kkg (22.9 gal/ton)
0
83.2 1/kkg (20.0 gal/ton)
0
251 1/kkg (60.2 gal/ton)

861 1/kkg (206 gal/ton)
1,280 1/kkg (307 gal/ton)
15.7 1/kkg (3.77 gal/ton)
1,000 1/kkg (240 gal/ton)
0
Normalized BPT and BAT Discharge

0
1.39 1/kkg (0.334 gal/ton)
8.01 1/kkg (1.92 gal/ton)
0

5,720 1/kkg (1,370 gal/ton)
54.9 1/kkg (13.2 gal/ton)
0
                               800

-------
Beryllium Forming Subcategory

Waste Stream

Sawing/Grinding Spent
  Lubricants
Inspection Testing Wastewater
Degreasing Spent Solvents
Normalized BPT and BAT Discharge

424 1/kkg (102 gal/ton)
0
0
Precious Metals Forming Subcategory
Waste Stream
Normalized BPT and BAT Discharge

818 1/kkg (196 gal/ton)

4.17 1/kkg (1.00 gal/ton)

0
Direct Chill Casting Contact
  Cooling Water
Stationary Casting Contact
  Cooling Water
Drawing Spent Neat Oils
Drawing Spent Soap Solutions     6.93 1/kkg (1.66 gal/ton)
Sawing/Grinding Spent Emulsions  6.05 1/kkg (1.45 gal/ton)
Surface Treatment Rinse Water    2,840 1/kkg (681 gal/ton)
Degreasing Spent Solvents        0

Iron and Steel/Copper/Aluminum Metal Powder Production and  Powder
Metallurgy Subcategory

Waste Stream
Metal Powder Production Wet
  Air Pollution Control
  Wastewater
Sizing Spent Lubricants
Sawing/Grinding Spent
  Lubricants
Degreasing Spent Solvents

Titanium Forming Subcategory

Waste Stream

Extrusion Spent Lubricants
Forging Spent Lubricants
Degreasing Spent Solvents
Grinding/Sawing Spent
  Lubricants
Normalized BPT and BAT Discharge

2,640 1/kkg (632 gal/ton)


0
1,000 1/kkg (240 gal/ton)

0



Normalized BPT and BAT Discharge

274 1/kkg (65.7 gal/ton)
0
0
49.7 1/kkg (11.9 gal/ton)
                              801

-------
Refractory Metals Forming Subcategory
Waste Stream

Rolling Spent Emulsions
Rolling Spent Neat Oils
Drawing Spent Lubricants
Forging Spent Lubricants
Pressing Spent Lubricants
Casting Contact Cooling Water
Surface Treatment Spent Baths
Surface Treatment Wet Air
  Pollution Control Blowdown
Metal Powder Produciton Wet Air
  Pollution Control Blowdown
Molten Salt Spent Baths
Molten Salt Rinsewater
Sawing/Grinding Spent Neat Oils
Sawing/Grinding Spent Emulsions
Degreasing Spent Solvents
Coating Wet Air Pollution
  Control Blowdown
                                 Normalized BPT  and BAT  Discharge

                                 1,200  1/kkg  (288  gal/ton)
                                 0
                                 0
                                 0
                                 0
                                 0
                                 12.7 1/kkg 93.04  gal/ton)
                                 11,800 1/kkg  (2,840 gal/ton)

                                 0

                                 0
                                 90,200 1/kkg  (21,600 gal/ton)
                                 0
                                 217  1/kkg  (52.1 gal/ton)
                                 0
                                 1,080  1/kkg  (258  gal/ton)
Zirconium/Hafnium Forming Subcategory
Waste Stream
                                 Normalized BPT  and BAT Discharge
                                 74.1  1/kkg (17.8  gal/ton)
                                 0
                                 34.9  1/kkg (8.36  gal/ton)
Extrusion Spent Emulsions
Drawing Spent Lubricants
Forging Solution Heat Treatment
  Contact Cooling Water
Sawing/Grinding Spent Lubricants  9.01  1/kkg  (2.16  gal/ton)
Sawing/Grinding Wet Air Pollu-    0
  tion Control Scrubber Blowdown
Tube Reducing Spent Lubricants    0
Degreasing Spent Baths           0
Magnesium Forming Subcategory

Waste Stream

Rolling Spent Emulsions
Forging Spent Lubricants
Forging Wet Air Pollution
  Control Scrubber Blowdown
Direct Chill Casting Contact
  Cooling Water
Sawing/Grinding Spent
  Lubricants
Degreasing Spent Solvents
Sanding, Repairing Wet Air
  Pollution Control Blowdown
                                 Normalized BPT  and BAT Discharge

                                 0
                                 0
                                 266,000  1/kkg  (63,800 gal/ton)

                                 0

                                 0

                                 0
                                 428  1/kkg (103  gal/ton)
                               802

-------
Uranium Forming Subcategory

Waste Stream

Extrusion Spent Lubricants
Forging Spent Lubricants
Surface Treatment Wet Air
  Pollution Control Scrubber
  Blowdown
Sawing/Grinding Spent Emulsions
Post-Sawing/Grinding Rinsewater  38.1 1/kkg  (9.12 gal/ton)
Normalized BPT and BAT Discharge

0
0
74.2 1/kkg (17.8 gal/ton)
3.10 1/kkg (0.744 gal/ton)
Degreasing Spent Solvents
0
Flow Reduced Contact Cooling Water - BAT Discharge Allowances

The Agency believes that recycle is a demonstrated flow-reducing
technology and is basing the BAT discharge allowance for contact
cooling water on recycle through a cooling tower.  Holding tanks
are used in place of cooling towers for streams with low flow
rates.  Because the Agency believes that some plants must dis-
charge a portion of the coolant to control water quality, 90 per-
cent recycle (i.e., 90 percent reduction of BPT flows) was
selected as the basis for the BAT discharge allowance.  The BAT
discharge allowance is equivalent to 10 percent of the BPT
discharge allowance for the streams listed below.
Lead/Tin/Bismuth Forming Subcategory

Waste Stream

Extrusion Press and Solution Heat
  Treatment Contact Cooling Water
Semi-Continuous Ingot Casting
  Contact Cooling Water
Shot Casting Contact Cooling Water

Nickel/Cobalt Forming Subcategory

Waste Stream

Rolling Contact Lubricant-Coolant
  Water
Rolling Solution Heat Treatment
  Contact Cooling Water
Forging Die Contact Cooling Water
Stationary and Direct Chill Casting
  Contact Cooling Water
Solution Heat Treatment Contact
  Cooling Water
     Normalized BAT Discharge

     175 1/kkg (41.9 gal/ton)

     2.94 1/kkg (0.704 gal/ton)

     4.20 1/kkg (1.01 gal/ton)



     Normalized BAT Discharge

     1,340 1/kkg (321 gal/ton)

     0.027 1/kkg (0.007 gal/ton)

     126 1/kkg (30.2 gal/ton)
     1,780 1/kkg (428 gal/ton)

     457 1/kkg (110 gal/ton)
                               803

-------
Zinc Forming Subcategory

Waste Stream

Rolling Contact Lubricant-Coolant
  Water
Direct Chill Casting Contact Cooling
  Water
Solution Heat Treatment Contact
  Cooling Water

Precious Metals Forming Subcategory

Waste Stream

Semi-Continuous and Continuous
  Casting Contact Cooling Water
Shot Casting Contact Cooling Water
Rolling Solution Heat Treatment
  Contact Cooling Water
Extrusion Solution Heat Treatment
  Contact Cooling Water
Annealing Heat Treatment Contact
  Cooling Water
Pressure Bonding Contact Cooling
  Water

Titanium Forming Subcategory

Waste Stream

Hot Rolling Contact Lubricant-
  Coolant Water
Forging Contact Cooling Water
Heat Treatment Contact Cooling Water

Refractory Metals Forming Subcategory

Waste Stream

Extrusion Heat Treatment Contact
  Cooling Water
Forging Solution Heat Treatment
  Contact Cooling Water
Sawing/Grinding Lubricant-Coolant
  Water
Normalized BAT Discharge

34.7 1/kkg (8.32 gal/ton)

50.3 1/kkg (12.1 gal/ton)

76.1 1/kkg (18.3 gal/ton)




Normalized BAT Discharge

1,120 1/kkg (268 gal/ton)

89.2 1/kkg (21.4 gal/ton)
700 1/kkg (168 gal/ton)

1,370 1/kkg (329 gal/ton)

1,000 1/kkg (240 gal/ton)

83.5 1/kkg (20 gal/ton)
Normalized BAT Discharge

430 1/kkg (103 Sal/ton)

300 1/kkg (72.1 gal/ton)
451 1/kkg (108 gal/ton)
Normalized BAT Discharge

346 1/kkg (83.0 gal/ton)

579 1/kkg (139 gal/ton)

812 1/kkg (195 gal/ton)
                              804

-------
Zirconium/Hafnium Forming Subcategory

Waste Stream                          Normalized BAT Discharge

Extrusion Heat Treatment Contact      28.5 1/kkg (6.84 gal/ton)
  Cooling Water

Magnesium Forming Subcategory

Waste Stream                          Normalized BAT Discharge

Forging Solution Heat Treatment       633 1/kkg (152 gal/ton)
  Contact Cooling Water

Uranium Forming Subcategory

Waste Stream                          Normalized BAT Discharge

Extrusion Solution Heat Treatment     272 1/kkg (65.3 gal/ton)
  Contact Cooling Water
Forging Solution Heat Treatment       284 1/kkg (68.2 gal/ton)
  Contact Cooling Water
Tool Contact Cooling Water            51.7 1/kkg (12.4 gal/ton)

Flow-Reduced Rinsewater - BAT Discharge Allowances

The BAT discharge allowance for rinsewater is based on installa-
tion of two-stage countercurrent cascade rinsing.   The discharge
is equivalent to 10 percent of the BPT discharge allowance for
the rinsewater streams listed below.

Lead/Tin/Bismuth Forming Subcategory

Waste Stream                         Normalized BAT Discharge

Alkaline Cleaning Rinsewater         646 1/kkg (155 gal/ton)

Nickel/Cobalt Forming Subcategory

Waste Stream                         Normalized BAT Discharge

Alkaline Cleaning Rinsewater         497 1/kkg (119 gal/ton)
Surface Treatment Rinsewater         1,060 1/kkg (254 gal/ton)

Zinc Forming Subcategory

Waste Stream                         Normalized BAT Discharge

Surface Treatment Rinsewater         486 1/kkg (117 gal/ton)
                              805

-------
Beryllium Forming Subcategory

Waste Stream                         Normalized BAT Discharge

Surface Treatment Rinsewater         767 1/kkg (184 gal/ton)

Precious Metals Forming Subcategory

Waste Stream                         Normalized BAT Discharge

Alkaline Cleaning Rinsewater         692 1/kkg (166 gal/ton)
Prebonding Cleaning Wastewater       340 1/kkg (81.7 gal/ton)

Titanium Forming Subcategory

Waste Stream                         Normalized BAT Discharge

Surface Treatment Rinsewater         2,110 1/kkg (505 gal/ton)
Alkaline Cleaning Rinsewater         276 1/kkg (66.3 gal/ton)

Refractory Metals Forming Subcategory

Waste Stream                         Normalized BAT Discharge

Surface Treatment Rinsewater         12,100 1/kkg (2,910  gal/ton)
Alkaline Cleaning Rinsewater         1,400 1/kkg (335 gal/ton)*

Zirconium/Hafnium Forming Subcategory

Waste Stream                         Normalized BAT Discharge

Surface Treatment Rinsewater          1,530 1/kkg (368 gal/ton)
Alkaline Cleaning Rinsewater          5,530 1/kkg (1,330  gal/ton)
Degreasing Rinsewater                 203 1/kkg (48.6 gal/ton)

Magnesium Forming Subcategory

Waste Stream                         Normalized BAT Discharge

Surface Treatment Rinsewater          1,770 1/kkg (425 gal/ton)

Uranium Forming Subcategory

Waste Stream                         Normalized BAT Discharge

Surface Treatment Rinsewater          148 1/kkg (35.5 gal/ton)



*Based on three-stage countercurrent  cascade rinsing
                              806

-------
Flow-Reduced Emulsions - BAT Discharge Allowances

The Agency believes that recycle is a demonstrated, flow-reducing
technology and is basing the BAT discharge allowance for emul-
sions on recycle through a holding tank equipped with in-line,
paper or cloth filters.  Because some plants must discharge a
portion of the recirculating flow to prevent the excessive
build-up of particulates, 90 percent recycle was selected as the
basis for the BAT discharge allowance.  The following emulsion
waste streams can be flow-reduced:
Precious Metals Forming Subcategory

Waste Stream

Rolling Spent Emulsions
Drawing Spent Emulsions

Titanium Forming Subcategory

Waste Stream

Rolling Spent Lubricants
Normalized BAT Discharge

36.0 1/kkg (8.60 gal/ton)
21.3 1/kkg (5.10 gal/ton)
Normalized BAT Discharge

334 1/kkg (80.0 gal/ton)
Flow-Reduced Wet Air Pollution Control Blowdown - BAT Discharge
Allowances

The Agency believes that recycle of scrubber liquor is a demon-
strated technology.  However, most plants will discharge a
portion of the recirculating flow to prevent excessive build-up
of dissolved solids.  Based on data submitted in the dcp's, the
Agency believes that recycling scrubber liquor with a 10 percent
blowdown will control scale formation and equipment corrosion.
Accordingly, the BAT discharge allowance is based on a 90 percent
reycle of the normalized flow of scrubber liquor.  The following
scrubber waste streams can be flow-reduced:
Lead/Tin/Bismuth Forming Subcategory

Waste Stream

Shot-Forming Air Pollution Control
  Blowdown

Precious Metals Forming Subcategory

Waste Stream
 Normalized BAT Discharge

 0.009 1/kkg (0.002 gal/ton)
 Normalized BAT Discharge
Stationary Casting Wet Air Pollution  5.86 1/kkg (1.40 gal/ton)
  Control Blowdown
                               807

-------
Iron and Steel/Copper/Aluminum Metal Powder Production and Powder
Metallurgy Subcategory~~

Waste Stream                          Normalized BAT Discharge

Steam Treatment Wet Air Pollution     284 1/kkg (68.1 gal/ton)
  Control Scrubber Slowdown

Titanium Forming Subcategory

Waste Stream                          Normalized BAT Discharge

Forging Wet Air Pollution Control     202 1/kkg (48.5 gal/ton)
  Blowdown
Surface Treatment Wet Air Pollution   17.0 1/kkg (4.08  gal/ton)
  Control Blowdown

Refractory Metals Forming Subcategory

Waste Stream                          Normalized BAT Discharge

Sawing/Grinding Wet Air Pollution     108 1/kkg (25.8 gal/ton)
  Control Blowdown

Uranium Forming Subcategory

Waste Stream                          Normalized BAT Discharge

Surface Treatment Wet Air Pollution   74.2 1/kkg (17.88 gal/ton)
  Control Scrubber Blowdown

Miscellaneous Flow-Reduced Waste Streams - BAT Discharge Flow
Allowances

The Agency believes that recycle through a holding tank is a
demonstrated flow-reduction technology for many wastewaters.   The
holding tank, equipped with in-line paper or cloth filters,  pro-
vides removal of particulates through settling and filtration.
This permits water recycle.  However, to control water quality,  a
portion of the recirculating flow must be purged.   Therefore, the
BAT discharge allowance is based on a discharge of 10 percent of
the normalized BPT flow allowances.  The following waste streams
are flow reduced by this method at BAT:

Nickel/Cobalt Forming Subcategory

Waste Stream                          Normalized BAT Discharge

Forging Equipment Cleaning Waste-     163 1/kkg (39.0 gal/ton)
  water
Hydrostatic Tube Testing              135 1/kkg (32.4 gal/ton)
                               808

-------
Precious Metals Forming Subcategory

Waste Stream                          Normalized BAT Discharge

Burnishing Wastewater                 2,570 1/kkg (617 gal/ton)
Tumbling Wastewater                   442 1/kkg (106 gal/ton)
Metal Powder Production Wastewater    2,170 1/kkg (520 gal/ton)

Iron and Steel/Copper/Aluminum Metal Powder Production and Powder
Metallurgy Subcategory

Waste Stream                          Normalized BAT Discharge

Tumbling Wastewater                   715 1/kkg (171 gal/ton)

Titanium Forming Subcategory

Waste Stream                          Normalized BAT Discharge

Tumbling Wastewater                   79.0 1/kkg (18.9 gal/ton)

Refractory Metals Forming Subcategory

Waste Stream                          Normalized BAT Discharge

Forging Equipment Cleaning Waste-     41.7 1/kkg (10.0 gal/ton)
  water
Tumbling Wastewater                   2,210 1/kkg (530 gal/ton)
Post-Sawing Grinding Wastewater       51.3 1/kkg (12.3 gal/ton)
Product Testing                       7.76 1/kkg (1.86 gal/ton)

Magnesium Forming Subcategory

Waste Stream                          Normalized BAT Discharge

Forging Equipment Cleaning Waste-     162 1/kkg (38.8 gal/ton)
  water

Spent Baths

Reducing the dumping frequency of spent baths will decrease the
volume of these baths discharged.  As with all flow reduction
technology, this will increase the concentration of pollutants in
the wastewater discharged, allowing a greater net removal during
treatment.  The following subcategories have spent baths which,
based on bath-use information obtained during the screen sampling
program, the Agency believes can be flow-reduced as follows:
                               809

-------
Beryllium Forming Subcategory

                            Present     BAT
                           Discharge  Discharge   BAT Normalized
Waste Stream                 Rate       Rate          Flow

Surface Treatment Spent    once/week  once/2 mos    308 1/kkg
  Bath                               (6 times/yr) (73.8 gal/ton)

Titanium Forming Subcategory

                            Present     BAT
                           Discharge  Discharge   BAT Normalized
Waste Stream                 Rate       Rate          Flow

Alkaline Cleaning Spent    once/week  once/month    638 1/kkg
  Bath                                            (153 gal/ton)

CALCULATION OF BAT EFFLUENT MASS LIMITATIONS

BAT mass limitations (mass of pollutant allowed to be discharged
per mass of product) are listed in Section II, Part 3, Subparts A
through K.  These limitations were calculated for each regulated
pollutant in each Subcategory as follows:   the BAT normalized
flow for each waste stream (summarized in Tables X-15 to X-25)
was multiplied by the one-day average and 10-day maximum effluent
concentrations achievable using the BAT treatment technology
selected for the subcategory (Table VII-9).  The 10-day average
is used to calculate the maximum monthly average because, as
discussed in Section VII, it provides a reasonable basis for a
monthly average and is typical of the sampling frequency required
by discharge permits.

COSTS AND BENEFITS

To evaluate the economic achievability of BAT, the Agency esti-
mated the cost of treatment and control and also estimated the
incremental increase in the mass of pollutants removed from
wastewater by that treatment and control.   Tables X-4 to X-14
list the Agency's estimate of the mass of pollutants removed, in
each subcategory, through the application of BAT to direct dis-
chargers.  The capital and annual costs (1982 dollars) of this
pollutant removal are listed in Table X-l.
                               810

-------
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                              Table X-l

          CAPITAL AND ANNUAL COST ESTIMATES FOR BAT OPTIONS
                     DIRECT DISCHARGERS ($1982)
    Subcategory        Option 1

Lead/Tin/B ismuth
Forming

  Capital                21,100
  Annual                 30,300

Nickel/Cobalt Forming

  Capital               141,200
  Annual                119,700

Zinc Forming

  Capital                13,300
  Annual                 26,700

Beryllium Forming

  Capital                     0
  Annual                      0

Precious Metals Forming

  Capital               173,400
  Annual                114,000

Iron and Steel/Copper/
Aluminum MPP and PM

  Capital               122,000
  Annual                 77,500
Titanium Forming

  Capital
  Annual

Refractory Metals
Forming

  Capital
  Annual
1,164,700
  858,300
   35,800
   70,400
                 Option 2*
                   164,600
                    14,500
                   213,700
                    71,800
                    72,000
                    42,000
                       500
                       300t
                   292,300
                   158,200
                   122,000
                    77,500
1,405,800
  729,100
  150,100
  102,500
                 Option
                   212,300
                    36,000
                   244,600
                    94,400
                    72,000
                    36,800
                       500
                       300t
                   345,500
                   184,900
                   142,900
                   101,600
1,509,200
  797,500
  171,000
  114,600
                                813

-------
                        Table X-l (Continued)

          CAPITAL AND ANNUAL COST ESTIMATES FOR BAT OPTIONS
                     DIRECT DISCHARGERS ($1982)
    Subcategory

Zirconium/Hafnium
Forming

  Capital
  Annual

Magnesium Forming

  Capital
  Annual

Depleted Uranium
Forming
  Capital
  Annual

Totals

  Capital
  Annual
 Option 1
  172,200
   88,500
   50,500
   70,900
  287,900
  148,400
2,182,000
1,626,000
Option 2(a)
    298,800
     79,100
    7 1,000
     50,500
    237,500
    136,600
  3,028,000
  1,483,000
Option 3(b)
    322,300
     92,900
     71,000
     44,600
    237,500
    126,600
  3,329,000
  1,652,000
 *Total cost to install Option 2 technology

**Total cost to install Option 3 technology

 tThe one beryllium forming plant currently incurs an aanual cost
  for disposal of sludges generated from treating nonferrous metals
  forming wastewater.   These costs were subtracted from the annual
  costs of Option 2 and Option 3 treatment technology.
                                814

-------
                            Table X-2



             SYMBOLS USED ON TABLES X-4 THROUGH X-14
Symbol



TOT TOXICS



TOT NONCON



TSS



TOT CONV



TOT POLL



e6



el



e8
Meaning



Total toxic pollutants



Total nonconventional pollutants



Total suspended solids



Total conventional pollutants



Total pollutants



x 1,000,000



x 10,000,000



x 100,000,000
                              815

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                            SECTION XI

                 NEW SOURCE PERFORMANCE STANDARDS


The basis for new source performance standards (NSPS) under
Section 306 of the Clean Water Act is the best available demon-
strated technology (BDT).   New plants have the opportunity to
design the best and most efficient production processes and
wastewater treatment technologies.  Therefore, NSPS includes pro-
cess changes, in-plant controls (including elimination of waste-
water streams), operating procedure changes, and end-of-pipe
treatment technologies to reduce pollution to the maximum extent
possible.  This section describes the control technology for
treatment of wastewater from new sources and presents mass dis-
charge limitations of regulated pollutants for NSPS, based on the
described control technology.

TECHNICAL APPROACH TO NSPS

The Agency considered three technology options which might be
applied as the best available demonstrated technology.  These
options are identical to those considered for BAT and are
described in detail in Section X.   The options are summarized
below:

NSPS Option 1:

     Lime and settle (chemical precipitation of metals, followed
       by sedimentation),  and
     pH adjustment; and, where required,
     Chemical emulsion breaking,
     Oil skimming,
     Ammonia steam stripping,
     Cyanide removal, and
     Hexavalent chromium reduction.

NSPS Option 2:

     NSPS Option 1, plus process wastewater flow minimization by
     the following methods:

        Heat treatment contact cooling water recycle through
        cooling towers.
        Air pollution control scrubber liquor recycle.
        Countercurrent cascade rinsing or other water efficient
        methods applied to surface treatment rinses.
                              845

-------
NSPS Option 3:

     NSPS Option 2, plus multimedia filtration at the end of the
     NSPS Option 2 treatment train.

NSPS OPTION SELECTION

EPA is proposing that NSPS for all 11 subcategories be equal to
BAT for those subcategories, since the Agency did not identify
any additional technology which removes significant quantities of
additional pollutants.  Specifically, BDT technology is equiva-
lent to NSPS Option 2 for the lead/tin/bismuth forming subcate-
gory and the iron and steel/copper/aluminum metal powder produc-
tion and powder metallurgy subcategory.  For the other nine
subcategories, BDT technology is equivalent to NSPS Option 3.
The technology basis for setting discharge limits for conven-
tional pollutants for each subcategory would also be the BAT
technology (even when BCT is less stringent than BAT for that
subcategory).

The data relied upon for selection of NSPS were the data devel-
oped for the evaluation of treatment Options 1 through 3 as BAT
for existing sources.  The Agency believes that compliance costs
could be lower for new sources than the cost estimates for equiv-
alent existing sources, because production processes can be
designed on the basis of lower flows and there will be no costs
associated with retrofitting the in-process controls.  Therefore,
new sources, regardless of whether they are plants with major
modifications (e.g., a nonferrous metals forming plant which
installs a new rolling operation) or greenfield sites, will have
costs that are not greater than the costs that existing sources
would incur in achieving equivalent pollutant discharge reduc-
tion.  Based on this the Agency believes that the selected NSPS
(NSPS Options 2 and 3) are appropriate for both greenfield sites
and existing sites undergoing major modifications.

As discussed in Section X, the Agency will consider promulgating
Option 2 as the BAT model technology for subcategories for which
Option 3 is proposed.  Similarly, the Agency will consider prom-
ulgating Option 2 as the NSPS model technology for subcategories
where the Agency is proposing NSPS based on Option 3 if the costs
of NSPS based on the addition of filtration have been signifi-
cantly underestimated.  Once again, integration of plants is a
particular concern, though it is generally easier and less expen-
sive to install appropriate wastewater treatment technology in
new plants than to retrofit existing plants.
                              846

-------
The Agency is also considering promulgating Option 3 as the BAT
model technology for both the lead/tin/bismuth and the iron and
steel/copper/aluminum metal powder production and powder metal-
lurgy subcategories.  Similarly, Option 3 will be considered as
the basis for PSNS if plant-by-plant analysis and additional data
show that filtration does remove significant additional quanti-
ties of pollutants in these two subcategories and that the
filtration technology is economically achievable.

Costs and Environmental Benefits of Treatment Options

Costs for an individual new source can be estimated using the
methods described in Section VIII.  The Agency has not estimated
total costs or benefits for the category or subcategories since
it is not known how many new nonferrous metals forming plants
will be built.

REGULATED POLLUTANT PARAMETERS

The Agency has no reason to believe that the pollutants that will
be found in significant quantities in processes within new
sources will be any different than those found in existing
sources.  Consequently, the toxic and nonconventional pollutants
selected for NSPS regulation are the same ones for each subcate-
gory that were selected for BAT in accordance with the rationale
of Section VI.  The pollutants regulated at NSPS also include
TSS, oil and grease, and. pH.

CALCULATION OF NEW SOURCE PERFORMANCE STANDARDS

Because the pollutants regulated  (with the addition of pH, oil
and grease, and TSS for NSPS), the regulatory PNF's, and treat-
ment trains at NSPS are identical to those at BAT, the NSPS (mass
of pollutant allowed to be discharged per mass of product) are
identical to BAT mass limitations and were calculated in the same
manner.  The one-day maximum and ten-day average effluent concen-
trations of each pollutant attainable by the selected treatment
options (Table VII-9) were multiplied by the regulatory produc-
tion normalized flows.  The ten-day average is used to calculate
the maximum monthly average because, as discussed in Section VII,
it provides a reasonable basis for a monthly average and is
typical of thessampling frequency required by discharge permits.
The resulting values are presented for each of the 11 subcate-
gories in Section II, Part 4, Subparts A through K.

Alternate NSPS,  based on Option 2 for those subcategories for
which Option 3 is proposed and Option 3 for those subcategories
for which Option 2 is proposed are found in Section II, Part 9,
Subparts A through K.
                              847

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                           SECTION XII

                      PRETREATMENT STANDARDS


Section 307 (b) of the Clean Water Act requires EPA to promulgate
pretreatment standards for existing sources (PSES).  These stan-
dards 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 adds a new dimension by requiring pretreatment
for pollutants, such as heavy metals, that limit POTW sludge
management alternatives, including the beneficial use of sludges
on agricultural lands.  The legislative history of the 1977 Act
indicates that pretreatment standards are to be technology based,
analogous to the best available technology for removal of toxic
pollutants.

Section 307 (c) of the Act requires EPA to promulgate pretreatment
standards for new sources (PSNS) at the same time that it promul-
gates NSPS.  New indirect discharge facilities, like new direct
discharge facilities, have the opportunity to incorporate the
best available demonstrated technologies, including process
changes, in-plant controls, and end-of-pipe treatment technol-
ogies, and to use plant site selection to ensure adequate treat-
ment system installation.

General Pretreatment Regulations for Existing and New Sources of
Pollution appear in 40 CFR Parts 125 and 403.   These regulations
describe the Agency's overall policy for establishing and enforc-
ing pretreatment standards for new and existing users of a POTW
and delineate the responsibilities and deadlines applicable to
each party in this effort.  Prohibited discharges which apply to
all users of a POTW appear in 40 CFR 403.5(b).

This section describes the treatment and control technology for
pretreatment of process wastewaters from existing sources and new
sources, and describes the calculation of mass discharge stan-
dards of regulated pollutants for existing and new sources, based
on the described control technology.

DISCHARGE OF NONFERROUS METALS FORMING WASTEWATERS TO A POTW

There are 114 plants in the nonferrous metals  forming industry
which discharge to a POTW.  The plants that may be affected by
pretreatment standards represent about 78 percent of the nonfer-
rous metals forming plants which discharge wastewater and approx-
imately 39 percent of the entire category.
                               849

-------
Pretreatment standards are established to ensure removal of pol-
lutants which interfere with, pass through, or are otherwise
incompatible with a POTW.  A determination of which pollutants
may pass through or be incompatible with POTW operations, and
thus be subject to pretreatment standards, depends on the level
of treatment employed by the POTW.  In general, more pollutants
will pass through or interfere with a POTW employing primary
treatment (usually physical separation by settling) than one
which has installed secondary treatment (settling plus biological
treatment).

Many of the pollutants contained in nonferrous metals forming
wastewaters are not biodegradable and are, therefore, ineffec-
tively treated by biological treatment systems.  Furthermore,
some of these pollutants are known to pass through or interfere
with the normal operations of these systems.   Problems associated
with the uncontrolled release of pollutant parameters identified
in nonferrous metals forming process wastewaters to POTWs are
discussed in the administrative record which accompanies this
rulemaking.   The discussion covers pass through, interference,
and sludge usability.

The Agency based the selection of pretreatment standards for the
nonferrous metals forming category on the minimization of pass
through of toxic pollutants at a POTW.  For each subcategory, the
Agency compared the percentage of a pollutant removed by a well-
operated POTW achieving secondary treatment with the percentage
removed by direct dischargers.  A pollutant was deemed to pass
through the POTW when the average percentage removed nationwide
by well-operated POTWs meeting secondary treatment requirements
was less than the percentage removed by direct dischargers com-
plying with BAT effluent limitations guidelines for that pollu-
tant.  (See generally, 46 FR 9415-16 (January 28, 1982).)

The Agency compared 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.   The POTW
removal rates were determined through a study conducted by the
Agency at over 40 POTWs and a statistical analysis of the data.
(See Fate of Priority Pollutants in Publicly Owned Treatment
Works, Final Report, EPA 4^U/1-»Z/3Uj, September 1982; and
Determining National Removal Credits for Selected Pollutants for
Publicly Owned Treatment Works, EPA 440/2-82-008, September,
lysz.;The percentremovalsachieved for seven of the toxic
metals and cyanide achieved by 25 percent of the POTWs in the "40
Cities Study" are presented in Table XII-1.  The removals ranged
from 19 to 66 percent.  Limited information showing the removal
                               850

-------
of other toxic and nonconventional pollutants is available.
However, the Agency assumes that the removals are in the same
range as the removals achieved for the studied pollutants.
Therefore, in cases where the BAT technology achieves a greater
percent removal of the seven toxic metals and cyanide than is
achieved by a well-operated POTW with secondary treatment  (i.e.,
these pollutants pass through the POTW), it is assumed that the
other toxic metals and nonconventional pollutants would also pass
through the POTW in the absence of pretreatment.

The Agency has concluded that the pollutants that would be regu-
lated in the nonferrous metals forming category (primarily toxic
metals) pass through a POTW.  This conclusion is based on the
fact that the percentage of these pollutants removed by a well-
operated POTW (see Table XII-1) is less than the percentage
removed by the treatment technology upon which BAT is based
(Table XII-2).  For example, a POTW will remove 48 percent of the
lead in an influent wastewater; a lead forming plant with Option
2 treatment technology (flow reduction, lime and settle) will
remove 99.9 percent of the lead from its wastewater.  Therefore,
lead is considered to pass through the POTW.

The percentage of each pollutant removed by BAT technology was
calculated as follows.  The total mass of the pollutant in dis-
charged wastewater treated by the technology selected for BAT for
the subcategory (BAT mass, kg/yr) was subtracted from the total
mass of the pollutant in untreated wastewater (raw mass, kg/yr).
This difference was divided by the raw mass and multiplied by 100
to yield the percent removed by BAT technology, or:

Raw Mass - BAT Mass x 100 = Percent Removed by BAT Technology
     Raw Mass

For some pollutants the percent removed was calculated for direct
dischargers and in other cases it was calculated for indirect
dischargers (see Table XII-2).

As described in Section X, the total mass of a pollutant in
untreated wastewater was estimated by multiplying the average
concentration of the pollutant in the total subcategory waste-
water by the total wastewater flow in the subcategory.  The total
mass of the pollutant in discharged wastewater treated by each
technology option was estimated by multiplying the average con-
centration of the pollutant achievable using that option (Table
VII-9) by the total flow discharged at that option.  Conse-
quently, if the average subcategory concentration was less than
the concentration achievable using the BAT treatment technology,
the calculated percent removal was zero.
                              351

-------
For some regulated pollutants (in particular, cyanide, ammonia,
and fluoride) the percent removals, calculated as described
above, are very low or zero.  This is due to the use of average
subcategory concentrations in the calculation.  These pollutants
are not expected to be present in all waste streams in a subcate-
gory  (see Section V).  When they are present, they are present in
concentrations significantly above treatable concentrations and
substantial removals would be achieved by treatment at an indi-
vidual plant.

No sampling data was available for several nonconventional
pollutants regulated in some subcategories (columbium, hafnium,
tantalum, tungsten and zirconium).  However, for all of these
pollutants, raw wastewater concentrations were estimated for the
benefit calculations described in Section X and percent removals
were calculated.  However, no estimates were made for vanadium
benefits or removal.

As discussed in Sections VIII and X, the Agency intends to recal-
culate the costs and benefits of each technology option on a
plant-by-plant basis prior to promulgation of these standards.
This method of calculation will eliminate the use of average sub-
category concentrations in estimating benefits and thus more
accurately represent the true removals of cyanide, ammonia and
fluoride achievable by the technology options.  After recalculat-
ing benefits, the Agency also intends to re-estimate percentages
of pollutants removed by BAT technology and include estimates for
vanadium.

However, based upon the estimate made for proposal of these
guidelines and standards, the national average percentage of the
toxic metals removed by a well-operated POTW meeting secondary
treatment requirements is about 50 percent (varying from 19 to 66
percent; see Table XII-1), whereas the percentage that can be
removed by BAT level treatment of nonferrous metals forming
wastewater is approximately 99 percent (see Table XII-2).  Hence,
the Agency has concluded that, in general, toxic metals pass
through a POTW and pretreatment standards for the indirect dis-
charge of nonferrous metals forming wastewater are required.

TECHNICAL APPROACH TO PRETREATMENT

The pretreatment options for existing sources and new sources are
identical to the options considered for BAT and are described in
detail in Section X.  The options are summarized below:
                               852

-------
Pretreatment Option 1:

     Lime and settle (chemical precipitation of metals followed
     by sedimentation)  and pH adjustment; and, where required,

        Chemical emulsion breaking,

        Oil skimming,

        Ammonia steam stripping,

        Cyanide removal, and

        Hexavalent chromium reduction.

Pretreatment Option 2:

     Pretreatment Option 1, plus process wastewater flow mini-
     mization by the following methods:

        Heat treatment contact cooling water recycle through
        cooling towers,

        Air pollution control scrubber liquor recycle, and

        Countercurrent cascade rinsing or other water effi-
        cient methods applied to surface treatment rinses.

Pretreatment Option 3:

     Pretreatment Option 2, plus multimedia filtration at the
     end of the pretreatment Option 2 treatment train.

PSES AND PSNS OPTION SELECTION

EPA has selected PSES equal to BAT for all subcategories except
the zinc and beryllium forming subcategories.  The Agency pro-
poses to exclude beryllium forming from PSES under the provisions
of Paragraph 8(b) of the Settlement Agreement because there are
no existing indirect dischargers in the beryllium forming sub-
category.

The Agency proposes to exclude zinc forming from regulation
because the economic impacts of pretreatment standards on this
subcategory appear to be disproportionate.  There are two indi-
rect dischargers and one direct discharger in the subcategory.
Costs of implementing the three technology options were estimated
using the computer cost model for the direct discharger.  The
estimated costs were extrapolated to the indirect dischargers.
Three methods of extrapolating the costs were used, each giving
                              853

-------
substantially different results.  However, for each method used,
one plant is projected to close if required to comply with any of
the three pretreatment options.  This plant is by far the larger
of the two indirect dischargers in the subcategory.

The Agency will reassess the costs of implementing the three
technology options at the indirectly discharging zinc forming
plants prior to promulgation.  If this reassessment indicates
that no plants will close, categorical pretreatment standards
will be promulgated for this subcategory.  These standards would
be based on one of the three technology options described above.

It should be noted that even if the Agency does not promulgate
categorical pretreatment standards for this subcategory,  indi-
rectly discharging zinc forming plants will still be subject to
the general pretreatment standards.

PSES is equal to BAT for the remaining subcategories.   That is,
the technology basis for PSES is pretreatment Option 2 for the
lead/tin/bismuth forming subcategory and the iron and steel/
copper/aluminum metal powder production and powder metallurgy
subcategory and pretreatment Option 3 for the seven other
subcategories regulated at PSES.  The options selected for PSES
achieve effective removal of toxic pollutants at a reasonable
cost for each subcategory.

Three of the indirect dischargers in the category have filtration
technology or provide additional sedimentation which is achieving
effluent concentrations equivalent to those achieved by filtra-
tion.   Implementation of the proposed PSES would remove annually
an estimated 64,000 kg (141,200 pounds) of toxic pollutants over
the current discharge.  Capital costs for achieving the proposed
PSES is $6.8 million, with an annualized cost of $3.72 million.

The technology options selected for PSES result in more stringent
standards than if the technology option equivalent to BPT (Option
1) were selected.  The Agency believes that Option 1 technology
would not provide adequate removal of toxic pollutants.  This
conclusion is based on the fact that the selected PSES options
would provide a substantial increase in percent removal over
Option 1 technology (see Table XII-3).

The percentage of each pollutant removed by the PSES technology
not removed by Option 1 technology was calculated in a manner
similar to the calculation of percentage removal by BAT technol-
ogy.  That is:

Option 1 Mass - PSES Mass x 100 = Percentage Removal Pretreatment
        PSES Mass                 Option 1 to Selected PSES
                                  Option
                              854

-------
This represents the percentage removal which would not be
achieved unless pretreatment standards were enacted (assuming
plants are presently using treatment technology equivalent to
Option 1).  For example, selecting PSES Option 2 would remove
66.8 percent more lead from lead forming wastewater than
selecting PSES Option 1.

Just as with BAT, the Agency will give consideration to adopting
Option 2 as the PSES technology for those subcategories where it
is proposing Option 3 if it determines that the costs of this
treatment level have been seriously underestimated.  The costs of
each technology option are listed in Table XII-4.  The pollutant
removals provided by each technology option are provided in
Tables XII-6 through XII-13.

The Agency is also considering promulgating Option 3 for both the
lead/tin/bismuth and the iron and steel/copper/aluminum metal
powder production and powder metallurgy subcategories, if the
plant-by-plant analysis and additional data show that filtration
does remove significant additional quantities of pollutants in
these two subcategories and that the filtration technology is
economicaly achievable.  The pollutant removals and costs of
removal provided by each technology option are provided in Tables
XII-4, XII-5, and XII-9.

Section 307 (c) of the Act requires EPA to promulgate pretreatment
standards for new sources (PSNS) at the same time that it promul-
gates NSPS.  New indirect dischargers will produce wastes having
the same pass through problems as described for existing dis-
chargers.  In selecting the technology basis for PSNS, the Agency
compared the toxic pollutant removals achieved by a well-operated
POTW to that achieved by a direct discharger meeting NSPS.  New
indirect dischargers, like new direct dischargers, have the
opportunity to incorporate the best available demonstrated tech-
nologies including process changes, in-plant controls, and end-
of-pipe treatment technologies, and to use plant site selection
to ensure adequate treatment system installation.

EPA is proposing mass-based PSNS for all subcategories to assure
that the identified flow reduction technologies are considered in
new plant designs.  In addition, EPA is proposing PSNS for the
zinc forming and beryllium forming subcategories for which BAT
and NSPS, but not PSES, are proposed.

The technology basis for the proposed PSNS is identical to NSPS,
that is, BAT.  It is necessary to propose PSNS for all regulated
toxic metals for the reasons given above under PSES.  The Agency
did not identify any economically feasible, demonstrated technol-
ogy that removes significantly more pollutants than BAT technol-
ogy.  Because PSNS does not include any additional costs compared
                               855

-------
to PSES, it is not believed that PSNS will prevent the entry of
new plants.

Pretreatment Option 3 (flow reduction, lime and settle,  multi-
media filtration) is selected for nine of the 11 subcategories as
the regulatory approach for PSNS and pretreatment Option 2 (flow
reduction, lime and settle) is selected for the lead/tin/bismuth
forming subcategory and the iron and steel/copper/aluminum metal
powder production and powder metallurgy subcategory.  These pre-
treatment technology options were selected because they  achieve
effective removal of toxic pollutants at a reasonable cost.

The data relied upon for selection of PSNS were the data devel-
oped for the evaluation of pretreatment Options 1 through 3 for
existing sources.  The Agency believes that compliance costs
could be lower for new sources than the cost estimates for equiv-
alent existing sources, because production processes can be
designed on the basis of lower flows and there will be no costs
associated with retrofitting the in-process controls.  Therefore,
new sources, regardless of whether they are plants with  major
modifications (e.g., a nonferrous metals forming plant which
installs a new rolling operation) or greenfield sites, will have
costs that are not greater than the costs that existing sources
would incur in achieving equivalent pollutant discharge  reduc-
tion.  Based on this, the Agency believes that the selected PSNS
(pretreatment Options 2 and 3) are appropriate for both  green-
field sites and existing sites undergoing major modifications.

For the same reasons as discussed for BAT, NSPS, and PSES, EPA is
considering promulgating Option 2 as the technology basis for
PSNS for the subcategories where it is proposing Option 3 as
PSNS.  The Agency is also considering promulgating Option 3 as
the technology basis for PSNS for the lead/tin/bismuth forming
and the iron and steel/copper/aluminum subcategories where it is
proposing Option 2 as PSNS.

Costs and Environmental Benefits of Treatment Options

As a means of evaluating the economic achievability of each of
the PSES options, the Agency developed estimates of the  compli-
ance costs and benefits.  Estimates of capital and annual costs
for the pretreatment options were prepared for each subcategory
as an aid in choosing the best pretreatment option.  The cost
estimates for indirect dischargers are presented in Table XII-4.

The method used to estimate costs has been described in  detail in
Section VIII.  The method used to estimate benefits has  been
described in detail in Section X.  The pollutant reduction bene-
fit estimates for eight subcategories are presented in Tables
XII-5 through XII-13.  Insufficient data were available  prior to
                               856

-------
proposal to estimate costs or benefits for the indirect dis-
charger in the uranium forming subcategory.  These data will be
added to the record as they become available.

REGULATED POLLUTANT PARAMETERS

The same pollutants selected for regulation at BAT have been
selected for regulation under the pretreatment standards for each
of the nine subcategories regulated under PSES and each of the 11
subcategories regulated under PSNS.  The selection process and
pollutants selected for regulation are given in detail in Section
VI.

CALCULATION OF PRETREATMENT STANDARDS

PSES for this category are expressed in terms of mass per unit of
production (mass-based) rather than concentration standards.
Regulation on the basis of concentration is not appropriate for
this category because flow reduction is a significant part of the
model technology for pretreatment.  Therefore, the Agency is not
proposing concentration-based pretreatment standards (40 CFR Part
403.6) for this category.

The regulatory production normalized flows for PSES and PSNS are
equivalent to BAT flows (see Tables X-15 to X-25).

Because the production normalized flows, regulated pollutants,
and treatment trains at PSES and PSNS are also identical to those
at BAT, the mass-based PSES and PSNS (mass of pollutant allowed
to be discharged per mass of product) for the toxic and noncon-
ventional pollutants are identical to BAT mass limitations and
were calculated in the same manner.  The one-day maximum and
ten-day average effluent concentrations of each pollutant attain-
able by the selected treatment options (Table VII-9) were multi-
plied by the BAT production normalized flows.  The ten-day
average is used to calculate the maximum monthly average because,
as discussed in Section VII, it provides a reasonable basis for a
monthly average and is typical of the sampling frequency required
by discharge permits.  The resulting PSES are found in Section
II, Part 5, Subparts A through K.  The resulting PSNS are found
in Section II, Part 6, Subparts A through K.

Alternate PSES, based on Option 2 for those subcategories for
which Option 3 is proposed and Option 3 for those subcategories
for which Option 2 is proposed are found in Section II, Part 10,
Subparts A through K.  Alternate PSNS, based on Option 2 for
those subcategories for which Option 3 is proposed and Option 3
for those subcategories for which Option 2 is proposed are found
in Section II, Part 11, Subparts A through K.
                              857

-------
Section 307(b)(l) of the Clean Water Act requires that the date
for compliance with PSES be no more than three years from the
regulation's final promulgation date.  Few of the 114 indirect
dischargers in this category have installed and are properly
operating the treatment technology proposed as the basis for
PSES.  The readjustment of internal processing conditions to
achieve reduced wastewater flows may require further time above
installation of end-of-pipe treatment equipment.   Many plants in
this and other industries also will be installing the treatment
equipment suggested as model technologies for this regulation
which may result in delays in engineering, ordering, installing,
and operating this equipment.  Under these circumstances, the
Agency believes that three years is the appropriate compliance
deadline under Section 307(b)(l) of the Clean Water Act.
                              858

-------
                           Table XII-1

    POTW REMOVALS OF TOXIC POLLUTANTS IN THE "40 CITIES STUDY"


                                           25th Percentile of the
Toxic Pollutant      Number of POTW's       Removal Distribution

Cadmium                     14                      38%
Chromium                    36                      65%
Copper                      39                      58%
Cyanide                     37                      52%
Lead                        11                      48%
Nickel                      30                      19%
Silver                      15                      66%
Zinc                        39                      65%
Source:   Determining National Removal Credits for Selected
         Pollutants for Publicly Owned Treatment'Works,  EPA
         440/2-82-008,  September, 1982.
                               859

-------




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                                  Table XI1-4

              CAPITAL AND ANNUAL COST ESTIMATES FOR PSES OPTIONS
                         INDIRECT DISCHARGERS ($1982)


              Subcategory                 Option 1     Option 2     Option 3

Lead/Tin/Bismuth Forming

  Capital                                   177,700      325,600      401,800
  Annual                                    125,000      114,000      154,000

Nickel/Cobalt Forming

  Capital                                 1,539,000    2,425,500    2,639,700
  Annual                                    886,500      826,600      949,500

Zinc Forming

  Capital                                    30,186       30,874       36,575
  Annual                                      9,909       10,931       13,233

Precious Metals Forming

  Capital                                   382,400      622,900      733,600
  Annual                                    241,800      313,500      369,700

Iron and Steel/Copper/Aluminum Metal
Powder Production and Powder Metallurgy

  Capital                                 1,770,000    1,479,000    1,527,200
  Annual                                    716,600      654,100      696,400

Titanium Forming

  Capital                                   310,300      527,700      567,200
  Annual                                    165,500      203,000      223,200

Refractory Metals Forming

  Capital                                   374,500      727,800      815,400
  Annual                                    244,500      310,100      355,900

Zirconium/Hafnium Forming

  Capital                                     1,900        3,300        3,500
  Annual                                        900        1,300        1,400
                                    866

-------
                            Table XI1-4 (Continued)

              CAPITAL AND ANNUAL COST ESTIMATES FOR PSES OPTIONS
                         INDIRECT DISCHARGERS ($1982)
              Subcategory

Magnesium Forming

  Capital
  Annual

Totals

  Capital
  Annual
Option 1
      210
      340
4,556,000
2,381,100
Oj>tion 2
      220
      360
6,112,000
2,423,000
Option 3
      280
      400
6,688,700
2,750,500
                                     867

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-------
                           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.  Conventional pollutants are
those defined in Section 304(a)(4) (biological oxygen demanding
pollutants  (8005), total suspended solids (TSS), fecal coli-
form, and pH), and any additional pollutants defined by the
Administrator as "conventional" (oil and grease, 44 FR 44501,
July 30, 1979).

BCT is not an additional limitation,  but replaces BAT for the
control of  conventional pollutants.  In addition to 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 and respond to a judicial remand of the BCT methodology
originally established in 1977.  A more specific explanation of
the BCT methodology than this document provides appears in the
October 29, 1982 Federal Register notice.

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 POTWs.   The POTV/ 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 con-
ventional pollutants removed,  resulting in an estimate of the
"dollars per pound" of pollutant removed, that is used as a
benchmark value.  The proposed POTW test benchmark is $0.27 per
pound in 1976 dollars.  (The benchmark cost is $0.48 per pound in
1982 dollars).  If the conventional pollutant removal cost per
pound for the candidate BCT is less than the POTW benchmark, Part
1 of the cost-reasonableness test is passed.  Part 2 of the cost-
reasonableness test is then performed.

Part 2 of the BCT test is an industry cost-effectiveness test
which requires the evaluation of the incremental costs of remov-
ing conventional pollutants by the BCT technology in relation to
the cost of removing conventional pollutants by BPT technology in
the same industry.  As a benchmark to assess the reasonableness
of the ratio between the cost per pound of removal to achieve BPT
                               877

-------
and to achieve BCT, EPA has developed a ratio for POTW costs
which compares the dollars per pound of conventional pollutant
removed in going from primary to secondary treatment levels with
that of going from secondary to a more advanced treatment level.
The proposed benchmark is 1.43.  If the cost ratio as defined for
a given subcategory is lower than 1.43, the subcategory passes
the BCT ratio test.  Both cost-tests must be passed to establish
BCT limitations more stringent than BPT limits.  If all candidate
BCT technologies fail the cost-reasonableness test, the BCT
requirements for conventional pollutants are equal to BPT.

The Agency 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
pollutants by EPA (see 44 FR 50733, August 29, 1979), only oil
and grease, the pollutant accounting for the greatest removal was
included in the cost analysis (See 47 FR 49181, October 29,
1982).  Oil and grease is used rather than BOD5 in the cost
analysis performed for nonferrous metals forming waste streams
(in addition to TSS), due to the common use of oils in this
industry.

TECHNICAL APPROACH TO BCT

The Agency has applied the proposed BCT cost test to assess can-
didate BCT technologies by comparing the annualized cost for the
candidate technologies to the annualized cost for the selected
BPT technology.  The incremental cost of each candidate BCT tech-
nology was then divided by the incremental amounts of conven-
tional pollutants (TSS and oil and grease) removed by the addi-
tional technology.  The annualized costs for each option consid-
ered as a candidate technology for each subcategory are presented
in Table XIII-1.  Option 1, lime and settle without flow reduc-
tion, was  selected as the BPT technology in all subcategories.
Option 2 is lime and settle with flow reduction, and Option 3 is
lime and settle plus filtration plus flow reduction.

Table XIII-1 shows that in many cases the higher level options
are less expensive than Option 1.  In those cases, the incremen-
tal cost is negative (there is a savings in annualized costs) and
the higher level option automatically passes both BCT cost tests.
Those higher level options with the same annualized costs as the
annualized BPT cost also pass both BCT cost tests, since there
are no incremental costs in those cases.  Therefore, the incre-
mental costs and incremental pollutant removals only have to be
assessed for those cases where the higher level options have
greater annualized costs than the BPT option.  An example of the
calculation is as follows:
                               878

-------
BCT cost for Lead/Tin/Bismuth Forming Subcategory direct dis-
chargers :

Annualized Cost of Option 1 = $30,301 per year
(from Table XIII-1)

Annualized Cost of Option 3 = $35,981 per year
(from Table XIII-1)
Incremental Cost
= $ 5,680 per year.
Conventional Pollutants Discharged at Option 1 = 1,114 pounds per
year  (505.1 kg/yr)  (from Table X-4)

Conventional Pollutants Discharged at Option 3 = 134 pounds per
year  (60.6 kg/yr) (from Table X-4)

Incremental Removal = 980 pounds per year (444.5 kg/yr)

Dollars Per Pound = $5,680 - 980 pounds = $5.80 per pound
($12.78/kg)

The calculated cost in dollars per pound of conventional pollu-
tants removed exceeds the benchmark cost for the first BCT cost
test, $0,48, and the candidate technology fails the proposed BCT
cost test.  Therefore, there is no need to consider the second
BCT cost test, and the candidate technology would not be selected
for BCT.

Results of part 1 of the BCT cost test for all 11 subcategories
are presented in Table XIII-2.  Results of part 2 of the BCT cost
test for all 11 subcategories are presented in Table XIII-3.

BCT OPTION SELECTION

The Agency selected BCT based on Option 3 for the following four
subcategories because the Option 3 technology passed the proposed
BCT cost test:

        Nickel/Cobalt Forming
        Titanium Forming
        Magnesium Forming
        Uranium Forming

As shown in Table XIII-1, in all four subcategories, the reduced
operating costs which result from flow reduction more than offset
the increased costs for the additional technology so that the
annualized cost for the selected BCT technology is less than the
annualized cost for the BPT technology.
                               879

-------
The Agency selected BCT based on Option 2 for the following three
subcategories:

        Lead/Tin/Bismuth Forming
        Zirconium/Hafnium Forming
        Iron and Steel/Copper/Aluminum Metal Powder Production
        and Powder Metallurgy

These subcategories failed the proposed BCT cost test with costs
ranging from $3.78 to $137.95 per pound of conventional pollu-
tants removed.   However, the annualized cost of Option 2 is less
than or equal to the annualized cost of the BPT technology
(Option 1) for these three subcategories.  Therefore, Option 2 is
appropriate for BCT.

The Agency selected BCT based on Option 1 for the following four
subcategories because both higher level options failed the
proposed BCT cost test:

        Zinc Forming
        Beryllium Forming
        Precious Metals Forming
        Refractory Metals Forming

The costs ranged from $2.20 to $173.25 per pound of conventional
pollutants removed when BCT is based on Option 2 technology.  The
costs ranged from $2.20 to $167.18 per pound of conventional pol-
lutants removed when BCT is based on Option 3 technology.

COSTS AND ENVIRONMENTAL BENEFITS OF TREATMENT OPTIONS

No separate cost or benefit estimates were prepared for BCT.  As
a matter of convenience, the costs and benefits for removal of
conventional pollutants are included in the estimates for BAT,
described in detail in Section X and presented in Tables X-4
through X-14.

REGULATED POLLUTANT PARAMETERS

The pollutants  regulated under BCT are oil and grease, TSS, and
pH.  These pollutants are regulated in all 11 subcategories.

BEST CONVENTIONAL TECHNOLOGY MASS LIMITATIONS

The regulatory production normalized flows and the selected
treatment options for each subcategory are presented in Table
XIII-4.  The ten-day average is used to calculate the maximum
monthly average because, as discussed in Section VII, it provides
a. reasonable basis for a monthly average and is typical of the
sampling frequency required by discharge permits.  The one-day
                              880

-------
maximum and ten-day average effluent concentrations of  each
pollutant achievable by the selected treatment options  (Table
VII-9) were multiplied by the regulatory production normalized
flows.  The resulting values are presented for each of  the 11
subcategories in Section II, Part 7, Subparts A through K.

ALTERNATIVE BCT COST TEST CALCULATIONS

It should be noted that the costs used in the BCT test  for the
nonferrous metals forming category are somewhat different from
those used in the economic impact analysis and in estimating the
total cost of compliance with this regulation.  For the BCT test,
the costs used for Option 1 are the engineering estimates of
costs to implement the technology used as the basis for BPT.
However, for the economic impact analysis and the estimate of
total compliance cost, if a plant could meet the BPT limitation
at a lower cost by installing flow reduction in conjunction with
its lime and settle system, i.e., Option 2, EPA assumed the plant
would do so.  In this case, the cost of BPT would then  be the
lower cost estimated for Option 2, even though flow reduction
would be unnecessary to meet the pollutant removals achievable by
the BPT technology.

The Agency's decision to use the actual engineering cost esti-
mates for Option 1 when using the proposed BCT cost test, rather
than assume that a company would install the cost-minimizing flow
reduction is consistent with the Agency's previous BCT  proposals.

Under an alternative calculation of costs for each option, the
cost of the lowest cost option for each model plant is  assigned
to BPT as long as it is not negative.  When the cost of Option 2
is negative, the cost is set equal to zero for that model plant.
The annualized costs for each option for each subcategory which
are estimated using this method are presented in Table  XIII-5.

Significantly different technology options would be selected in
several subcategories as BCT technology using the costs presented
in Table XIII-5, because in no case, using those cost estimates,
is the annualized cost of a higher level option less than the
annualized cost of BPT.  Those cases where the annualized costs
are the same would still pass the BCT cost test since the incre-
mental cost is zero.   However, where the annualized cost of the
higher level option exceeds that of BPT, the higher level option
fails the proposed BCT cost test.  An example calculation is as
follows:

BCT cost test for Lead/Tin/Bismuth Forming Subcategory  direct
dischargers:
                              881

-------
Annualized Cost of Option 1 = $12,822  per year
(from Table XIII-3)

Annualized Cost of Option 2 = $14,482  per year
(from Table XIII-3)

Incremental Cost            = $ 1,660  per year

Conventional Pollutants Discharged at  Option 1 = 1,114 pounds  per
year (505.1 kg/yr) (from Table X-4)

Conventional Pollutants Discharged at  Option 2 = 234 pounds  per
year (105.8 kg/yr) (from Table X-4)

Incremental Removals = 880 pounds per  year (399.3 kg/yr)

Dollars Per Pound = $1,660 * 880 pounds = $1.88 per pound
($4.16/kg)

The candidate BCT technology failed  the BCT cost test.  There-
fore, Option 1 would have been selected as BCT for this subcate-
gory if the alternative costs had been used.

Alternate results of part 1 of the BCT cost test for all 11
subcategories are presented in Table XIII-6.   Alternate results
Of part 2 of the BCT cost test for all 11 subcategories are
presented in Table XIII-7.
                              882

-------
                           Table XIII-1

              ANNUALIZED BCT COST ESTIMATES FOR THE
                NONFERROUS METALS FORMING CATEGORY
 Subcategory

Lead/Tin Bismuth
Forming

Nickel/Cobalt
Forming

Zinc Forming

Beryllium Forming

Precious Metals
Forming

Iron and Steel,
Copper, and Aluminum
Metal Powder Produc-
tion and Powder
Metallurgy

Titanium Forming

Refractory Metals
Forming

Zirconium/Hafnium
Forming

Magnesium Forming

Uranium Forming
 Option 1
Annualized
 Cost ($)

  30,301


 119,721


  26,708

       0

 113,936


  77,523
 858,341

  70,374


  88,523


  70,850

 148,395
 Option 2
Annualized
 Cost ($)

  14.482
  71,844


  36,841

     310

 158,200


  77,523
 729,081

 102,479


  79,063


  44,564

 126,619
 Option 3
Annualized
 Cost ($)

  35,981


  94,392


  36,841*

     310*

 184,855


 101,641
 797,492

 114,577


  92,881


  44,570

 126,619*
*There is only one direct discharger in this subcategory.  This
 plant already has a filter or provides additional treatment
 which achieves equivalent results in the nonferrous metals
 forming industry, and no additional costs would be incurred for
 the additional treatment.
                              883

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-------
                           Table XIII-4

  BCT PRODUCTION NORMALIZED FLOWS AND SELECTED TREATMENT OPTIONS


                                        Production     Selected
                                        Normalized     Treatment
	Subcategory	      Flow (a)       Option (b)^


Lead/Tin/Bismuth Forming                   BAT           L + S

Nickel/Cobalt Forming                      BAT           L, S + F

Zinc Forming                               BPT           L + S

Beryllium Forming                          BPT           L + S

Precious Metals Forming                    BPT           L + S

Iron and Steel, Copper, and Aluminum       BAT           L + S
Metal Powder Production and Powder
Metallurgy

Titanium Forming                           BAT           L, S + F

Refractory Metals Forming                  BPT           L + S

Zirconium/Hafnium Forming                  BAT           L + S

Magnesium Forming                          BAT           L, S + F

Uranium Forming                            BAT           L, S + F
(a)  BPT production normalized flows are presented in Tables
     IX-12  through IX-22; BAT production normalized flows are
     presented in Tables X-15 through X-25.

(b)  L + S    = lime and settle technology
     L, S + F = lime, settle, filter technology
                              886

-------
                           Table XIII-5

        ALTERNATIVE ANNUALIZED BCT COST ESTIMATES FOR THE
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 Subcategory

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Forming

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Zinc Forming

Beryllium Forming

Precious Metals
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Titanium Forming

Refractory Metals
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Zirconium/Hafnium
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Magnesium Forming

Uranium Forming
 Option 1
Annualized
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  61,020


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74,504
26,708
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80,897
36,841
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94,392
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-------
                           SECTION XIV

                            REFERENCES


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Aluminum Association  Forging and Impacts Division, Aluminum
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American Society for Metals, 1958, Handbook Metals Engineering
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American Society for Metals, 1964, Heat Treating, Cleaning, and
Finishing, Metals Handbook, 8th ed., Vol.2, Metals Park, Ohio.

American Society for Metals, 1970, Forging and Casting, Metals
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American Society for Metals, 1977, Definitions of Metallurgical
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American Society for Metals, 1982, Surface Cleaning, Finishing
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ANDCO Environmental Processes,  Inc., 1981, "Andco Chromate and
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Avitur, Betzalel, 1968, Metal Forming; Processes and Analysis,
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Avitur, Betzalel, 1980, Metal Forming, Dekker, New York, New
York.

Bailey, P.A., "The Treatment of Waste Emulsified Oils by
Ultrafiltration," Filtration and Separation, January-February
1977.	

Barksdall, J., 1966, Titanium:   Its Occurrence, Chemistry and
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Beddow, John K., 1978, The Production of Metal Powders by
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Blazynski, T.Z., 1976, Metal Forming, Wiley, New York, New York.

Bradbury, Samuel, ed., 1979, Source Book on Powder Metallurgy,
American Society for Metals, Metals Park,Ohio.

Brush Wellman Inc., Alloy Information Packet.
                               891

-------
Bureau of Mines, 1975, Mineral Facts and Problems,  United  States
Department of the Interior.

Bureau of Mines, Mineral Commodity Profiles,  1978,  Tin.

Bureau of Mines, Mineral Commodity Profiles,  1978,  Zinc.

Bureau of Mines, Mineral Commodity Profiles,  1979,  Antimony.

Bureau of Mines, Mineral Commodity Profiles,  1979,  Beryllium.

Bureau of Mines, Mineral Commodity Profiles,  Lithium.

Bureau of Mines, Mineral Commodity Profiles,  1979,  Rhenium.

Bureau of Mines, 1981, Minerals Yearbook,  U.S.  Department  of  the
Interior.

Burns and Roe, Inc.,  1978,  Handbook of Wastewater Treatment
Costs, Randolph, New  Jersey.

Butts, Allison, 1967, Silver:   Economics,  Metallurgy  and Use,  Van
Nostrand, New York, New York.

Cairns, John Harper and P.T.  Gilbert,  1967, The Technology of
Heavy Non-Ferrous Metals and  Alloys.

Church, Fred L., "Zinc Sheet:   Ample Capacity,  Stable  Price,
Markets Needed," Modern Metals, November,  1980.

Conard, B.R., E.A. Devuyst  and V.A. Ettel, 1982,  "Pilot Plant
Operation of the INCO S02/Air Cyanide Removal Process,"
Canadian Mining Journal, August 1982.

Conard, B.R., E.A. Devuyst  and W.  Hudson,  "Commercial-Scale
Trials of the INCO S02/Air  Cyanide Removal Process,"  To Be
Presented at the Canada/EC  Seminar Treatment  of Complex Minerals,
the Government Conference Centre,  Ottawa,  October 12-14, 1982.

Dodge Building Cost Services,  Dodge Guide to  Public Works  and
Heavy Construction Costs, McGraw-Hill, New York, New  York.

Emley, Edward F., 1966, Principles of Magnesium Technology,
Pergamon Press, New York^New York.

Erbin, E.F., 1969, Applications of Titanium,  ASM, Metals
Engineering Institute, Metals Park, Ohio.

Federal Register, 44  FR 69464.
                               892

-------
Federal Register, 44 FR 75028.

Federal Register, 44 FR 38749.

Federal Register, 45 FR 79318.

Federal Register, 47 FR 51512.

Federal Register, 47 FR 49176.

Federal Register, 48 FR 36942.

Federal Register, 48 FR 49126.

Federal Register, 49 FR 5831.

Floyd, D.R. and J.N. Lowe, ed.,  1979,  Beryllium Science  and
fr
Technology, Vol. 2, Plenum Press,  New York,New York.

Forging Industries Association, 1982-1983 Forging Capability
Chart, Cleveland, Ohio.

Gumerman, R.C., R.L. Gulp and S.P. Hansen, Estimating  Water
Treatment Costs, Volume 2,  EPA-600/2-79-l620b,  U.S.  Environmental
Protection Agency, Cincinnati, Ohio,  August  1979.

Hausner, H.H., ed., 1965, Beryllium:   Its Metallurgy and
Properties, University of California  Press,  Berkeley,  California.

Hawley, Gessner G. , rev., The Condensed Chemical Dictionary,  9th
ed.

Hockenberry, H.R. and J.E.  Lieser, "Practical Application of
Membrane Techniques of Waste Oil Treatment," Journal of the
American Society of Lubrication Engineers, May^ 1976.

Indium Corporation of America, Product Literature.

International Magnesium Association,  1982 Buyer's Guide, Dayton,
Ohio.

Jacobs Engineering Group, 1980, Draft Development Document for
Effluent Limitations and Guidelines,  New Source Performance
Standards and Pretreatment Standards  for the Metal Powders
Segment of the Mechanical Products Point Source Category.

JRB Associates, Statistical Analysis  Group,  A Statistical
Analysis of the Combined Metals Industries Effluent DatlT7
November 4, 198Z.
                               893

-------
Keenan, Charles W. and Jesse H.  Wood,  1971,  General College
Chemistry, 4th Edition, Harper and Row,  New  York.

Kennametal Inc., 1977, Properties and  Proven Uses  of Kennametal
Hard Carbide Alloys,  Latrobe, Pennsylvania.

Kirk-Othmer, 1981, Encyclopedia of Chemical  Technology,  Third
Edition, John Wiley & Sons,  Inc., New  York,  New York.

Kirk-Othmer, 1963, Encyclopedia of Chemical  Technology,  Second
Edition, Interscience Publishers, New  York,  New York.

Lange, Norbert, Adolph, 1973, Handbook of Chemistry, McGraw-Hill,
New York, New York.

Lead Industries Association, 1965,  Lead and  Zinc,  New York,  New
York.

Lead Industries Association, 1979,  Lead,  New York,  New York.

Lenel, Fritz V., 1980, Powder Metallurgy:  Principles  and
Applications, MPIF, Princeton,  New Jersey.

Liptak, E.G., 1974, Environmental Engineer's Handbook, Volume TL_ -
Water Pollution, Chilton Book Company, Radnor,  Pennsylvania.

Lustman and Kerze, 1955, The Metallurgy of Zirconium.

Manko, Howard H.,  1979, Solders  and Soldering,  McGraw-Hill,  New
York, New York.

Metal Progress, "Trends in Nonferrous  Metal  Technology," January,
1983.

Metal Progress, "Trends in Powder Metallurgy Technology,"
January,1983.

Metal Progress, "Trends in Special-Duty Materials  Technology,"
January,1983.

Metal Progress, "Trends in Superalloy  Technology,"  January,  1983.

Metcalf & Eddy, Inc., 1979,  Wastewater Engineering:   Treatment,
Disposal, Reuse, McGraw-Hill, New York,  New  York.

MPIF, 1982, Powder Metallurgy Equipment Directory,  13th  Edition,
New Jersey.

MPIF, 1983, Members of the Metal Powder Industries  Federation,
Princeton, New Jersey.
                              894

-------
Northcott, L., 1956, Metallurgy of Rarer Metals -5:   Molybdenum,
Academic Press, New York, New York.

Nutt, S.G. and S.A. Zaidi, "Treatment of Cyanide-Containing
Wastewaters by the Copper-Catalyzed S02/Air Oxidation Process,"
Presented at the 38th Annual Purdue Industrial Waste Conference
Purdue University, West Lafayette, Indiana, May 10-12,  1983.

Perry, R.H. and C.H. Chilton, 1973, Chemical Engineer's Handbook,
5th Edition, McGraw-Hill.

Peters, M.S. and K.D. Timmerhaus, 1980,  Plant Design and
Economics for Chemical Engineers, Third Edition, McGraw-Hill.

Radian Corporation, 1982, The Cost Digest - Cost Summaries  of
Selected Environmental Control Technologies (unpublished report),
DCN 82-203-001-47-03, May.

Refractory Metals Association, 1980, What Are Refractory Metals .
. . and How Do They Affect Our Lives?  MPIF, Princeton, New
Jersey.

Richardsons Engineering Services, Inc.,  1980, Process Plant
Construction Estimating Standards, Volumes 1, T] 3^  and A-,  Solana
Beach, California.

Rinehart, John S. and John Pearson, 1963, Explosive  Working of
Metals, Pergamon Press, New York, New York.

Ro, D.H., M.W. Toaz and V.S.  Moxson, "The Direct Powder Rolling
Process for Producing Thin Metal Strip," Journal of  Metals,
January, 1983.

Ronson Metals Corporation, Product Literature.

Schemel, J.H., 1977, ASTM Manual on Zirconium and Hafnium,  ASTM
Special Technical Publication 639.

Technical Materials Inc., 1976, Handbook for Clad Metals,
Lincoln, Rhode Island.

Thomas Register of American Manufacturers and Thomas Register
Catalog File, 1982, Torrington, Connecticut.

Timet, Titanium.

U.S. Environmental Protection Agency, 1975, Process  Design  Manual
for Suspended Solids Removal, EPA 625/1-75-003-a,  Technology
transfer Series,  January.
                               895

-------
U.S. Environmental Protection Agency, 1977, Sampling and Analy-
sis Procedures for Screening of Industrial Effluents for Prior-
ity Pollutants, April.

U.S. Environmental Protection Agency, 1977, Sources and Treatment
of Wastewater in the Nonferrous Metals Industry,  Radian
Corporation,February.

U.S. Environmental Protection Agency, 1979, Methods for Chemical
Analysis for Water and Wastes,  EPA-600/4-79-020,  March, 1979.

U.S. Environmental Protection Agency, 1980, Treatability Manual,
Volume IV.  Cost Estimating, EPA 600/8-80/042-d,  July.

U.S. Environmental Protection Agency, 1982, Determining National
Removal Credits for Selected Pollutants for Publicly Owned
Treatment Works, EPA 440/2-82/008, September.

U.S. Environmental Protection Agency, 1982, Development Document
for Proposed Effluent Limitations Guidelines and  Standards for
the Aluminum Forming Point Source Category, EPA 44-0/1 -82/073-b,
November.

U.S. Environmental Protection Agency, 1982, Development Document
for Proposed Effluent Limitations Guidelines and  Standards for
the Copper Forming Point Source Category,  EPA 440/1-82/074-b,
October.

U.S. Environmental Protection Agency, 1982, Development Document
for Effluent Limitations Guidelines and Standards for the
Inorganic Chemicals Manufacturing Point Source Category, EPA
440/1-82/007, June.

U.S. Environmental Protection Agency, 1982, Development Document
for Effluent Limitations Guidelines and Standards for the Iron
and Steel Manufacturing Point Source Category^EPA 440/1-82/024,
May.

U.S. Environmental Protection Agency, 1982, Development Document
for Proposed Effluent Limitations Guidelines and  Standards for
the Metal Finishing Point Source Category, EPA 440/1-82/091-b.

U.S. Environmental Protection Agency, 1982, Fate  of Priority
Pollutants in Publicly Owned Treatment Works,  Final Report,  EPA
440/1-82/303, September.

U.S. Environmental Protection Agency, 1982, Handbook for Sampling
and Sample Preservation of Water and Wastevater,EPA
600/4-82/029, September.
                               896

-------
U.S. Environmental Protection Agency, 1983, Development Document
for Proposed Effluent Limitations Guidelines and Standards for
the Nonferrous Metals Point Source Category, Volume 1,EPA"
440/l-83/019b, March.

U.S. Environmental Protection Agency, 1983, Development Document
for Proposed Effluent Limitations Guidelines and Standards for
the Inorganic Chemicals Point Source Category,  Phase II,  EPA
440/l-S3/007-b, September.

U.S. Environmental Protection Agency, 1984, Economic Analysis  of
Proposed Effluent Limitations and Standards for the Nonferrous
Metals Forming Industry, EPA 44U/2-84/005,  February.

U.S. Steel, 1971, The Making and Shaping of Steel,  9th  Edition,
Herbick and Held, Pittsburgh, Pennsylvania.

Wang, Yih, 1979, Tungsten:  Metallurgy Properties and
Application, Plenum Press, New York, New York.

Wilkinson, W.D., 1962, Uranium Metallurgy,  Interscience.

Williams, S.C., 1965, Report on Titanium, The Ninth Industrial
Metal.

Wise, Edmund M., 1964, Gold:  Recovery, Properties  and
Applications, Van Nostrand, New York, New York.

Zinc Institute, Inc., U.S. Zinc and Cadmium Industries, Annual
Review, 1981, New York, New York.

Zinc Institute, Inc., Zinc!  December, 1983.
                               897

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                             SECTION  XV

                             GLOSSARY
This section is an alphabetical  listing  of  technical  terms  (with
definitions) used in  this  document which may  not  be  familiar  to
the reader.

4-AAP Golorimetric Method

An analytical method  for total phenols and  total  phenolic com-
pounds  that involves  reaction with the color  developing  agent
4-aminoantipyrine.

Acidity

The quantitative capacity  of aqueous  solutions  to react  with
hydroxyl  ions.  Measured by titration with  a  standard solution of
a base  to a specified end  point.  Usually expressed as milligrams
per liter of calcium  carbonate.

The Act

The Federal Water Pollution Control Act  Amendments of 1972  as
amended by the Clean Water Act of 1977 (PL  92-500).
A change in the properties of certain metals and alloys that
occurs at ambient or moderately elevated temperatures  after hot
working or heat treatment  (quench aging in  ferrous alloys,
natural or artificial aging in ferrous and  nonferrous  alloys) or
after a cold working operation (strain aging).  The change in
properties is often due to a phase change  (precipitation), but
never involves a change in chemical composition of the metal or
alloy.

Alkaline Cleaning

A process in which a solution, usually detergent, is used to
remove lard, oil, and other such compounds  from a metal surface.

Alkalinity

The capacity of water to neutralize acids,  a property  imparted by
the water's content of carbonates, bicarbonates, hydroxides, and
occasionally borates, silicates,  and phosphates.   It is measured
by titration with a standardized acid to a  specified end point,
and is usually reported in milligrams per liter of calcium car-
bonate.
                               899

-------
A substance having metallic properties and being composed  of  two
or more chemical elements of which at least one is an elemental
metal.

Amortization

The allocation of a cost or account according to a specified
schedule, based on the principal, interest and period of cost
allocation.

Analytical Quantification Level

The minimum concentration at which quantification of a specified
pollutant can be reliably measured.

Annealing

A generic term describing a metal's treatment process that  is
used primarily to soften metallic materials, but also to simul-
taneously produce desired changes in other properties or in
microstructure.  The purpose of such changes may be, but is not
confined to, improvement of machinability, facilitation of  cold
work, improvement of mechanical or electrical properties,  and/or
increase in stability of dimensions.  Annealing consists of heat-
ing and cooling the metal at varying rates to achieve the  desired
properties.

Anvil

In drop forging, the base of the hammer into which the sow  block
and lower die part are set.  Also, a block of steel upon which
metal is forged.

Atomization

The process in which a stream of water or gas impinges upon a
molten metal stream, breaking it into droplets which solidify as
powder particles.

Backwashing

The operation of cleaning a filter or column by reversing  the
flow of liquid through it and washing out matter previously
trapped.

Ball Mill

A mill in which materials are finely ground on a rotating
cylinder containing balls (usually steel).
                               900

-------
Batch Treatment

A waste treatment method where wastewater  is collected over  a
period of time and then treated prior to discharge.  Treatment is
not continuous, but collection may be continuous.

Bench Scale Pilot Studies

Experiments providing data concerning the  treatability of a
wastewater stream or the efficiency of a treatment process con-
ducted using laboratory-size equipment.

Best Available Demonstrated Technology (BADT)

Treatment technology upon which new source performance standards
are based as defined by Section 306 of the Act.

Best Available Technology Economically Achievable  (BAT)

Level of technology applicable to toxic and nonconventional
pollutants on which effluent limitations are established.  These
limitations are to be achieved by July 1,  1984 by  industrial dis-
charges to surface waters as defined by Section 301(b) (2) (C) of
the Act.

Best Conventional Pollutant Control Technology (BCT)

Level of technology applicable to conventional pollutant effluent
limitations to be achieved by July 1, 1984 for industrial dis-
charges to surface waters as defined in Section 301(b)(2)(E) of
the Act.

Best Management Practices (BMP)

Regulations intended to control the release of toxic and hazard-
ous pollutants from plant runoff, spillage, leaks, solid waste
disposal, and drainage from raw material storage.

Best Practicable Control Technology Currently Available  (BPT)

Level of technology applicable to effluent limitations to have
been achieved by July 1, 1977 (originally) for industrial dis-
charges to surface waters as defined by Section 301(b)(l)(A) of
the Act.

Billet

A long slender cast product used as raw material in subsequent
forming operations.
                              901

-------
Biochemical Oxygen Demand  (BOD)

The quantity of oxygen used in the biochemical oxidation of
organic matter under specified conditions for a specified time.

Blowdown

The minimum discharge of circulating water for the purpose of
discharging dissolved solids or other contaminants contained in
the water, the further buildup of which would cause concentration
in amounts exceeding limits established by best engineering
practice.

Boring

A machining method using single-point tools on internal surfaces
of revolution.

Bjrazing

A process that bonds two metal pieces by heating them to a suit-
able temperature and by using a filler material which melts above
425°C (800°F) but below the melting point of the metal being
joined.   The filler material is distributed between the surfaces
of the joint by capillary  action.

Bright Annealing

Annealing in a protective  medium to prevent discoloration of the
bright surface.

Brittleness

The quality of a metal that leads to crack propagation without
appreciable plastic deformation.

Burnishing

A surface finishing process in which minute surface irregulari-
ties are displaced rather  than removed.

Burr

A turned-over edge on a metal piece resulting from cutting,
pressing, or grinding.

Catalyst

An agent that (1) reduces  the energy required for activating a
chemical reaction and (2)  is not consumed by that reaction.
                               902

-------
Chelation

The formation of coordinate covalent bonds between a central
metal ion and a liquid that contains two or more sites for com-
bination with the metal ion.

Chemical Finishing

Producing a desired finish on the surface of a metallic product
by immersing the workpiece in a chemical bath.

Chemical Oxygen Demand (COD)

A measure of the oxygen-consuming capacity of the organic and
inorganic matter present in the water or wastewater.

Chromating

Treating a metal in a solution of hexavalent chromium compound to
produce a conversion coating consisting of trivalent and hexaval-
ent chromium compound.

Clad Metal

A composite metal containing two or more layers that have been
metallurgically bonded together by roll bonding (co-rolling),
solder application (or brazing) and explosion bonding.

Coining

A closed-die squeezing operation, usually performed cold, in
which all surfaces of the work are confined or restrained,
resulting in a well-defined imprint of the die upon the work.

Cold Working

Deforming metal plastically at a temperature lower than the
recrystallization temperature of the metal, generally at room
temperature.

Colloid

Suspended solids whose diameter may vary between less than one
micron and 15 microns.

Compact (Briquet)

An object produced by the compression of metal powder.
                               903

-------
Composite Samples

A series of samples collected over a period of time but combined
into a single sample for analysis.  The individual samples can be
taken after a specified amount of time has passed  (time compos-
ited) , or after a specified volume of water has passed the sam-
pling point (flow composited).  The sample can be  automatically
collected and composited by a sampler or can be manually
collected and combined.

Consent Decree (Settlement Agreement)

Agreement between EPA and various environmental groups, as
instituted by the United States District Court for the district
of Columbia, directing EPA to study and promulgate regulations
for the toxic pollutants (NRDC  Inc. v Train, 8 ERC 2120  (D.D.C.
1976), modified March 9, 19/9, 12 ERC 1833, 1841).

Contact Water

Any water or oil that comes into direct contact with nonferrous
metal during forming operations,  whether the metal is raw mate-
rial, intermediate product, waste product, or finished product.

Continuous Casting

A casting process that produces sheet, rod, or other long shapes
by solidifying the metal while it is being poured through an
open-ended mold using little or no contact cooling water.  Thus,
no restrictions are placed on the length of the product and it is
not necessary to stop the process to remove the cast product.

Continuous Treatment

Treatment of waste streams operating without interruption as
opposed to batch treatment.  Sometimes referred to as flow-
through treatment.

Cpntractor Removal (Contract Hauling)

Disposal of oils, spent solutions, or sludge by a commercial
firm.

Conventional Pollutants

Constituents of wastewater as determined by Section 304(a)(4) of
the Act, including but not limited to pollutants classified as
biological-oxygen-demanding, oil  and grease, suspended solids,
fecal coliforms,  and pH.
                               904

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Conversion Coating

A coating consisting  of  a  compound  of  the  surface  metal,  produced
by chemical or electrochemical  treatments  of  the metal.   Examples
are  chromate  coatings  on zinc  and magnesium,  oxides  or  phosphate
coatings on steel.  Also,  the  process  of producing such a coat-
ing.

Cooling Tower

A hollow, vertical  structure with internal baffles designed  to
break up falling water so  that  it is cooled by upward-flowing air
and  the evaporation of water.

Corrosion

The  deterioration of  a metal by chemical or electrochemical
reaction with its environment.

Countercurrent Cascade Rinsing

A staged process that employs recycled, often untreated water as
a rinsing medium to clean  metal products.   Water flow is  opposite
to product flow such  that  the  most  contaminated water encounters
incoming product first.

Crucible

A vessel or pot made  of  a  material  with a  high melting  point used
for  melting metals.

Data Collection Portfolio  (dcp)

The questionnaire used in  the survey of the nonferrous  metals
forming industry.

Deoxidizing

The  removal of any  oxide film  from  a metal.

Desmutting

A process that removes smut by  immersing the product in an acid
solution,  usually nitric acid.

Die

Various tools used  to impart shape  to  metal primarily because of
the  shape of the die  itself.  Examples are forging dies,  drawing
dies, and extrusion dies.
                              905

-------
Direct Chill Casting

A method of casting where the molten metal is poured  into  a
water-cooled mold.  The base of this mold is the top  of a
hydraulic cylinder that lowers the metal first through the mold
and then through a water spray and bath to cause solidification.
The vertical distance of the drop limits the length of the ingot.
This process is also known as semi-continuous casting.

Direct Discharger

Any point source that discharges to a surface water.

Drag-out

The solution that adheres to the objects removed from a bath or
rinse, more precisely defined as that solution which  is carried
past the edge of the tank.

Drawing

Pulling the metal through a die or succession of dies to reduce
the metal's diameter or alter its shape.

Drying Beds

Areas for dewatering of sludge by evaporation and seepage.

Ductility

The ability of a metal to deform plastically without  fracturing.

Dummy Block

In extrusion, a thick unattached disk placed between  the ram and
billet to prevent overheating of the ram.

Effluent

Discharge from a point source.

Effluent Limitation

Any standard (including schedules of compliance) established by a
state or EPA on quantities, rates, and concentrations of chemi-
cal, physical, biological, and other constituents that are dis-
charged from point sources into navigable waters, the waters of
the contiguous zone, or the ocean.
                               906

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Electrochemical Finishing

Producing a desired  finish on  the  surface  of  a  metallic  product
by immersing the workpiece in  an electrolyte  bath  through which
direct current is passed.

Electroplating

The production of a  thin coating of  one  metal on another by  elec-
trodeposition.

Electrostatic Precipitatoir (ESP)

A gas cleaning device that induces an electrical charge  on a
solid particle which is then attracted to  an  oppositely  charged
collector plate.  The collector plates are  intermittently
vibrated to discharge the collector  dust to a hopper.

Emulsifying Agent

A material that increases the  stability  of  a  dispersion  of one
liquid in another.

Emulsions

Stable dispersions of two immiscible liquids.   In  the nonferrous
metals forming category this is usually  an  oil  and water mixture.

End-of-Pipe Treatment

The reduction of pollutants by wastewater  treatment prior to dis-
charge or reuse.

Etching

The removal of surface imperfections, oxides, and  scratches  by
chemical action.  Etching can  also provide  surface roughness.

Eutectic Temperature

The lowest temperature at which a  solution  (in  this case, the
solution is molten metal and various alloying materials) remains
completely liquid.

Extrusion

A process in which high pressures  are applied to a metal billet,
forcing the metal to flow through  a  die orifice.
                               907

-------
Finishing

The coating or polishing of a metal  surface.

Fluxes

Substances added to molten metal  to  help  remove  impurities  and
prevent excessive oxidation, or promote the fusing of the metals.

Forging

Deforming metal, usually hot, with compressive force into desired
shapes, with or without dies.  Where dies are used, the;  metal  is
forced to take the shape of the die.

Gas Chromatography/Mass Spectroscopy (GC/MS)

Chemical analytical instrumentation  used  for quantitative organic
analysis.

Grab Sa.mple

A single sample of wastewater taken  without regard to time  or
flow.

Grain

An individual crystal in a polycrystalline metal or alloy.

Green Compact

An unsintered compact.

Grinding

The process of removing stock from a workpiece by the xise of a
tool consisting of abrasive grains held by a rigid or semi-rigid
binder.  Grinding includes surface finishing, sanding, and  slic-
ing.

Hammer Forging

Forging in which the workpiece is deformed by repeated blows.

Hardness

Resistance of metal to plastic deformation by indentation,
scratching, abrasion or cutting.
                              908

-------
Heat Treatment

A process that changes the physical properties of the metal, such
as strength, ductility, and malleability by controlling the rate
of cooling.

Homogenizing

Holding solidified metal at high temperature to eliminate or
decrease chemical segregation by diffusion.

Hot Working

Deforming metal plastically at such a temperature and rate that
strain hardening does not occur.  The low  limit of temperature is
the recrystallization temperature of the metal.

Hydraulic Press

A press in which fluid pressure is used to actuate and control
the ram.

Impacting

Forming, usually cold, a part from a metal slug confined in a
die, by rapid single-stroke application of force through a punch,
causing the metal to flow around the punch.

Indirect Discharger

Any point source that discharges to a publicly owned treatment
works.

Inductively-Coupled Argon Plasma Spectrophotometer (ICAP)

A laboratory device used for the analysis of metals.

Ingot

A large, block-shaped casting produced by various methods.
Ingots are intermediate products from which other products are
made.

In-Process Control Technology

Any procedure or equipment used to conserve chemicals and water
throughout the production operations, resulting in a reduction of
the wastewater volume.
                               909

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Jet

A stream of fluid  (gas or liquid) discharged  from a narrow  open-
ing or nozzle.

Mandrel

A rod used to retain the cavity in hollow metal products  during
working.

Metal Powder Production

Any process operations which convert metal to a finely  divided
form without an increase in metal purity.

Neat Oil

A pure oil with no or few impurities added.  In nonferrous  metals
forming its use is mostly as a lubricant.

New Source Performance Standards  (NSPS)

Effluent limitations for new industrial point sources as  defined
by Section 306 of the Act.

Nonconventional Pollutant

Parameters selected for use in performance standards that have
not been previously designated as either conventional or  toxic
pollutants.

Nonferrous Meta^L

Any pure metal other than iron, copper or aluminum; or  metal
alloy for which a metal other than iron, copper, and aluminum is
its major constituent in percent by weight.

Nonferrous Metals Forming

A set of manufacturing operations in which nonferrous metals and
nonferrous alloys are made into semifinished products by  hot or
cold working.   It also includes metal powder production and
powder metallurgy of all metals,  including iron, copper,  and
aluminum.

Non-Water Quality Environmental Impact

The ecological impact as a result of solid, air, or thermal pol-
lution due to the application of  various wastewater technolo-
gies to achieve the effluent guidelines limitations.  Also  asso-
ciated with the non-water quality aspect is the energy  impact of
wastewater treatment.
                               910

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NPDES Permits

Permits used by EPA or  an  approved  state  program under  the
National Pollutant Discharge Elimination  System.

Off-Gases

Gases, vapors, and fumes produced as a result  of a  nonferrous
metals forming operation.

Off-Kilogram (Off-Pound)

The mass of nonferrous  metal or  metal alloy  removed from a form-
ing operation or associated surface or heat  treatment operation
at the end of a process cycle  for transfer to  a  different process
or machine.  For example,  one  kilogram for all pounds of metal
that is cold rolled twice  in succession on the same or  tandem
rolling mill and then annealed represents one  off-kilogram for
all pounds for cold rolling and  one off-kilogram for all pounds
for annealing; one off-kilogram  for all pounds of metal  that is
cold rolled once then annealed and  cold rolled again represents
two off-kilograms for all  pounds for cold rolling and one off-
kilogram for all pounds for annealing.  Product  storage  is also  a
factor in calculating off-kilograms for all  pounds:  one off-
kilogram for all pounds of metal that is  cold  rolled, taken off
the line and stored, then  cold rolled at  a later date represents
two off-kilograms for all  pounds for cold rolling.

Oil and Grease (OkG)

Any material that is extracted by freon from an  acidified sample
and that is not volatilized during the analysis, such as hydro-
carbons, fatty acids, soaps, fats, waxes, and  oils.

Oxidation

A reaction in which there  is an  increase  in  valence resulting
from a loss of electrons.

2H

The pH is the negative logarithm of the hydrogen ion activity of
a solution.

Phosphating

Forming an adherent phosphate  coating on  a metal immersed in a
suitable aqueous phosphate solution.
                               911

-------
Pickle Liquor

A spent acid-pickling bath.

Pickling

Removing oxides from metals by chemical or  electrochemical
reactions.

Pig

A metal casting used in remelting.

Plate

A flat, extended, rigid metal body having a thickness greater
than or equal to 6.3 mm (0.25 inches).

Pointing

Reducing the diameter of wire, rod, or tubing over a short  length
by swaging, hammer forging or squeezing to  facilitate entry  into
a drawing die and gripping in the drawhead.

Pollutant Parameters

Those constituents of wastewater determined to be detrimental
and, therefore, requiring control.

Powder

Particles of matter characterized by small  size, i.e., 0.1  to
1,000 urn.

Powder Metallurgy

The art of producing metal powders and using metal powders  for
the production of massive materials (ingots, billets) and shaped
objects (parts).

Press Forging

Forging metal, usually hot, between dies in a press.

Pressing

In powder metallurgy, forming a powder-metal part with com-
press ive force.
                               912

-------
Priority Pollutants

Those pollutants included in Table 2 of Committee Print number
95-30 of the "Committee on Public Works and Transportation of the
House of Representatives," subject to the Act.

Process Water

Water used in a production process that contacts the product, raw
materials, or reagents.

Production Normalized Water Discharge

The volume of water discharged from a given process per mass of
nonferrous metal processed.  The water may be discharged to
further treatment, discharged without treatment, or removed by a
contractor.  Differences between the water use and wastewater
flows associated with a given stream result from recycle,
evaporation, and carryover on the product.

Production Normalized Water Use

The volume of water or other fluid (e.g., emulsions, lubricants)
required per mass of metal processed through the operation.
Water use is based on the sum of recycle and make-up flows to a
given process.

Production Normalizing Parameter (PNP)

The unit of production specified in the regulations used to
determine the mass of pollutants that a production facility may
discharge.

PSES

Pretreatment standards (effluent regulations) for existing
sources, under Section 307(b) of the Act.

PSNS

Pretreatment standards (effluent regulations) for new sources,
under Section 307(c) of the Act.

Publicly Owned Treatment Works (POTW)

A waste treatment facility that is owned by a state or municipal-
ity.

Quenching

Rapid cooling, in air, vapor or water.
                              913

-------
Rain

The moving part of a hammer or press to which a tool is  fastened.

Recrystallization Temperature

The minimum temperature at which a new, stain-free grain struc-
ture is formed from that existing in a cold worked metal.

Recycle

Returning treated or untreated wastewater to the production pro-
cess from which it originated for use as process water.

Reduction

A reaction in which there is a decrease in valence resulting  from
a gain in electrons.

Repressing

The application of pressure to a previously pressed and  sintered
compact, usually to improve some physical property.

Reuse

The use of treated or untreated process wastewater in a  different
production process.

Ring Rolling

A forging process used to shape weldless rings from pierced disks
or thick-walled, ring-shaped blanks.  The rings are forged
between rolls or a mandrel and hammer.

Rinsing

A process in which water is used to wash surface treatment and
cleaning chemicals from the surface of metal.

Rod

An intermediate metal product having a solid, round cross section
9.5 mm (3/8 inches) or more in diameter.

Roll Bonding

The process by which a permanent bond is created between  two
metals by rolling under high pressure in a bonding mill
(co-rolling) .
                               914

-------
Rolling

A  forming process  that reduces  the  thickness  of  a workpiece  by
passing it between a pair of  lubricated steel rollers.

Sand Blasting

Abrasive blasting with sand.

Sawing

Cutting a workpiece with a band, blade, or circular disk having
teeth.

Scale

A  thick layer of oxidation products  formed on metals at high tem-
peratures.  Also deposits of water-insoluble constituents  formed
on surfaces in cooling towers and wet air pollution control
equipment.

Scrubber Liquor

The untreated wastewater stream produced by wet  scrubbers  clean-
ing gases produced by nonferrous metals forming  operations.

Seal Water

A  water curtain used as a barrier between the furnace atmosphere
and the outside atmosphere.

Semi-Fabricated Products

Intermediate products that are the final product of one process
and the raw material for a second process.

Sheet

A  flat-rolled metal product thinner  than plate.

Shot

Small spherical particles of metal,  larger in diameter than
powder.

Shot Casting or Shotting

The production of shot by pouring metal in finely divided
streams.   Solidified spherical particles formed  during the
descent  are cooled in a tank of water.
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 Shot  Peening

 Cold  working  the  surface  of  a  metal  by  metal-shot  impingement.

 Sintering

 The bonding of  adjacent surfaces  of  particles  in a mass  of metal
 powders or a  compact, by  heating  to  a temperature  less than the
 melting point of  the  metal.

 Sizing

 Final pressing  of  a sintered compact to produce specified
 dimensions and  tolerances.

 Skiving

 Removal of a  material in  thin  layers with a high degree  of shear
 or slippage or  both.  This process is used to  form a  trough in  a
 strip of base metal in preparation for producing clad inlay
 strip.

 Soldering

 A process that  bonds  two  metal pieces by heating them to a suit-
 able  temperature and by using a filler material which melts  below
 425°C (800°F).  The filler material  is  distributed between the
 surfaces of the joint by  capillary action.

 Solid Solution

 A single solid homogeneous crystalline phase containing  two  or
 more  chemical species.

 Solution Heat Treatment

 Heating an alloy to a suitable temperature, holding it at  that
 temperature long enough to cause one or more constituents  to
 enter into solid solution, and then  cooling rapidly enough to
 hold  these constituents in solution.

 Stainless Steel

 An iron-base alloy, containing chromium and sometimes nickel or
 manganese, which is extremely resistant to corrosion.  £>ome
 alloys called stainless steel are greater than 50  percent  nickel.

 Stationary Casting

A process in which the molten metal  is poured into molds and
 alloyed to cool.  It  is often used to recycle in-house scrap.
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Steam Oxidation  (Bluing)

Subjecting  the surface  of  a  ferrous  alloy  to  the action of steam
at a suitable temperature, thus  forming  a  thin  blue  film or oxide
and improving the  appearance  and resistance to  corrosion.   This
process is  often used for  iron and steel parts  pressed  from metal
powders.

Steel

An iron-base alloy,  containing manganese,  usually carbon,  and
often other alloying elements.

Strain Hardening

An increase in hardness and strength caused by  plastic  deforma-
tion at temperatures lower than  the  recrystallization tempera-
ture.

Strip

A sheet of  metal in which the length is  many  times the  breadth.

Subcategorization

The process of segmentation of an industry into groups  of  plants
for which uniform  effluent limitations can be established.

Surface Treatments

Operations  such as pickling,  etching, phosphating, and  chromating
which chemically alter  the metal surface.

Surface Water

Any visible stream or body of water,  natural  or man-made.   This
does not include bodies of water whose sole purpose  is  wastewater
retention or the removal of pollutants,  such  as holding ponds or
lagoons.

Surfactants

Surface active chemicals that tend to lower the surface tension
between liquids.

Swaging

A process in which a solid point is  formed at the  end of a  tube,
rod, or bar by the repeated blows of one or more pairs  of  oppos-
ing dies.   It is often  the initial step  in the  drawing  process.
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Swarf

Metallic particles and abrasive fragments removed by a cutting or
grinding tool.

Tensile Strength

The ratio of maximum load to original cross-sectional area.

Total Dissolved Solids (TDS)

Organic and inorganic molecules and ions that are in solution in
the water or wastewater.

Total Organic Carbon (TOG)

A measure of the organic contaminants in a wastewater.  The TOG
analysis does not measure as much of the organics as the COD or
BOD tests, but is much quicker than these tests.

Total Recycle

The complete reuse of a stream, with makeup water added for
evaporation losses.  There is no blowdown stream from a totally
recycled flow and the process water is not periodically or con-
tinuously discharged.

Total Suspended Solids (TSS)

Solids in suspension in water, wastewater, or treated effluent.
Also known as suspended solids.

Trepanning

A type of boring where an annular cut is made into a solid mate-
rial with the coincidental formation of a plug or solid cylinder.
Used to prepare billets for extrusion into tubing.

Tube Reducing

Reducing both the diameter and wall thickness of tubing with a
mandrel and a pair of rolls with tapered grooves.

Tubing Blank

A sample taken by passing one gallon of distilled water through a
composite sampling device before initiation of actual wastewater
samp ling.
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 Tumbling (Barrel Finishing)

 An operation in which castings,  forgings,  or parts pressed from
 metal powder are rotated in a barrel with  ceramic  or metal slugs
 or abrasives to remove scale, fins, or  burrs.   It  may be done dry
 or with an aqueous solution.

 Turning

 Removing stock from a rotating workpiece with a tool.

 Ultrasonic Cleaning

 Immersion cleaning aided by sound waves with frequency greater
 than 15 kHz that cause microagitation.

 Volatile Substances

 Materials that are readily vaporized at relatively low tempera-
 tures.

 Wet Scrubbers

 Air pollution control devices used to remove particulates  and
 fumes from air by entraining the pollutants  in a water spray.

 Wire

 A slender strand of metal with a diameter  less than 9.5 mm (3/8
 inches).

 Work-Hardening

 An increase in hardness and strength and a loss of ductility that
 occurs  in the workpiece as a result of  passing through cold form-
 ing or  cold working operations.  Also known  as strain-hardening.

 Zero Discharger

 Any industrial or municipal facility that  does not discharge
 wastewater.
•U.S. GOVERNMENT PRIMING OFFICE : 1984 0-421-545/3105      919

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