United States         Effluent Guidelines Division      EPA-440/1-84/019-b
       Environmental Protection      WH-552            July 1984
       Agency           Washington, D.C. 20460          S
       Water and Waste Management
                            EPA 440-1-84-001B1
EPA   Development          Proposed
       Document for
       Effluent Limitations
       Guidelines and
       Standards for the

       Nonferrous Metals

       Point Source Category
     .  Phase II
      Supplemental Development
      Document For:

      Bauxite Refining

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                  DEVELOPMENT DOCUMENT

                          for

    EFFLUENT  LIMITATIONS GUIDELINES AND  STANDARDS

                        for the

NONFERROUS METALS MANUFACTURING POINT SOURCE CATEGORY

                        PHASE II

              Bauxite  Refining Supplement
                     Jack E.  Ravan
          Assistant  Administrator for Water
                    Edwin L.  Johnson
                        Director
      Office of Water Regulations and Standards
                         V^D ST4t.f
                                   U.S Environmental Protection Agency
                              i     Priori V, Libiary
                                   231» South Dcai born Street
                                   Chicago, Illinois  60604
              Jeffery  D.  Denit,  Director
             Effluent  Guidelines Division
              Ernst  P.  Hall,  P.E., Chief
             Metals  and Machinery Branch
                James  R.  Berlow,  P.E.
              Technical  Project Officer
                       July 1984
         U.S. Environmental Protection Agency
                   Office  of Water
      Office of Water  Regulations and Standards
             Effluent  Guidelines Division
               Washington,  D.C.   20460

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U,S. Environmental Protsctton Agency

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                                I

                   BAUXITE REFINING SUJJCATEGORY

                        TABLE OF CONTENTS


Section                                                     Page

I         SUMMARY AND CONCLUSIONS	      1

II        RECOMMENDATIONS	      5

III       INDUSTRY PROFILE 	      7

          DESCRIPTION OF BAUXITE REFINING PROCESSES. ...      7
          RAW MATERIALS	      8
          BAUXITE GRINDING AND DIGESTION 	      8
          RED MUD REMOVAL AND LIQUOR PURIFICATION	      9
          PRECIPITATION AND CLASSIFICATION 	    10
          CALCINATION	    12
          PROCESS WASTEWATER SOURCES 	    12
          OTHER WASTEWATER SOURCES 	    12
          AGE, PRODUCTION,  AND PROCESS PROFILE 	    12

IV        SUBCATEGORIZATION	    21

          FACTORS CONSIDERED IN SUBCATEGORIZATION	    21
          FACTORS CONSIDERED IN SUBDIVIDING THE BAUXITE
          REFINING SUBCATEGORY 	    22
          OTHER FACTORS	    22
          TYPE OF PLANT	    22
          RAW MATERIALS	    22
          PLANT LOCATION	    23

V         WATER USE AND WASTEWATER CHARACTERISTICS ....    25

          WASTEWATER CHARACTERISTICS DATA	    26
          DATA COLLECTION PORTFOLIOS 	    26
          FIELD SAMPLING DATA	    26
          WASTEWATER CHARACTERISTICS AND FLOWS BY
          SUBDIVISION	    27
          DIGESTER CONDENSATE	    28
          BAROMETRIC CONDENSER EFFLUENT	    28
          CARBONATION PLANT EFFLUENT 	    28
          MUD IMPOUNDMENT EFFLUENT 	    29

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                   BAUXITE REFINING SUBCATEGORY

                  TABLE OF CONTENTS (Continued)
Section
VI
VII
VIII
IX

X
                                                  Page

SELECTION OF POLLUTANT PARAMETERS	    59

CONVENTIONAL AND NONCONVENTIONAL POLLUTANT
PARAMETERS	    59
CONVENTIONAL AND NONCONVENTIONAL POLLUTANT
PARAMETERS SELECTED	    59
TOXIC POLLUTANTS	    60
TOXIC POLLUTANTS NEVER DETECTED	    60
TOXIC POLLUTANTS NEVER FOUND ABOVE THEIR
ANALYTICAL QUANTIFICATION LEVEL	    62
TOXIC POLLUTANTS PRESENT BELOW CONCENTRATIONS
ACHIEVABLE BY TREATMENT	    63
TOXIC POLLUTANTS DETECTED IN A SMALL NUMBER
OF SOURCES	    63
TOXIC POLLUTANTS SELECTED FOR FURTHER
CONSIDERATION FOR LIMITATION 	    65

CONTROL AND TREATMENT TECHNOLOGIES 	    71

CURRENT CONTROL AND TREATMENT PRACTICES	    71
MUD IMPOUNDMENT EFFLUENT 	    71
CONTROL AND TREATMENT OPTIONS	    72
OPTION E	    72

COSTS OF WASTEWATER TREATMENT AND CONTROL. ...    73

TREATMENT OPTIONS COSTED FOR EXISTING SOURCES.  .    73
COST METHODOLOGY	    73
NONWATER QUALITY ASPECTS 	    74
ENERGY REQUIREMENTS	    74
SOLID WASTE	    74
AIR POLLUTION	    75

BEST PRACTICABLE TECHNOLOGY CURRENTLY AVAILABLE.    77

BEST AVAILABLE TECHNOLOGY ECONOMICALLY
ACHIEVABLE	    79

TECHNICAL APPROACH TO BAT	    79
OPTION E	    80
INDUSTRY COST AND POLLUTANT REMOVAL ESTIMATES.  .    80
POLLUTANT REMOVAL ESTIMATES	    80
COMPLIANCE COSTS	    80
                              ll

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                   BAUXITE REFINING SUBCATEGORY

                  TABLE OF CONTENTS (Continued)


Section                                                     Page

          BAT OPTION SELECTION 	    81
          REGULATED POLLUTANT PARAMETERS 	    81
          EFFLUENT LIMITATIONS 	    82
          BAT EFFLUENT LIMITATIONS UNDER CONSIDERATION
          FOR THE BAUXITE REFINING SUBCATEGORY 	    83

XI        NEW SOURCE PERFORMANCE STANDARDS 	    87

          TECHNICAL APPROACH TO NSPS	    87
          OPTION E	    87
          NSPS OPTION SELECTION	    88
          REGULATED POLLUTANT PARAMETERS 	    88
          NEW SOURCE PERFORMANCE STANDARDS 	    88
          NSPS UNDER CONSIDERATION FOR THE BAUXITE
          REFINING SUBCATEGORY 	    88

XII       PRETREATMENT STANDARDS 	    89

XIII      BEST CONVENTIONAL POLLUTANT CONTROL TECHNOLOGY .    91
                              111

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Number
                   BAUXITE REFINING  SUBCATEGORY

                          LIST  OF  TABLES
Page
III-1     INITIAL OPERATING YEAR  (RANGE) SUMMARY  OF
          PLANTS IN THE BAUXITE REFINING SUBCATEGORY
          BY DISCHARGE TYPE	     14

II1-2     PRODUCTION RANGES FOR THE BAUXITE REFINING
          SUBCATEGORY	     15

III-3     SUMMARY OF BAUXITE REFINING SUBCATEGORY
          PROCESSES AND ASSOCIATED WASTE STREAMS  	     16

V-1       WATER USE AND DISCHARGE RATES FOR MUD
          IMPOUNDMENT EFFLUENT  	     30

V-2       BAUXITE REFINING SUBCATEGORY DIGESTER
          CONDENSATE SAMPLING DATA	     31

V-3       BAUXITE REFINING SUBCATEGORY BAROMETRIC
          CONDENSER (HOT WELL) DISCHARGE RAW WASTEWATER
          SAMPLING DATA	     38

V-4       BAUXITE REFINING SUBCATEGORY CARBONATION
          PLANT EFFLUENT RAW WASTEWATER SAMPLING  DATA. .  .     45

V-5       BAUXITE REFINING SUBCATEGORY MUD LAKE DISCHARGE
          RAW WASTEWATER SAMPLING DATA	     50

VI-1      FREQUENCY OF OCCURRENCE OF TOXIC POLLUTANTS
          BAUXITE REFINING RAW WASTEWATER	     67

VIII-1    COST OF COMPLIANCE FOR THE BAUXITE REFINING
          SUBCATEGORY DIRECT DISCHARGERS 	     76

X-1       POLLUTANT REMOVAL ESTIMATES BAUXITE REFINING
          SUBCATEGORY	     84

X-2       COST OF COMPLIANCE FOR THE BAUXITE REFINING
          SUBCATEGORY	     85

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                   BAUXITE REFINING SUBCATEGORY

                         LIST OF FIGURES


Number                                                      Page

    1     BAUXITE REFINING PROCESS 	    17
III-2     GEOGRAPHIC LOCATIONS OF THE BAUXITE REFINING
          SUBCATEGORY PLANTS 	     19

V-1       SAMPLING SITES AT BAUXITE REFINING PLANT A ...     57

V-2       SAMPLING SITES AT BAUXITE REFINING PLANT B . .  .     58

X-1       OPTION E TREATMENT SCHEME FOR THE BAUXITE
          REFINING SUBCATEGORY 	     86
                              vii

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                  BAUXITE REFINING SUBCATEGORY

                            SECTION I

                     SUMMARY AND CONCLUSIONS


Pursuant to Sections 301, 304, 306, 307, and  501  of  the  Clean
Water  Act  and  the  provisions  of  the Settlement Agreement in
Natural Resources Defense Council v. Train, 8  ERC  2120  (D.D.C.
1976)  modified, 12 ERC 1833  (D.D.C. 1979), EPA has collected and
analyzed data for plants in the bauxite refining subcategory.  On
April 8, 1974, EPA promulgated effluent limitations based on best
practicable  technology  currently  available  (BPT)   and   best
available  technology economically achievable (BAT), standards of
performance for new sources (NSPS) and pretreatment standards for
new sources (PSNS).  See 39 FR 12822-12830, April 8, 1974 and  40
CFR  Part  421  Subpart  A.   In  each  case, the limitations and
standards required no discharge of process wastewater  pollutants
with  an  allowance  for  discharge  of monthly net precipitation
(i.e., the difference in water volume between  precipitation  and
evaporation  in  a  one  month  period)  that  accumulates in the
impoundments used by bauxite refineries to store  the  undigested
solids  produced  in the refining process.  This document and the
administrative record provide the technical basis for  review  of
the promulgated effluent limitations and standards.

The  bauxite  refining  subcategory comprises 8 plants.  Of the 8
plants, three discharge directly to rivers, lakes, or streams and
five achieve zero discharge of process wastewater.

EPA first studied the bauxite refining subcategory  to  determine
whether   differences   in   raw   materials,   final   products,
manufacturing processes, equipment, age and size  of  plants,  or
water  usage,  required  the  development  of  separate  effluent
limitations  and  standards  for  different   segments   of   the
subcategory.   This  involved  a  detailed analysis of wastewater
discharge and treated effluent characteristics, including (1) the
sources and volume of water used, the  processes  used,  and  the
sources  of  pollutants and wastewaters in the plant; and (2) the
constituents of wastewaters, including toxic  pollutants.   As  a
result,   four   subdivisions   have  been  identified  for  this
subcategory that warrant separate  effluent  limitations.   These
include:

     •    Digester Condensate
     •    Barometric Condenser Effluent
     •    Carbonation Plant Effluent
     •    Mud Impoundment Effluent

EPA  also  identified  several  distinct  control  and  treatment
technologies (both in-plant and end-of-pipe)  applicable  to  the
bauxite   refining   subcategory.    The   Agency  analyzed  both

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historical and newly generated data on the performance  of  these
technologies,  including  their  nonwater  quality  environmental
impacts and air  quality,  solid  waste  generation,  and  energy
requirements.   EPA  also  studied flow reduction reported in the
data collection portfolios (dcp) and plant visits.

Engineering costs were prepared for each discharging  plant   (and
one  zero  discharger)  for  the  control  and  treatment  option
considered for the subcategory.  These costs were  then  used  by
the  Agency  to estimate the impact of implementing the option in
the subcategory.  For this  control  and  treatment  option,  the
number  of  potential closures, number of employees affected, and
impact on price were estimated.  These results are reported in  a
separate  document  entitled  "The  Economic  Impact  Analysis of
Proposed Effluent Limitations Guidelines and  Standards  for  the
Nonferrous Smelting and Refining Industry."

After examining the various treatment technologies being operated
in   the  subcategory,  the  Agency  has  identified  BPT  to  be
equivalent to the existing promulgated BPT  effluent  limitations
published  on  April  8,  1974  (40 CFR Part 421 Subpart A).  This
requires  no  discharge  of  process  wastewater  pollutants   to
navigable   waters,   while   permitting  the  discharge  of  net
precipitation from red mud lake impoundments.   Minor  amendments
to   the  regulatory  language  are  being  proposed  to  clarify
references   to    fundamentally    different    factors    (PDF)
considerations   under   40   CFR  Part  125  and  references  to
pretreatment standards under 40 CFR Part 128.  As a  result,  the
bauxite  refining  subcategory  will  not  incur  any incremental
capital or annual costs to comply with the BPT limitations.

For BAT, the Agency is considering revising the  promulgated  BAT
to include treatment of mud impoundment effluent by pH adjustment
and activated carbon adsorption technology for removal of organic
pollutants.   This  potential  revision  is  based  on  new  data
collected by the Agency  since  the  previous  promulgation  that
indicated   the  presence  of  phenolic  compounds  at  treatable
concentrations in the mud impoundment effluent.

To meet the BAT effluent limitations based  on  this  technology,
the  bauxite refining subcategory is estimated to incur a capital
cost of $7.6 million and an annual cost of $2.98 million.

The technical  basis  of  NSPS  is  equivalent  to  the  existing
promulgated  BAT.   In  selecting  NSPS,  EPA recognizes that new
plants have the  opportunity  to  implement  the  best  and  most
efficient   manufacturing  processes  and  treatment  technology.
However,  no  such  processes   or   treatment   technology   were
considered  to meet the NSPS criteria.  Therefore, the technology
basis of  BAT  has  been  determined  as  the  best  demonstrated
technology, the technology basis of NSPS.  However, the Agency is
also  considering  the application of pH adjustment and activated

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carbon adsorption technology to the mud impoundment effluent  for
new sources.

The  limitations  and  standards for BPT, BAT, NSPS, and PSNS are
presented in Section II.

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                  BAUXITE REFINING SUBCATEGORY

                           SECTION II

                         RECOMMENDATIONS


1.    No change to the existing promulgated BPT  is  proposed  for
the  bauxite refining subcategory.  The regulation establishes no
discharge of process wastewater pollutants with an allowance  for
discharge  of  net  precipitation  from the mud impoundment.  The
technology basis for BPT  is  impoundment  and  recycle  for  all
process wastewater.

2.    EPA is not substantially modifying the existing  promulgated
BAT   limitations.    However,  the  Agency  is  considering  the
establishment of  limitations  providing  additional  control  of
toxic organic pollutants in net precipitation discharges from the
mud  impoundment  based  on  pH  adjustment  and activated carbon
adsorption.  The following BAT  effluent  limitations  are  being
considered:

Pollutant or                         Maximum for
Pollutant Property	Any One Day (mq/1 )

Phenol                                   0.010
2-chlorophenol                           0.010
Total phenols (4-AAP)                    0.010

3.    Similar to BAT,  EPA  is  not  substantially  modifying  the
existing  promulgated  NSPS, but is considering the establishment
of performance standards based on control of  organic  pollutants
in the discharges from the mud impoundment based on pH adjustment
and   activated   carbon   adsorption.    The   standards   under
consideration are:

Mud Impoundment Effluent

Pollutant or                          Maximum for
Pollutant Property	Any One Day (mq/1)

Phenol                                   0.010
2-chlorophenol                           0.030
Total Phenols (4-AAP)                    0.010

4.    EPA is  not  proposing  PSES  limitations  for  the  bauxite
refining  subcategory  because  there  are  no  existing indirect
dischargers.

5.    EPA is modifying the existing promulgated PSNS since  it  is
unlikely  that  any  new  bauxite sources could be constructed as
indirect dischargers.

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6.    EPA is not proposing  best  conventional  pollutant  control
technology (BCT) limitations at this time.

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                  BAUXITE REFINING SURCATEGORY

                           SECTION III

                        INDUSTRY PROFILE
This section of the bauxite refining supplement describes the raw
materials  and  processes  used  in  refining  bauxite to produce
alumina and presents a profile of the alumina  plants  identified
in  this  study.  For a discussion of the purpose, authority, and
methodology for this study and a general description of the  non-
ferrous  metals  manufacturing  category, refer to Section III of
the General Development Document.

EPA promulgated effluent limitations for BPT and BAT, new  source
performance standards, and pretreatment standards for new sources
for  the bauxite refining subcategory on April 8, 1974 as Subpart
A  of  40  CFR  Part  421.    The  pollutants  considered  in  the
development  of  those regulations included alkalinity, pH, total
dissolved solids, total suspended solids, and sulfate.

The Clean Water Act of 1977 mandates the achievement of  effluent
limitations   requiring   the   application   of  BAT  for  toxic
pollutants.  In keeping with this emphasis on  toxic  pollutants,
EPA  is  re-examining  the  discharge  of  toxic  pollutants from
process  wastewater  impoundments   in   the   bauxite   refining
subcategory.

Most  of  the alumina produced by bauxite refiners is sold to the
primary aluminum industry.   Aluminum metal  is  widely  used  for
building  and  construction  materials, transportation equipment,
and containers and packaging  products.   The  remainder  of  the
alumina   is   sold  to  the  chemical,  abrasive,  ceramic,  and
refractory industries for the manufacture  of  products  such  as
chemical   alums,   activated   alumina,   polishes,   electrical
insulators, and heat exchange media.

DESCRIPTION OF BAUXITE REFINING PROCESSES

Bauxite is the only ore of  aluminum  used  commercially  in  the
United   States.   Aluminum  production  is  unique  among  metal
manufacturing techniques  in  that  nearly  all  purification  is
accomplished  in  the  bauxite  refining process.  No significant
removal of impurities occurs during the subsequent  reduction  to
metal.

In the United States, bauxite is refined using the Bayer process.
The  classic Bayer process may be broadly divided into four major
operations:

     1.   Bauxite grinding and digestion,
     2.   Red mud removal and liquor purification,

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     3.    Precipitation and classification, and
     4.    Calcination.

A variation of the process, known  as  the  combination  process,
allows additional alumina recovery from solid residues when high-
silica bauxites are used as the raw material.

Bauxite  refining  is  characteristically conducted in very large
scale installations.  The process is conducted in an  essentially
closed circuit with extensive reuse and recycle of process water.
Economic  considerations  make  the  maximum recovery of heat and
reagents a  necessity.   Production  processes  for  the  bauxite
refining  subcategory are presented schematically in Figure III-l
and described in detail below.

RAW MATERIALS

Bauxite  consists  of  hydrated  aluminum   oxide   and   various
impurities,  including  iron  oxide,  titanium  dioxide,  silicon
dioxide, and compounds  of  phosphorus  and  vanadium.   A  basic
distinction  is  made between monohydrate bauxite, which contains
alumina in the form of boehmite or diaspore  (A1203) •  H20),  and
trihydrate  bauxite,  in  the  form  of  gibbsite  (A1203«3H20 or
Al(OH)j),  because they require  different  digestion  conditions.
Further  distinctions  of  ore  type  include  high or low silica
content, high or low iron content, and fast- or slow-settling red
mud after digestion.

BAUXITE GRINDING AND DIGESTION

Bauxite  ore  is  crushed  and  wet-ground  with  a  caustic-rich
solution  in  preparation for the digestion process.  The bauxite
must be ground finely enough to ensure  effective  digestion  but
not  so  finely that the red mud residue presents problems during
settling and filtration.  One plant reports the use of  scrubbers
for dust control in the bauxite handling operations.  Because the
water  from these scrubbers is returned to the process to recover
the bauxite value, it is considered to be a process stream rather
than a wastewater stream.

The ground bauxite slurry is fed to digesters where the  hydrated
alumina  in  the  bauxite  is converted to a soluble salt, sodium
aluminate.  The reaction  is  accomplished  using  either  sodium
hydroxide   or  a  combination  of  lime  and  sodium  carbonate.
Wastewater from wet air pollution control on lime  kilns  at  two
plants  is  sent to the digesters.  Because the scrubber effluent
is returned to the process and not discharged, it  is  considered
to be a process stream rather than a wastewater stream.

Digestion   conditions   (temperature,   pressure,   and  caustic
concentration)  depend  on  the  type   of   bauxite   processed.
Monohydrate  bauxites  require temperatures between 200 and 250°C
at up to 500 psi pressure.  Trihydrate bauxites can  be  digested
                                   8

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under  the  more moderate conditions of 120 to 170°C and 50 to 70
psi pressure.

The product of the  digestion  process  is  a  slurry  containing
sodium  aluminate  in  aqueous  solution  and undissolved solids.
This slurry enters a system of expansion vessels or "flash tanks"
for cooling, pressure reduction, and heat recovery.   The  stream
recovered from the expansion process is returned to the digesters
to  provide  some of the heat needed to maintain proper digestion
temperatures.  Condensate from the* vapor is frequently  used  for
boiler  water.   At  one  plant  condensate  is  used for hydrate
washing.  Excess condensate or condensate which is unsuitable for
use in boilers may be disposed of.

RED MUD REMOVAL AND LIQUOR PURIFICATION

The digested bauxite suspension contains solid, insoluble bauxite
particles of various sizes and compositions in a sodium aluminate
solution.  Particles above a certain size, e.g., TOO microns, are
called  "sand"  and  may  include  undigested   bauxite,   quartz
particules,  or  common  sand.   Sand is usually removed from the
suspension before red mud thickening.

The insoluble residue remaining in suspension after desanding  is
commonly  known  as  red  mud.   Red  mud  contains  iron oxides,
titanium  dioxide,  aluminum  present  with  silica,  and   other
secondary  impurities.   A  flocculating  agent  is  added to the
process suspension to  enhance  settling  of  the  fine  red  mud
particles.

The  overflow  from  the  mud  settling  and  thickening steps is
further clarified by  filtration.   This  step  removes  red  mud
particles from the supersaturated aluminate liquor.

The red mud settled from the process liquor is thickened, washed,
and  sometimes  filtered  to  recover caustic and alumina values.
The mud is then moved as a waterborne  slurry  to  a  waste  area
known as a red mud lake or impoundment for disposal.

When high-silica bauxites such as those from Arkansas are used as
the   raw  material  for  alumina  production,  the  "combination
process" can be applied to  recover  alumina  and  sodium  values
which  would  otherwise  be lost in the red mud.  As much as one-
third of the total  alumina  value  produced  by  a  plant  using
Arkansas   bauxite   may   be   trapped   in   insoluble   sodium
aluminosilicates which are removed from the process with the  red
mud.

In  the  combination  process,  the  red  mud is treated fir^t by
filtration to reduce the evaporative load and then  by  sintering
and  leaching  to  recover alumina.  After filtering and washing,
the .remaining solid residue or "brown mud" is sent to a mud  lake
for  disposal.  The very pure filtrate, known as white liquor, is

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either combined with  the  process  stream  or  precipitated  and
calcined separately to produce chemical-grade alumina.

Red  muds  from  various  bauxites have different characteristics
which produce differing disposal  considerations.   For  example,
the  yield  of  red  mud  residue  from  Surinam  bauxite  is low
(approximately 1/3 ton per ton of alumina product), and  the  mud
is  amenable  to  filtration  and  effective washing on a filter.
Thus, the final residue is relatively easy to handle and disposal
area requirements are moderate.  On the other hand, red muds from
Arkansas and Jamaican  bauxites  are  produced  in  much  greater
yield,  (approximately  2  tons  and  1  ton  per ton of alumina,
respectively), because of their larger content  of  contaminants.
The physical characteristics of Jamaican bauxite red mud are such
that  filtration  is difficult and countercurrent decantation may
be  required.   It  also  settles  poorly,  reaching   a   solids
concentration  of  only about 30 percent after normal settling as
compared to more than 50 percent solids for the muds  from  other
ores.  As a result, area requirements for these red mud lakes are
large.

One  company  which refines Jamaican bauxite has developed a sand
bed filtration technique.  In this technique, red mud  is  pumped
to  a  drying  bed  where  the solids concentration of the mud is
increased from 15 or 20 percent to more  than  50  percent.   The
surface  of  the  mud drying bed is kept dry by drawing water off
the top and, at one of the two plants using sand bed  filtration,
pumping it to a "clear lake." Underflow is also drawn out through
the  sandy  bottom  of the bed and sent to the clear lake.  Clear
lake water is then recycled to the  bauxite  refining  operations
for  use  as process water, forming a nearly-closed water system.
The second plant that practices sand bed filtration  of  red  mud
wastes  does  not  have a clear lake, practices no recycle of mud
lake water to the process, and  discharges  neutralized  effluent
directly to surface waters.

Of  the  alumina plants which do not practice sand bed filtration
of red mud, all report the use of red mud lakes.  In addition,   a
refinery  may  have  a  process  water lake for recycle of higher
quality water than is found in the mud lake  and  a  storm  water
lake  to collect large volumes of rainwater runoff from the plant
site.  Minor remaining storage  capacity  in  abandoned  red  mud
lakes  may  be utilized to dispose of small quantities of aqueous
wastes which are intolerable in the recycle circuit.  Examples of
such wastes are spent  acids  from  equipment  cleaning  and  the
effluent from salting-out evaporators.

PRECIPITATION AND CLASSIFICATION

The purified sodium aluminate solution obtained by removing solid
impurities   from   the   digested  liquor  passes  through  heat
exchangers and is  cooled  before  being  discharged  into  large
                                   10

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precipitation  vessels.  Vapor produced in the flash cooling area
is condensed and reused in other parts of the plant.

During precipitation,  aluminum hydroxide  crystallizes  from  the
super-saturated   sodium   aluminate  in  the  presence  of  seed
crystals.  The precipitation conditions are carefully  controlled
so that the solids formed will be amenable to easy separation and
washing.   The  precipitated  hydrate  crystals are classified by
size; small crystals are washed and fed  to  calcining  furnaces.
Aluminum   trihydrate  scale  can  also  be  recovered  from  the
precipitators and processed to  make  an  activated  alumina  by-
product.

The  spent  liquor  separated  from  the  hydrate crystals during
classification  is  returned  to  the  grinding   and   digestion
processes  to recover the caustic value of the stream.  The spent
caustic is first heated in heat exchangers by the steam recovered
from  the  flash   cooling   of   the   process   liquor   before
precipitation.   The liquor then passes through evaporators which
remove excess water.  The caustic is thus  reconcentrated  before
being mixed with the bauxite ore in the digesters.

The vapor generated in the spent caustic evaporators is condensed
in   barometric  condensers  using  once-through  cooling  water.
Although occasional upsets may cause entrainment of caustic,  the
barometric  condensate,  also  referred  to as hotwell discharge,
from properly operated evaporators is-generally  a  high  quality
water  which  is  either impounded with the red mud or discharged
directly to surface waters.

Some provision must be made to bleed off a part of  the  recycled
caustic  to  prevent  the  accumulation  of  soluble salts in the
system.  In some plants, one of the evaporators  is  a  "salting-
out"  evaporator  which  concentrates  a  portion of the recycled
caustic stream.  The concentrated stream is then disposed  of  in
an old mud lake or a landfull.

An alternate method of removing salts is to mix some of the spent
liquor   with   the  slurry  from  the  digesters.   The  soluble
contaminants are removed by the red mud which  is  then  filtered
out  and  discarded.   This  technique  of  salt removal has been
demonstrated in only one plant and may not be possible  with  red
mud from all bauxite ore types.

One plant removes soluble salts from the process by carbonating a
small  amount  of  pregnant liquor from the precipitation process
and some of the hydrate seed.  An alumina precipitate is  settled
from  the  carbonated mixture and calcined.  The recovered sodium
aluminale is then returned to  the  process  at  the  mixing  and
digestion  operation.    The  solution  from which the alumina was
precipitated  contains  neutralized  soluble  impurities  and  is
directly discharged without further treatment.
                                  11

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CALCINATION

The  moist  filter  cake of aluminum oxide from the precipitation
and classification operations is conveyed tcu.calciners  where  it
is  converted  to  anhydrous  alumina, the form most suitable for
later use in electrolytic  reduction  to  aluminum  metal.   Dust
control   for   the   calciners   is  provided  by  electrostatic
precipitators or baghouse filters.

One plant dries part of  the  hydrate  filter  cake  rather  than
exposing  it  to  the more severe conditions of calcination.  The
product of this operation is sold as a dried hydrate.  Condensate
from the dryers is collected  and  reused  in  the  precipitation
process.

PROCESS WASTEWATER SOURCES

A  variety  of  processes  are involved in bauxite refining.  The
significant wastewater sources  that  are  associated  with  this
subcategory can be subdivided as follows:

     1.   Digester condensate,
     2.   Barometric condenser effluent,
     3.   Carbonation plant effluent, and
     4.   Mud impoundment effluent.

OTHER WASTEWATER SOURCES

There  are  other  waste  streams  associated  with  the  bauxite
refining subcategory.  These waste streams include, but  are  not
limited to:

     1.   Stormwater other than that which falls within the
          process water impoundment area, and
     2.   Maintenance and cleanup water.

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

AGE. PRODUCTION, AND PROCESS PROFILE

Figure  III-2  shows  the  location  of  the eight alumina plants
operating in the United  States.   This  figure  shows  that  the
plants  are located  in the southern states and  in the U.S. Virgin
Islands.

Table III-l summarizes the relative age and discharge  status  of
the  eight alumina plants.  Most of the plants  are between 20 and
                                   12

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40 years old.  None of the alumina plants are more than 50  years
old.

Table  III-2  lists  the  1982^ production ranges for the alumina
plants.  Four of the eight  plants  produce  200,000  to  300,000
kkg/yr  as  aluminum  contained.   Two  plants  produce less than
200,000 kkg/yr, and the remaining two produce more  than  400,000
kkg/yr as aluminum contained.

Table  III-3 lists the major production processes associated with
the refining of bauxite.  Also shown  is  the  number  of  plants
generating wastewater from these processes.
                                   13

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                           Table III-2

      PRODUCTION RANGES FOR THE BAUXITE REFINING SUBCATEGORY


 Type of       Alumina Production Ranges for 1982         Total
  Plant      (Thousand kkg/yr as Aluminum Contained)      Number
Discharge    0-200200-300300-400400-600     of Plants

Direct         0300            3

Indirect       0000            0

Zero           2102            5_

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                  BAUXITE REFINING SUBCATEGORY

                           SECTION IV

                        SUBCATEGORIZATION


As  discussed  in Section IV of the General Development Document,
the   nonferrous   metals   manufacturing   category   has   been
subcategorized   to   take   into   account   pertinent  industry
characteristics, manufacturing process variations, and  a  number
of  other  factors  which affect the ability of the facilities to
achieve  effluent  limitations.   This  section  summarizes   the
factors considered during the designation of the bauxite refining
subcategory and its related subdivisions.

FACTORS CONSIDERED IN SUBCATEGORI2ATION

The  following  factors  were  evaluated  for  use  in  determing
appropriate subcategories for the nonferrous metals category:

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

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

In Section IV of the General Development Document, each of  these
factors  is  described,  and  the  rationale  for selecting metal
products,  manufacturing  processes  and  raw  materials  as  the
principal  factors  used  for subcategorization is discussed.  On
the basis of these factors, the nonferrous  metals  manufacturing
category  (phase II) was divided in 21 subcategories, one of them
being bauxite refining.

Bauxite refining was considered as a  single  subcategory  during
the previous (1974) rulemaking (40 CFR Part 421, Subpart A).  The
1974  rulemaking established BPT and BAT effluent limitations and
                                  21

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standards for new sources and sources discharging to  POTWs  for
the  bauxite  refining  subcategory.  The purpose of this present
rulemaking is to propose minor  technical  modifications  to  the
effluent   limitations  and  standards  and  solicit  comment  on
additional requirements  for  the  net  precipitation  discharges
allowed by the existing regulation.

FACTORS   CONSIDERED   IN   SUBDIVIDING   THE   BAUXITE  REFINING
SUBCATEGORY

The rationale for considering further subdivision of the  bauxite
refining subcategory is based primarily on the production process
used.   Within this subcategory, a number of different operations
are performed,  which  may  or  may  not  have  a  water  use  or
discharge,  and  which  may require the establishment of separate
effluent limitations and standards.  While  bauxite  refining  is
still   considered   a   single   subcategory,  a  more  thorough
examination of the production processes has illustrated the  need
for  limitations  and  standards based on a specific set of waste
streams.  Limitations and standards will  be  based  on  specific
flow allowances for the following subdivisions:

     1.   Digester condensate,
     2.   Barometric condenser effluent,
     3.   Carbonation plant effluent, and
     4.   Mud impoundment effluent.

OTHER FACTORS

Factors  other than manufacturing processes which were considered
in this evaluation either support the establishment of  the  four
subdivisions  or  were  determined  to be inappropriate bases for
subdivision.  Air pollution control methods, treatment costs, and
total  energy  requirements  are  functions   of   the   selected
subcategorization  factors,  namely metal product, raw materials,
and production processes.  For reasons discussed in Section IV of
the General Development Document,   factors  such  as  plant  age,
plant  size,  and  number  of  employees  were also evaluated and
determined to be inappropriate  bases  for  subdivision  of  this
nonferrous metals subcategory.

TYPE OF PLANT

There is fundamentally only one process for refining bauxite: the
Bayer process.  The combination process, a variation of the Bayer
process,  further treats the red mud waste from the Bayer process
to   recover  additional  aluminum   and   alkali   values.    The
differences in the manufacturing processes and wastes produced at
Bayer-process  plants  and  combination  process  plants  are not
significant enough to warrant further subdivision based on  plant
type.

RAW  MATERIALS
                                   22

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The  major  process waste associated with the refining of bauxite
is the  red  mud  residue.   While  the  monohydrate  content  of
different   ores   requires  different  digestion  conditions  at
different plants, the  quality  of  the  red  mud  waste  is  not
significantly  affected.   Similarly,  the differences in quality
between the red mud from the Bayer  process  and  the  brown  mud
waste  generated  when  residues  from  high-silica  bauxites are
treated  by  the  combination  process  do  not  warrant  further
subdivision.

There  are  differences in the amount of mud generated per ton of
alumina produced which depend on the source of the bauxite*.  Only
one-third ton of mud is produced per ton of alumina when  Surinam
bauxite  is  processed;  two or more tons of mud are produced per
ton of bauxite when Arkansas bauxite is  refined.   Nevertheless,
these differences affect the size, not the nature of the disposal
problem.   Therefore,  the  specific type of bauxite raw material
refined is not chosen as a basis for further subdivision.

PLANT LOCATION

The relationship between annual rainfall and  annual  evaporation
is  significant  at  bauxite  refining plants because the process
facilities and red mud lakes typically cover  large  land  areas.
In  regions  where  precipitation  exceeds evaporation, collected
rainfall runoff can accumulate  and  present  disposal  problems.
However,  if provisions are made to segregate process wastewaters
and runoff from plant sites, the runoff can be discharged to  its
normal  water  course.  By allowing the discharge of net rainfall
from the impoundment areas, accumulation of water and  disruption
of  the plant's water balance can be avoided.  Therefore, further
subdivision based on plant location is not necessary.
                                   23

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                  BAUXITE REFINING SUBCATEGORY

                            SECTION V

            WATER USE AND WASTEWATER CHARACTERISTICS


This  section  describes  the   characteristics   of   wastewater
associated  with  the bauxite refining subcategory.  Data used to
quantify  wastewater  flow  and  pollutant   concentrations   are
presented,   summarized,  and  discussed.   The  contribution  of
specific production processes to the overall wastewater discharge
from bauxite refining plants is identified whenever possible.

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

In  order  to  quantify  the  pollutant  discharge  from  bauxite
refining  plants,  a  field  sampling  program   was   conducted.
Wastewater  samples  were  analyzed  for  124  of  the  126 toxic
pollutants and other pollutants deemed appropriate.  (Because the
analytical standard for TCDD was judged to be too hazardous to be
made generally available, samples were never  analyzed  for  this
pollutant.   Also,  samples  were  never  analyzed  for asbestos.
There is no reason to expect  that  TCDD  or  asbestos  would  be
present   in  bauxite  refining  wastewater.)   Two  plants  were
selected for sampling in the  bauxite  refining  subcategory.   A
complete  list  of the pollutants considered and a summary of the
techniques used in sampling and laboratory analyses are  included
in  Section  V  of the General Development Document.  In general,
the samples were analyzed for three classes of  pollutant:  toxic
organic   pollutants,   toxic   metal  pollutants,  and  criteria
pollutants (which includes both conventional and  nonconventional
pollutants).

As  described  in  Section  IV  of  this  supplement, the bauxite
refining  subcategory  has  been  further   divided   into ,  four
subdivisions.    Differences   in   the  characteristics  of  the
wastewater streams corresponding to each subdivision  are  to  be
expected  and  are  addressed  separately in the discussions that
follow.  These wastewater sources are:

     1.   Digester condensate,
     2.   Barometric condenser effluent,
     3.   Carbonation plant effluent, and
     4.   Mud impoundment effluent.
                                   25

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WASTEWATER CHARACTERISTICS DATA

Data used to characterize the various wastewaters associated with
bauxite  refining  come  from  two  sources:    data   collection
portfolios (dcp) and analytical data from field sampling trips.

DATA COLLECTION PORTFOLIOS

In  the data collection portfolios, plants were asked to indicate
which of the toxic pollutants were known or were believed  to  be
present  in  their  effluent.   Two  plants  indicated that toxic
organics were known to be  present.   Three  plants  stated  that
toxic  metals  were  known  or  believed  to  be present in their
effluent.  The responses from the  three  plants  which  provided
information are summarized below.
         Pollutant
23.
44.
48.
65.
68.
70.
86.
114.
115.
117.
118.
119.
120.
121 .
122.
123.
124.
125.
126.
127.
128.
chloroform
methylene chloride
dichlorobromomethane
phenol
di-n-butyl phthalate
diethyl phthalate
toluene
antimony
arsenic
beryllium
cadmium
chromium (Total)
copper
cyanide (Total)
lead
mercury
nickel
selenium
silver
thallium
zinc
Known Present

      1
      1
      1
      2
      1
      1
      1
      2
      2
    .  1
      1
      2
      2
      1
      2
      2
      1
      2
      2
      1
      2
Believed Present

       0
       0
       0
       2
       0
       0
       0
       2
       3
       1
       2
       3
       3
       0
       3
       3
       2
       3
       3
       2
       3
FIELD SAMPLING DATA
 In  order to quantify the concentrations of pollutants present  in
 wastewater from bauxite refining plants, wastewater samples  were
 collected  at  two  of the eight plants.  Diagrams  indicating the
 sampling sites and contributing production processes  are  shown  in
 Figures V-l and V-2 at the end of this section.

 The sampling  data  for  the  bauxite  refining  subcategory  are
 presented in tables at the end of this section.  The  stream codes
 listed  may  be  used  to  identify  the  location  of each of the
 samples on the process flow diagrams   in  Figures   V-l  and  V-2.
                                   26

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Where  no  data  are  listed  for a specific day of sampling, the
wastewater samples for the stream were not collected.

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

Second, the detection limits shown on the data tables are not the
same  in  all  cases  as the published detection limits for these
pollutants by the same analytical methods.  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,   and   daily   operator-specific
factors.   These  factors  can  include day-to-day differences in
machine calibration, variation in stock solutions, and  variation
in operators.

Third,  the  statistical  analysis  of data includes some samples
measured at concentrations considered  not  quantifiable.   Toxic
organics  data reported as an asterisk or with a "less than" sign
are considered as detected but below quantifiable concentrations,
and a value of zero is used for averaging.  A value  of  zero  is
also  used  for  averaging  if  a  pollutant  is  reported as not
detected.  Finally, toxic metal values reported as  less  than  a
certain value were considered as below quantification and a value
of zero is used in the calculation of the average.

Finally,  appropriate  source  water concentrations are presented
with the sampling data.  The method  by  which  each  sample  was
collected is indicated by number as follows:

     1.   One-time grab
     2.   Manual composite during intermittent process operation
     3.   8-hour manual composite
     4.   8-hour automatic composite
     5.   24-hour manual composite
     6.   24-hour automatic composite

WASTEWATER CHARACTERISTICS AND FLOWS BY SUBDIVISION

Bauxite  refining  involves four principal sources of wastewater,
each of which has  potentially  different  characteristics.   The
                                   27

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wastewater characteristics corresponding to each subdivision will
be described separately in the discussions that follow.

EPA  promulgated limitations for the bauxite refining subcategory
on April  8,  1974  as  Subpart  A  of  40  CFR  Part  421.   The
established  limitations allow no discharge of process wastewater
pollutants to navigable waters.  A  discharge is allowed from the
overflow of a process wastewater impoundment in a volume equal to
the difference between the precipitation that  falls  within  the
impoundment  and  the  evaporation from that impoundment (this is
termed  net   precipitation).    EPA   is   not   proposing   any
modifications   to   the  no  discharge  limitation  for  process
wastewater pollutants.  For this reason, water use and  discharge
flow  will  be  addressed only with regard to the mud impoundment
effluent in the discussions that follow.

DIGESTER CONDENSATE

Bauxite ore is digested with  caustic  to  produce  a  slurry  of
sodium  aluminate  in  aqueous  solution with undissolved solids.
This slurry enters a system of expansion vessels or "flash tanks"
for  cooling,  pressure  reduction,  and  heat  recovery.   Vapor
released  in the flash tanks is condensed as a high quality water
suitable for reuse as boiler water or product  wash  water.   The
digester  condensate is characterized by treatable concentrations
of phenols, low concentrations of suspended solids, and high  pH.
Sampling  data for the digester condensate are presented in Table
V-2.

BAROMETRIC CONDENSER EFFLUENT

The spent liquor  separated  from  the  hydrate  crystals  during
classification   is   returned  to  the  grinding  and  digestion
processes to recover the caustic value of the stream.  The liquor
passes through evaporators which  remove  excess  water  and  re-
concentrate the caustic stream for reuse.

The vapor generated in the spent caustic evaporators is condensed
in  barometric  condensers.  Although occasional upsets may cause
entrainment of caustic,  the  condensate,  also  referred  to  as
hotwell  discharge,  is  a good quality, somewhat alkaline water.
This stream  is  characterized  by  treatable  concentrations  of
phenols  and  suspended  solids.   Sampling  data  for barometric
condenser effuent are presented in Table V-3.

CARBONATION PLANT EFFLUENT

Some provision must be made  to  remove  soluble  salts  from  the
recycled caustic to prevent  the accumulation of impurities in the
process.  One plant removes  and carbonates a small portion of the
process  liquor  and  the  hydrate  seed.   The resulting alumina
precipitate  is returned to the digesters.  The overflow from  the
carbonation   process   contains  the  soluble  impurities  in   a
                                   28

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neutralized  solution  which  is   characterized   by   treatable
concentrations  of  phenols  and suspended solids.  Sampling data
for carbonation plant effluent are presented in Table V-4.

MUD IMPOUNDMENT EFFLUENT

Red mud is the major waste stream from the bauxite refinery.   It
contains  all  of  the  impurities from the bauxite, such as iron
oxide, silicon dioxide, and titanium  dioxide,  as  well  as  by-
products  formed  during  the  process,  such  as sodium aluminum
silicates and calcium silicates.  Red mud is discharged to ponds,
along  with  other  process  streams,  where  insoluble   solids,
including   the  oxides  of  metallic  elements,  settle  out  of
suspension.  The clarified  liquid,  characterized  by  treatable
concentrations  of  phenols  and  high  pH,  can  be recycled and
discharged directly from the mud lake or  decanted  to  a  "clear
lake" before recycle or discharge.

The  water  use and discharge rates of this wastewater are listed
in Table V-l in liters per  year  of  mud  impoundment  effluent.
Sampling  data  for  the  effluent  from  mud impoundments at two
plants are presented in Table V-5.  At plant A,  the  impoundment
effluent is discharged directly from the mud lake without recycle
to  the process.  At plant B, overflow and underflow from the red
mud drying beds are sent to a clear  lake  from  which  water  is
recycled or discharged.
                                   29

-------
                            Table V-1

                WATER USE AND DISCHARGE  RATES  FOR
                     MUD IMPOUNDMENT  EFFLUENT
                           (liters/yr)
               Plant Code            Discharge  Flow

                  1171                  1 .45   x  109

                  1141                  5.95   x  109

                  1076                  2.983  x  1 08

                  1136                  0

                  1073                  0

                  1135                  0

                  1032                  0

                  1015                  0
NR = Present, but data not reported in dcp
                              30

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                  BAUXITE REFINING SUBCATEGORY

                           SECTION VI

                SELECTION OF POLLUTANT PARAMETERS


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

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

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

CONVENTIONAL AND NONCONVENTIONAL POLLUTANT PARAMETERS

This  study  considered  samples  from   the   bauxite   refining
subcategory  for three conventional pollutant parameters (oil and
grease, total suspended solids, and pH) and  two  nonconventional
pollutant   parameters   (chemical   oxygen   demand   and  total
phenolics).  Because existing BPT regulations (40 CFR  Part  421,
Subpart   A)   specify   zero  discharge  of  process  wastewater
pollutants, only sampling data  from  allowable  mud  impoundment
effluents  were  considered  in the selection of conventional and
nonconventional pollutant parameters for regulation.

CONVENTIONAL AND NONCONVENTIONAL POLLUTANT PARAMETERS SELECTED
                                   59

-------
The conventional  and  nonconventional  pollutants  or  pollutant
parameters  selected  for  consideration  for  limitation in this
subcategory are:

     PH
     phenolics

The pH values observed in five samples ranged from 11.5 to 11.76.
Effective and consistent removal of toxic organics  by  activated
carbon  or  chemical  oxidation  requires  careful control of pH.
Therefore, pH is selected for  consideration  for  limitation   in
this subcategory.

Phenolics concentrations in six samples ranged from 0.116 to 1.23
mg/1.    The  observed  concentrations  are above those considered
treatable by identified treatment technology.  Sampling data from
process wastewater streams, presented in Section V, indicate  the
presence  of  phenolic  compounds throughout the bauxite refining
process.  Therefore, phenolics are considered for  limitation   in
this subcategory.

The  major  source  of  oil  and  grease  in the bauxite refining
subcategory  is  from  the  lubrication  of  process   machinery.
Because  oil  and  grease in process wastewater is not present  in
significant concentrations, oil and grease is  not  selected  for
limitation.

Total  suspended solids (TSS) concentrations in six samples range
from 2 to 18 mg/1.  Although treatable, these concentrations  are
not  considered  to  be  significant  and  are  not  expected   to
interfere  with  end-of-pipe  treatment  technologies   such    as
activated  carbon  adsorption  or chemical oxidation.  Therefore,
total suspended solids are not selected  for  limitation  in  the
bauxite refining subcategory.

TOXIC POLLUTANTS

The  frequency  of  occurrence  of  the  toxic  pollutants in the
wastewater samples taken is presented in Table VI-1.  These  data
provide  the basis for the categorization of specific pollutants,
as discussed below.  Table VI-1 is based on  the   raw  wastewater
data  from  mud  impoundment effluents at plant A and plant B (see
Section V).  All other wastewaters have existing   zero  discharge
regulations  and  were  therefore not considered here.  Treatment
plant and source  water  samples  were  not  considered  in  this
frequency count.

TOXIC POLLUTANTS NEVER DETECTED

The toxic pollutants listed below were either not  analyzed or not
detected   in   any  wastewater  samples  from  this  subcategory;
therefore,  they  are   not   selected   for   consideration    in
establishing regulations:
                                  60

-------
 2.    acrolein*
 3.    acrylonitrile*
 4.    benzene*
 5.    benzidene*
 7.    chlorobenzene*
 8.    1,2,4-trichlorobenzene*
 9.    hexachlorobenzene*
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*
17.    bis  (chloromethyl) ether (deleted)*
18.    bis  (2-chloroethyl) ether*
19.    2-chloroethyl vinyl ether (mixed)*
20.    2-chloronaphthalene*
22.    parachlorometa cresol
25.    1,2-dichlorobenzene*
26.    1,3-dichlorobenzene*
27.    1,4-dichlorobenzene*
28.    3,3'-dichlorobenzidine*
29.    1,1-dichloroethylene*
30.    1,2-trans-dichloroethylene*
32.    1,2-dichloropropane*
33.    1,2-dichloropropylene (1,3-dichloropfopene)*
35.    2,4-dinitrotoluene*
36.    2,6-dinitrotoluene*
37.    1,2-diphenylhydrazine*
38.    ethylbenzene*
40.    4-chlorophenyl phenyl ether*
41.    4-bromophenyl phenyl ether*
42.    bis(2-chloroisopropyl) ether*
43.    bis(2-choroethoxy) methane*
45.    methyl  chloride (chlorotnethane) *
46.    methyl  bromide (bromomethane)*
47.    bromoform (tribromomethane)*
49.    trichlorofluoromethane (deleted)*
50.    dichlorodifluoromethane (deleted)*
51.    chlorodibromomethane*
52.    hexachlorobutadiene*
53.    hexachlorocyclopentadiene*
54.    isophorone*
56.    nitrobenzene*
59.    2,4-dinitrophenol
61.    N-nitrosodimethylamine*
62.    N-nitrosodiphenylamine*
63.    N-nitrosodi-n-propylamine*
69.    di-n-octyl phthalate*
72.    benzo (a)anthracene (1,2-benzanthracene)*
73.    benzo (a)pyrene (3,4-benzopyrene)*
74.    3,4-benzofluoranthene*
                              61

-------
    75.    benzo(k)fluoranthane (11,12-benzofluoranthene)*
    76.    chrysene*
    78.    anthracene*
    79.    benzo(ghi)perylene (1,11-benzoperylene)*
    81.    phenanthrene*
    82.    dibenzo (a,h)anthracene (1,2,5,6-dibenzanthracene)*
    83.    indeno (1,2,3-cd)pyrene (w,e,-o-phenylenepyrene)*
    87.    trichloroethylene*
    88.    vinyl chloride (chloroethylene)*
    89.    aldrin*
    90.    dieldrin*
    94.    4,4'-DDD(p,p'TDE)*
   105.    g-BHC-Delta*
   113.    toxaphene*
   116.    asbestos
   117.    beryllium*
   118.    cadmium*
   119.    chromium (Total)*
   120.    copper*
   122.    lead*
   123.    mercury*
   124.    nickel*
   128.    zinc*

   129.    2,3,7,8-tetrachlorodibenzo-p-dioxin (TCDD)


*We  did  not  analyze  for  these  pollutants  in samples of raw
wastewater from  this  subcategory.    These  pollutants  are  not
believed  to  be  present  based on the Agency's best engineering
judgement which  includes  consideration  of  raw  materials  and
process operations.


TOXIC    POLLUTANTS    NEVER   FOUND   ABOVE   THEIR   ANALYTICAL
QUANTIFICATION LEVEL

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
consideration in establishing regulations.

     1.    acenaphthene
     6.    carbon tetrachloride (tetrachloromethane)
    34.   - 2,4-dimethylphenol
    39.    fluoranthene
    48.    dichlorobromomethane
    64.    pentachlorophenol
    67.    butyl benzyl phthalate
    80.    fluorene
    84.    pyrene
    86.   toluene
    91.    chlordane  (technical mixture and metabolites)
                                   62

-------
    92.    4,4'-DDT
    93.    4/4'-DDE(p,p'DDX)
    95.    a-endosulfan-Alpha
    96.    b-endosulfan-Beta
    97.    endosulfan sulfate
    98.    endrin
    99.    endrin aldehyde
   100.    heptachlor
   101.    heptachlor epoxide
   102.    alpha-BHC
   103.    beta-BHC
   104.    r-BHC (lindane)-Gamma
   106.    PCB-1242 (Arochlor 1242)
   107.    PCB-1254 (Arochlor 1254)
   108.    PCB-1221 (Arochlor 1221)
   109.    PCB-1232 (Arochlor 1232)
   110.    PCB-1248 (Arochlor 1248)
   111.    PCB-1260 (Arochlor 1260)
   112.    PCB-1016 (Arochlor 1016)
   114.    antimony
   121.    cyanide (Total)
   125.    selenium
   126.    silver

TOXIC  POLLUTANTS  PRESENT  BELOW  CONCENTRATIONS  ACHIEVABLE  BY
TREATMENT

The pollutants listed below are not selected for consideration in
establishing  limitations  because  they  were  not  found in any
wastewater samples from  this  subcategory  above  concentrations
considered   achievable   by   existing  or  available  treatment
technologies.

     115. arsenic
     127. thallium

Arsenic was detected above its analytical quantification limit in
five of five samples from two plants.  These samples  were  below
the  0.34  mg/1 concentration considered achievable by treatment.
Therefore, arsenic is not selected for limitation.

Thallium was detected above its analytical  quantification  limit
in  one  of  five samples from two plants.  This sample was below
the 0.34 mg/1 concentration considered achievable  by  identified
treatment  technology.   Therefore,  thallium is not selected for
limitation.

TOXIC POLLUTANTS DETECTED IN A SMALL NUMBER OF SOURCES

The following pollutants were not selected for limitation because
they were detected in only a small number of sources:

     23.  chloroform
                                  63

-------
     44.  methylene chloride
     55.  naphthalene
     60.  4,6-dinitro-o-cresol
     66.  bis(2-ethylhexyl) phthalate
     68.  di-n-butyl phthalate
     70.  diethyl phthalate
     71.  dimethyl phthalate
     77.  acenaphthylene
     85.  tetrachloroethylene

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

Chloroform was detected above its treatable limit  in  three of  six
samples  from  two  plants at concentrations of 0.015, 0.026,  and
0.063 mg/1.  This pollutant is not  attributable   to  any source
within  the refinery.  It also appears  in the source  water and it
is commonly used in the analytical  laboratories   as  a   solvent.
For these reasons chloroform is not considered for limitation.

Methylene chloride was found above its  treatable concentration in
three of four samples from two plants  at concentrations  of 0.020,
0.051,  and  0.170  mg/1.   This pollutant is not  attributable to
specific materials or processes associated with bauxite  refining.
It is, however, a common solvent used  in analytical laboratories.
Since  the  possibility  of  sample  contamination   is    likely,
methylene chloride is not selected for  limitation.

Naphthalene was detected above its treatable concentration in  one
of  two  samples from one plant, at a  concentration of 0.02 mg/1.
This pollutant is not attributable to  bauxite refining operations
or raw materials; it is also  present   only  slightly above   the
treatability  concentration.   For  these reasons,  naphthalene is
not considered for limitation.

4,6-Dinitro-o-cresol   was   found   above    its     treatability
concentration in one sample from one plant, at a concentration of
0.011  mg/1.   Because  this pollutant  is not attributable to  any
specific  materials  or  processes  in   the   bauxite    refining
operation, and it is present only slightly above the  treatability
concentration  of  0.01  mg/1, this pollutant is not  selected  for
limitation.

Bis(2-ethylhexyl)  phthalate  was  found  above    its   treatable
concentration  of  0.01  mg/1  in  five of  six samples from  two
plants.   This   compound   is  a  plasticizer  commonly   used    in
laboratory  and  field sampling equipment and is not used as a  raw
material  or  formed  as   a  by-product in   this   subcategory.
Therefore,   bis(2-ethylhexyl)  phthalate  is  not selected   for
limitation.
                                   64

-------
Di-n-butyl phthalate was found above its treatable  concentration
of  0.01   mg/1  in  one  of  six  samples  from two plants.  This
compound is a plasticizer commonly used in laboratory  and  field
sampling equipment and is not used as a raw material or formed as
a   by-product   in   this  subcategory.   Therefore,  di-n-butyl
phthalate is not selected for limitation.

Diethyl phthalate was found above its treatable concentration  of
0.01 mg/1 in one of two samples from one plant.  This compound is
a  plasticizer  commonly  used  in  laboratory and field sampling
equipment and is not used as a raw material or formed  as  a  by-
product in this subcategory.  Therefore, diethyl phthalate is not
selected for limitation.

Dimethyl phthalate was found above its treatable concentration in
one  of  two  samples  from  two plants at a concentration of 1.5
mg/1.  This pollutant is not attributable to  specific  materials
or   processes   associated  with  bauxite  refining.   The  high
concentration is probably due to  contamination  from  laboratory
equipment.   Therefore,  dimethyl  phthalate  is not selected for
limitation.

Acenaphthylene was  found  above  its  analytical  quantification
limit  in  two of three samples from two plants at concentrations
of 0.018 and 0.086 mg/1.  This pollutant has  been  shown  to  be
present  in the wastewater from briquette quenching operations in
the primary aluminum subcategory.  The  two  sampled  plants  are
integrated  facilities  which  manufacture  a number of aluminum-
based products.  Therefore, because it is likely to be  generated
by processes outside the bauxite refining subcategory and because
it  is  not  specifically  attributable  to  the bauxite refining
process,  acenaphthylene is not selected for limitation.

Tetrachloroethylene was found above its treatability limit in one
sample from one plant, at a concentration of  0.012  mg/1.   This
pollutant  is  not attributable to any process or material in the
refining  process;  it  is  present  only  slightly   above   its
treatability concentration of 0.01 mg/1 and it is frequently used
in  the  laboratory,  where contamination could occur.  For these
reasons,  tetrachloroethylene is not selected for limitation.

TOXIC  POLLUTANTS  SELECTED   FOR   FURTHER   CONSIDERATION   FOR
LIMITATION

The  toxic  pollutants  listed  below  are  selected  for further
consideration in establishing limitations for  this  subcategory.
The  selected pollutants are discussed individually following the
list.

     21.   2, 4,6-trichlorophenol
     24.   2-chlorophenol
     31.   2,4-dichlorophenol
     57.   2-nitrophenol
                                   65

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     58.  4-nitrophenol
     65.  phenol

2,4,6-Trichlorophenol   was   found    above    its    analytical
quantification  limit  in  three  of four samples from two plants
with concentrations ranging from 0.048 to 0.072 mg/1.  All  three
of   those   samples  were  above  the  0.01  mg/1   concentration
considered  achievable  by   identified   treatment   technology.
Therefore,   2,4,6-trichlorophenol   is   selected   for  further
consideration for limitation.

2-Chlorophenol was  found  above  its  analytical  quantification
limit in two of two samples from one plant with concentrations of
0.065  and 0.720 mg/1.  Both of those samples were above the 0.01
mg/1 treatability  concentration.   Threfore,  2-chlorophenol  is
selected for further consideration for limitation.

2,4-Dichlorophenol  was found above its analytical quantification
limit in four of five samples from two plants with concentrations
ranging from 0.047 to 0.060 mg/1.  All four of those samples were
above the 0.01 mg/1 treatability concentration.  Therefore,  2,4-
dichlorophenol   is   selected   for  further  consideration  for
limitation.

2-Nitrophenol was found above its analytical quantification limit
in one of three samples from two plants  at  a  concentration  of
0.067  mg/1.   That  sample  was above the 0.01 mg/1 treatability
concentration.  Therefore, 2-nitrophenol is selected for  further
consideration for limitation.

4-Nitrophenol was found above its analytical quantification limit
in  three  of  four  samples  from two plants with concentrations
ranging from 0.017 to 0.310 mg/1.  Those three samples were above
the  0.01  mg/1  treatability   concentration.    Therefore,   4-
nitrophenol is selected for further consideration for limitation.

Phenol was found above its analytical quantification limit  in six
of  six  samples from two plants with concentrations ranging from
0.034 to 0.750 mg/1.  All six of those  samples  were  above  the
0.01  mg/1 treatability concentration.  Also, phenolics have been
identified as constituents of bauxite ore.  Therefore, phenol  is
selected for further consideration for limitation.
                                   66

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                  BAUXITE REFINING SUBCATEGORY

                           SECTION VII

               CONTROL AND TREATMENT TECHNOLOGIES


The  preceding sections of this supplement discussed the sources,
flows, and characteristics of the wastewaters  generated  in  the
bauxite   refining  subcategory.   This  section  summarizes  the
description of these  wastewaters  and  indicates  the  level  of
treatment which is currently practiced for each waste stream.

CURRENT CONTROL AND TREATMENT PRACTICES

Control  and  treatment  technologies are discussed in general in
Section VII of  the  General  Development  Document.   The  basic
principles   of  these  technologies  and  the  applicability  to
wastewater  similar  to  that  found  in  this  subcategory   are
presented  there.   This section presents a summary of the control
and treatment technologies that are currently applied to each  of
the  sources  generating  wastewater  in  this  subcategory.   As
discussed in Section V, wastewater associated  with  the  bauxite
refining   subcategory   is  characterized  by  the  presence  of
treatable concentrations of phenolic compounds and high pH.  This
analysis is supported by  the  raw  (untreated)  wastewater  data
presented  for  specific  sources  in  Section  V.   According to
promulgated BPT limitations (40 CFR Part  421,  Subpart  A),  the
only allowable discharge of wastewater pollutants for the bauxite
refining  subcategory  is  from  the  mud impoundment.  The other
three subdivisions  (digester  condensate,  barometric  condenser
effluent,  and  carbonation plant effluent) are all restricted to
zero discharge of wastewater pollutants under the promulgated BPT
regulation.  Three plants in this subcategory currently discharge
treated water from the mud impoundment area.  One option has been
selected for consideration for BPT, BAT, NSPS,  and  pretreatment
based on this waste stream.

MUD IMPOUNDMENT EFFLUENT

Red   mud  is  the  major  waste  stream  from  bauxite  refining
operations.  It contains the impurities from the bauxite  ore  as
well  as by-products formed during the refining process.  Red mud
is deposited in large ponds where insoluble solids, including the
oxides of metallic elements, settle out of suspension.   Rainfall
from  the  plant  site  is  often  routed to the mud impoundment.
Water from the impoundment can be recycled to the plant  directly
from  the mud lake or it can be decanted to a separate clear lake
before recycle.

Three plants currently discharge water from the mud  impoundment.
At  one  plant,  water  is discharged after pH adjustment without
recycle to the process.  At another plant, a portion of the water
                                   7i

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which is recycled to the plant from a clear  lake  is  discharged
without  treatment.  The third plant discharges excess stormwater
from closed mud lakes after pH adjustment.   The  remaining  five
plants  in  this  subcategory currently achieve zero discharge by
permanent lagoon impoundment and partial recycle.   However,  one
of  these plants is considering a process technology change which
would result in a mud impoundment discharge.

CONTROL AND TREATMENT OPTIONS

The Agency examined one control and treatment alternative that is
applicable to  the  bauxite  refining  subcategory.   The  option
selected  for  evaluation  represents  an  end-of-pipe  treatment
technology.

OPTION E

Option E for the bauxite refining  subcategory  consists  of  all
control requirements of the existing BPT  (no discharge of process
wastewater  pollutants,  and  discharge of net precipitation from
process wastewater impoundments) plus pH adjustment and activated
carbon adsorption treatment  of  the  mud  impoundment  effluent.
Activated  carbon adsorption is used to remove organic compounds,
including phenolics, from the effluent wastewater.  Adjustment of
pH is  required  to  ensure  consistent  removal  performance  by
adsorption and to meet discharge quality standards.
   »
The  Agency also considered the use of pH adjustment and chemical
oxidation  to  remove  phenolic  compounds  from   the   effluent
wastewater.   Adjustment  of  pH is required to ensure consistent
removal performance by chemical oxidation and to  meet  discharge
quality  standards.   Hydrogen  peroxide  is  suggested  for  the
oxidation of phenols,  but  other  chemicals,  such  as  chlorine
dioxide and ozone, may perform satisfactorily.
                                   72

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                  BAUXITE REFINING SUBCATEGORY

                          SECTION VIII

            COSTS OF WASTEWATER TREATMENT AND CONTROL


This  section  describes  the  method  used  to develop the costs
associated with the control and treatment technologies of  Option
E  discussed in Section VII for wastewaters from bauxite refining
plants.  Plant-by-plant compliance costs  for  this  option  were
developed.   Compliance  costs  for  chemical oxidation were also
estimated.  The energy requirements of the considered  option  as
well as solid waste and air pollution aspects are also discussed.
Section   VIII  of  the  General  Development  Document  provides
background on the capital and annual  costs  for  the  technology
discussed herein.

TREATMENT OPTIONS COSTED FOR EXISTING SOURCES

As  discussed  in  Section  VII,  one  treatment  option has been
considered for existing bauxite refining plants.  This option  is
summarized below and is schematically presented in Figure X-l.

OPTION E

Option E consists of the BPT requirements with additional control
of  the mud impoundment discharges by pH adjustment and activated
carbon adsorption.  The Agency also prepared capital  and  annual
costs  for  pH  adjustment  and  chemical  oxidation  of  the mud
impoundment effluent at one median plant.  The  calculated  costs
were much higher in relation to the costs for activated carbon at
the  same plant, therefore, no further consideration was given to
this technology.

COST METHODOLOGY
                                         t
A detailed discussion of the  methodology  used  to  develop  the
compliance  costs  is  presented  in  Section VIII of the General
Development Document.  Plant-by-plant compliance costs have  been
estimated  for  the  nonferrous metals manufacturing category and
are documented in detail in the administrative record  supporting
this  regulation.   The  costs for the option in this subcategory
are presented in Table VII1-1.

Each of the general assumptions used to develop compliance  costs
is presented in Section VIII of the General Development Document.
Each  subcategory  also  contains  a  unique set of waste streams
requiring certain  subcategory-specific  assumptions  to  develop
compliance  costs.  The major assumptions specific to the bauxite
refining subcategory are discussed briefly below.
                                   73

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     (1)   The Option E treatment system consists of pH adjustment
          followed by carbon adsorption.
     The flows were determined from information provided  in  the
     dcp  for  red  mud  impoundment  discharge  flow  only.  The
     influent concentrations for phenol and  2-chlorophenol  were
     determined  from  averages  of  field sampling data from two
     plants.   These data are found in Table V-5.

     (2)   Costs for pH adjustment were based on reduction  of  pH
          from 11.5 to 9 using sulfuric acid.

     (3)   The  carbon  exhaustion  rate   was   determined   from
          adsorption  isotherms  for  phenol  and 2-chlorophenol,
          influent concentrations from the sampling data, and  an
          effluent  concentration  in  both  cases of 0.010 mg/1.
          Using this procedure and an excess of  50%  to  account
          for other adsorbable organics,  a carbon exhaustion rate
          of 2.321 lbs/1000 gallons was determined.

     (4)   Plants 1076 and 1141 have pH  adjustment  equipment  in
          place;  capital  cost  estimates  are  included for all
          other equipment at the three discharging plants and the
          one existing  zero  discharger  who  is  considering   a
          discharge.

NONWATER QUALITY ASPECTS

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

ENERGY REQUIREMENTS

The methodology used for determining the energy requirements  for
the  various  options is discussed in Section VIII of the General
Development Document.   Energy  requirements  for  Option  E  are
estimated  at  11,500,000  kWh/yr.   This  represents less than  3
percent of the total energy usage of  the  four  plants.   It  is
therefore concluded that the energy requirements of the treatment
option  considered  will  not  have a significant impact on total
plant energy consumption.

SOLID WASTE

No significant amounts of  solid  wastes  are  generated  by  the
technologies  considered  for  this  regulation  in  the  bauxite
refining subcategory.  Activated carbon is thermally  regenerated
either  on-site  or off-site, and in neither case are appreciable
quantities of solid waste generated.
                                   74

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AIR POLLUTION

There is no reason to believe that any substantial air  pollution
problems  will  result  from  implementation  of activated carbon
treatment and  pH  adjustment.   Thermal  regeneration  of  spent
carbon  may  release  trace  quantities  of pollutants, but these
should be readily oxidized at the temperatures  under  which  the
carbon is regenerated.
                                  75

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                           Table VIII-1

     COST OF COMPLIANCE FOR THE BAUXITE  REFINING SUBCATEGORY
                       DIRECT DISCHARGERS*

                      (March,  1982  Dollars)
                       Total Required              Total
      Option            Capital Cost            Annual  Cost

        E                7,600,000                2,980,000
*Includes one plant currently practicing zero discharge of
 process wastewater.
                              76

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                  BAUXITE REFINING SUBCATEGORY

                           SECTION IX

         BEST PRACTICABLE TECHNOLOGY CURRENTLY AVAILABLE


EPA   promulgated   BPT  limitations  for  the  bauxite  refining
subcategory on April 8, 1974 as Subpart A of  40  CFR  Part  421.
EPA  is  proposing  only  minor  technical modifications to these
limitations.

The following limitations establish the quantity  or  quality  of
pollutants  or  pollutant properties which may be discharged by a
point source after application of the  best  practicable  control
technology  currently  available:   There shall be no dischage of
process wastewater pollutants to navigable waters.

During any calendar month,  there  may  be  discharged  from  the
overflow  of  a process wastewater impoundment either a volume of
wastewater equal to the difference between the precipitation  for
that  month that falls within the impoundment and the evaporation
within the impoundment for that month, or, if greater,  a  volume
of  process  wastewater  equal to the difference between the mean
precipitation for that month that falls  within  the  impoundment
and  the  mean  evaporation  for that month as established by the
National  Climatic  Center,  National  Oceanic  and   Atmospheric
Administration, for the area in which such impoundment is located
(or  as  otherwise  determined  if  no  monthly  data  have  been
established by the National Climatic Center).

EPA does not believe that the data gathered  since  the  original
promulgation  warrant  any  adjustment  in  the BPT requirements.
Minor amendments to the regulatory language are being proposed to
clarify  references  to  fundamentally  different  factors  (PDF)
considerations   under   40   CFR  Part  125  and  references  to
pretreatment standards under 40 CFR Part 128.  As a  result,  the
bauxite  refining  subcategory  will  not  incur  any incremental
capital or annual costs to comply with the BPT limitations.
                                   77

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                  BAUXITE REFINING SUBCATEGORY

                            SECTION X

        BEST AVAILABLE TECHNOLOGY ECONOMICALLY ACHIEVABLE


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

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

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

TECHNICAL APPROACH TO BAT

In pursuing this second round of effluent limitations, the Agency
reviewed  a  wide  range  of technology options and evaluated the
available possibilities to ensure that  the  most  effective  and
beneficial  technologies  were  used  as  the  basis  of BAT.  To
accomplish this, the Agency elected  to  examine  one  technology
option which could be applied to the bauxite refining subcategory
as an alternative for the basis of BAT effluent limitations.  The
treatment technologies considered for BAT are summarized below:

Option E (Figure X-l):

     •    Zero discharge of process wastewater pollutants
     •    Discharge of net precipitation from process wastewater
                                   79

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          impoundments
          pH adjustment
          Activated carbon adsorption
OPTION E
Option  E consists of the existing BPT requirements  (no discharge
of process wastewater pollutants, discharge of net  precipitation
from  a  process  wastewater impoundment), with pH adjustment and
activated carbon adsorption treatment of  the  net  precipitation
discharge.   Activated  carbon technology is used to remove toxic
organic  compounds,  including  phenolics,  from   the   effluent
wastewater.   Adjustment  of  pH is required to ensure consistent
removal performance by adsorption and to meet  discharge  quality
standards.

INDUSTRY COST AND POLLUTANT REMOVAL ESTIMATES

As  one  means of evaluating the technology option, EPA developed
estimates of the pollutant removal estimates and  the  associated
compliance costs.  The methodologies are described below.

POLLUTANT REMOVAL ESTIMATES

A  complete  description of the methodology used to  calculate the
estimated  pollutant  removal,  or  benefit,  achieved   by   the
application  of the treatment option is presented in Section X of
the  General  Development  Document.   In  short,  sampling  data
collected   during  the  field  sampling  program  were  used  to
characterize the pollutant concentrations  in  the   waste  stream
considered  for  regulation.   This information was  used with the
wastewater discharge rates measured during  sampling  or  derived
from  each dcp to estimate the mass of toxic pollutants generated
by each plant in the bauxite refining subcategory.

The mass of pollutant discharged was estimated by multiplying the
achievable concentration values attainable by the  option  (mg/1)
by the estimated volume of wastewater discharged by  each plant in
the  subcategory.   The mass of pollutant removed, referred to as
the benefit, is simply the difference between the estimated  mass
of  pollutant  generated  by each plant and the mass of pollutant
discharged after application of the treatment option.  The  total
subcategory  removal was. then estimated by summing the individual
plant  removal  estimates  for  each  pollutant.   The  pollutant
removal  estimates  for  the  bauxite  refining  subcategory  are
presented  in Table X-1.

COMPLIANCE COSTS

EPA  calculated  compliance  costs  for   the   bauxite   refining
subcategory  by  developing  a wastewater treatment  system design
and cost estimation model that estimates  capital and annual costs
for the  treatment  option  being  considered.   This  model  was
                                   80

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applied  to  each plant's flow and pollutant characteristics, and
the calculated capital and annual costs were summed to arrive  at
total  subcategory  costs.   These  costs, which are presented in
Table X-2, were used in EPA's economic impact analysis.

BAT OPTION SELECTION

EPA  promulgated  BAT  limitations  for  the   bauxite   refining
subcategory  on  April  8,  1974 as Subpart A of 40 CFR Part 421.
These  limitations  allow  no  discharge  of  process  wastewater
pollutants  to navigable waters.  A discharge is allowed from the
overflow of a process wastewater impoundment in a volume equal to
the net precipitation that falls within the impoundment.  EPA  is
not proposing any modification to these limitations at this time.
However,  the Agency is considering the establishment of effluent
limitations  based  on  pH  adjustment   and   activated   carbon
adsorption  treatment  of  toxic  organic  pollutants  in the mud
impoundment overflow.  This  revision  is  in  keeping  with  the
emphasis of the Clean Water Act of 1977 on toxic pollutants.

Implementation  of  this  organics  control  option  would remove
annually an estimated 4,835 kg of toxic pollutants from  the  raw
discharge.   Estimated  capital  cost  for  achieving this option
would be $7.60 million, with estimated annualized costs of  $2.98
million.

Activated  carbon  is  being considered because of its ability to
remove toxic organics to very low  concentrations.   Although  no
plants  in  the  nonferrous  metals  manufacturing  category have
installed  this  technology   for   organics   removal,   it   is
demonstrated  in  the iron and steel manufacturing category.  EPA
believes that  the  influent  characteristics  are  similar  with
respect  to  organics  for  both  categories, and that, if proper
design procedures are used, similar removals  will  be  achieved.
Activated  carbon  will remove adsorbable organics to essentially
nondetectable levels if sufficient carbon and  contact  time  are
provided.   These  design  parameters  have  been  carefully  and
conservatively selected by EPA for this subcategory.   Therefore,
based  on these considerations and the performance data from iron
and steel manufacturing a level of  0.010  mg/1  for  phenol,  2-
chlorophenol,  and  total  phenols  (4-AAP) can be achieved.  The
Agency  solicits  comments  on  the  costs  and  performance   of
activated   carbon,  and  the  applicability  of  these  effluent
limitations to the bauxite refining subcategory.

REGULATED POLLUTANT PARAMETERS

In implementing the terms of the Consent  Agreement  in  NRDC  v.
Train,  Op.  Cit.,  and 33 U.S.C. 1314(b)(2)(A and B) (1976), the
Agency placed particular emphasis on the toxic  pollutants.   The
raw  wastewater concentrations from individual operations and the
subcategory as a whole were examined to select certain pollutants
and pollutant parameters for limitation.   This  examination  and
                                   81

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evaluation,   presented   in   Section  VI,  concluded  that  six
pollutants  and  pollutant  parameters  are  present  in  bauxite
refining  wastewaters  at  concentrations  that can be reduced by
identified treatment technologies.

The  high  cost  associated  with  analysis  for  toxic   organic
pollutants has prompted EPA to consider an alternative method for
regulating  and  monitoring  toxic  pollutant discharges from the
nonferrous metals manufacturing category.  Rather than developing
specific effluent limitations and standards for each of the toxic
organics found in treatable concentrations in the raw  wastewater
from  a  given  subcategory,  the  Agency is considering effluent
limitations only for those pollutants generated in  the  greatest
quantities  as  shown by the pollutant removal estimate analysis.
On this basis,  the  pollutants  being  considered  for  specific
limitation are listed below:

     24.  2-chlorophenol
     65.  phenol

By  establishing  limitations  and  standards  for  certain toxic
organic pollutants, dischargers would attain the same  degree  of
control  over  toxic  organic  pollutants as they would have been
required to achieve had all the  toxic  organic  pollutants  been
directly limited.  This approach is technically justified because
the design of activated carbon columns must consider the presence
of  other  organic  compounds  which  will  be  removed  from the
wastewater.   Even  though  the  removal  of  different  phenolic
compounds  will  occur at different rates, treatment of the above
listed organics to the concentration  values  attainable  by  the
option will be accompanied by a reduction in concentration of the
unregulated  organics.   One nonconventional pollutant parameter,
total phenolic (4-AAP), is being  considered  for  limitation  to
ensure  adequate  removal  of phenolics other than 2-chlorophenol
and phenol.  No toxic metal pollutants are selected for  specific
limitation in this subcategory.

The  following  toxic  pollutants  are  not  being considered for
specific limitation on the basis that they would  be  effectively
controlled   by   the   limitations   being   considered  for  2-
chlorophenol, phenol, and total phenolics  (4-AAP):

     21.  2,4,6-trichlorophenol
     31.  2,4-dichlorophenol
     57.  2-nitrophenol
     58.  4-nitrophenol

The conventional pollutant parameter pH may  be  limited  by  the
best conventional technology  (BCT) effluent limitations.

EFFLUENT LIMITATIONS
                                   82

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The concentrations achievable by application of pH adjustment and
activated  carbon  are  discussed  in  Section VII of the General
Development  Document.   The   effluent   limitations   for   mud
impoundment effluent under consideration for BAT are shown below.

BAT  EFFLUENT  LIMITATIONS  UNDER  CONSIDERATION  FOR THE BAUXITE
REFINING SUBCATEGORY

Mud Impoundment Effluent

Pollutant or                           Maximum for
Pollutant Property	Any One Day (mq/1)

Phenol   .                                  0.010
2-Chlorophenol                             0.010
Total Phenols (4-AAP)                      0.010
                                   83

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                            Table X-2

     COST OF COMPLIANCE FOR THE BAUXITE REFINING SUBCATEGORY

                       Direct Dischargers*
                      Capital Cost       Annual Cost
          Option     (1982 Dollars)     (1982 Dollars)

            E          7,600,000           2,980,000
*Includes one plant currently practicing zero discharge of
 process wastewater.
                              85

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                  BAUXITE REFINING SUBCATEGORY

                           SECTION XI

                NEW SOURCE PERFORMANCE STANDARDS


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

This   section   describes  the  technologies  for  treatment  of
wastewater  from  new  sources  and  presents   the   performance
standards  being  considered  for  NSPS  in  the bauxite refining
subcategory, based on the selected treatment technology.

TECHNICAL APPROACH TO NSPS

EPA promulgated new source performance standards for the  bauxite
refining  subcategory  on April 8 1974.  The technology basis for
this promulgation was identical to BAT.  EPA  is  proposing  only
minor  technical amendments to the promulgated regulation.  It is
also  considering  the  limitations  described  in  the  previous
section  for  BAT,  i.e.,  pH  adjustment  and  activated  carbon
adsorption  of  mud  impoundment  overflow.   This  result  is  a
consequence  of  careful  review by the Agency of a wide range of
technology options for new  source  treatment  systems  which  is
discussed  in  Section  XI  of  the General Development Document.
This review of the bauxite refining  subcategory  found  no  new,
economically  feasible,  demonstrated technologies which could be
considered an improvement over those chosen for consideration for
BAT.  Additionally, there was nothing found to indicate that  the
wastewater  flows  and characteristics of new plants would not be
similar to those from existing plants, since the  processes  used
by  new  sources  are  not  expected to differ from those used at
existing sources.

The treatment  technology  considered . for  the  NSPS  option  is
identical  to  the  treatment  technology  considered for the BAT
option.  This option is:

OPTION E

     •    Zero discharge of process wastewater pollutant
     •    Discharge of net precipitation from process
          wastewater impoundments
                                   87

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     •    pH adjustment
     •    Activated carbon adsorption

NSPS OPTION SELECTION

As discussed earlier,  with  the  exception  of  minor  technical
amendments,  the Agency is not modifying the existing promulgated
regulation for the bauxite refining subcategory.  The  Agency  is
considering  and solicits comments on performance standards based
on Option E technology.

REGULATED POLLUTANT PARAMETERS

The Agency has no reason to believe that the pollutants that will
be found in treatable  concentrations  in  processes  within  new
sources  will  be  any  different  than  with  existing  sources.
Accordingly, pollutants and pollutant parameters being considered
for limitation under NSPS, in accordance with  the  rationale  of
Sections  VI  and  X, are identical to those being considered for
BAT.  The conventional  pollutant  parameter  pH  is  also  being
considered  for  limitation.  For NSPS, the Agency is considering
pH limitations for mud impoundment effluent within the  range  of
7.5  to  10.0  at  all  times,  and  solicits  comments  on  this
limitation.

NEW SOURCE PERFORMANCE STANDARDS

The modified performance standards being considered based  on  pH
adjustment  and activated carbon adsorption technology are listed
below.

NSPS UNDER CONSIDERATION FOR THE BAUXITE REFINING SUBCATEGORY

Mud Impoundment Effluent

Pollutant or                      Maximum for
Pollutant Property	Any One Day (mg/1)	

Phenol                                0.010
2-Chlorophenol                        0.010
Total Phenols (4-AAP)                 0.010
                                 88

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                  BAUXITE REFINING SUBCATEGORY

                           SECTION XII

                     PRETREATMENT STANDARDS


EPA  is not proposing pretreatment standards for existing sources
at this time because there are currently no indirect  discharging
facilities in this subcategory.

EPA  promulgated  PSNS  for  the  bauxite refining subcategory on
April 8, 1974 as Subpart A of 40 CFR  Part  421.   The  following
limitations  establish  the  quantity or quality of pollutants or
pollutant properties which may be discharged by  a  new  indirect
discharger:  There  shall  be  no discharge of process wastewater
pollutants to navigable waters.

During any calendar month,  there  may  be  discharged  from  the
overflow  of  a process wastewater impoundment either a volume of
wastewater equal to the difference between the precipitation  for
that  month that falls within the impoundment and the evaporation
within the impoundment for that month, or, if greater,  a  volume
of  process  wastewater  equal to the difference between the mean
precipitation for that month that falls  within  the  impoundment
and  the  mean  evaporation  for that month as established by the
National  Climatic  Center,  National  Oceanic  and.   Atmospheric
Administration, for the area in which such impoundment is located
(or  as  otherwise  determined  if  no  monthly  data  have  been
established by the National Climatic Center).

EPA is not proposing  any  modifications  to  PSNS  since  it  is
unlikely  that  any  new  bauxite  sources will be constructed as
indirect dischargers.
                                   89

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                  BAUXITE REFINING SUBCATEGORY

                          SECTION XIII

         BEST CONVENTIONAL POLLUTANT CONTROL TECHNOLOGY


EPA  is  not  proposing  best  conventional   pollutant   control
technology (BCT) limitations for the bauxite refining subcategory
at this time.

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