Eff lint Guidelines Division EPA 440/1-84/073
June 1984
evelopmeit
ocument 1
Guidelines ajnd
Standards for the
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DEVELOPMENT DOCUMENT
for
EFFLUENT LIMITATIONS GUIDELINES AND STANDARDS
for the
ALUMINUM FORMING POINT SOURCE CATEGORY
William D. Ruckelshaus
Administrator
Jack E. Ravan
Assistant Administrator for Water
Steven Schatzow
Director
Office of Water Regulations and Standards
Jeffery D. Denit
Director, Effluent Guidelines Division
Ernst P. Hall, Chief
Metals & Machinery Branch
Janet K. Goodwin
Technical Project Officer
June 1984
U.S. Environmental Protection Agency
Office of Water
Office of Water Regulations and Standards
Effluent Guidelines Division
Washington, D.C. 20460
-------
Agency
U,S.
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CONTENTS
Section Title
I SUMMARY AND CONCLUSIONS 1
II RECOMMENDATIONS 13
BPT 1 3
BAT 31
NSPS 41
PSES 58
PSNS 71
III INTRODUCTION 87
Legal Authority 87
Data Collection and Utilization 87
Data Collection Since Proposal 91
Description of the Aluminum Forming Category 93
Description of Aluminum Forming Processes 97
IV INDUSTRY SUBCATEGORIZATION 135
Basis for Subcategorization 135
Production Normalizing Parameter 146
Description of Subcategories 148
V WATER USE AND WASTEWATER CHARACTERISTICS 165
Sources of Data 165
Presentation of Wastewater Characteristics 174
Core Operations Unique to Major Forming
Operations 175
Core Operations Not Unique to Specific
Forming Operations 179
Ancillary Operations 181
Treated Wastewater Samples 187
VI SELECTION OF POLLUTANT PARAMETERS 541
Rationale for Selection of Pollutant
Parameters 542
Description of Pollutant Parameters 543
Pollutant Selection for Core Waste
Streams 616
Pollutant Selection for Ancillary
Waste Streams 647
Pollutant Selection by Subcategory 674
VII CONTROL AND TREATMENT TECHNOLOGY 697
End-of-Pipe Treatment Technologies 697
Major Technologies 698
Major Technology Effectiveness 720
iii
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CONTENTS (Continued)
Section Title
Minor Technologies 736
In-Plant Technology 771
VIII COST OF WASTEWATER TREATMENT AND CONTROL 855
General Approach 855
Cost Estimation Methodology: Pre-Proposal 856
Cost Estimation Methodology: Post-Proposal 880
Summary of Costs 897
Normal Plant 897
Nonwater Quality Aspects 897
IX BEST PRACTICABLE CONTROL TECHNOLOGY CURRENTLY
AVAILABLE 959
Technical Approach to BPT 959
Rolling with Neat Oils Subcategory 965
Rolling With Emulsions Subcategory 972
Extrusion Subcategory 978
Forging Subcategory 984
Drawing with Neat Oils Subcategory 987
Drawing with Emulsions or Soaps
Subcategory 991
Application of the Limitations in Permits 995
X BEST AVAILABLE TECHNOLOGY ECONOMICALLY
ACHIEVABLE 1049
Technical Approach to BAT 1049
Selected Option for BAT 1057
Regulated Pollutant Parameters 1058
Rolling with Neat Oils Subcategory 1061
Rolling with Emulsions Subcategory 1064
Extrusion Subcategory 1065
Forging Subcategory 1068
Drawing with Neat Oils Subcategory 1070
Drawing with Emulsions or Soaps Subcategory 1072
XI NEW SOURCE PERFORMANCE STANDARDS 1147
Technical Approach to NSPS 1147
NSPS Option Selection 1148
Regulated Pollutant Parameters 1149
New Source Performance Standards 1150
XII PRETREATMENT STANDARDS 1173
Introduction of Aluminum Forming
Wastewater into POTW 1173
Technical Approach to Pretreatment 1176
iv
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CONTENTS (Continued)
Section Title Page
PSES and PSNS Option Selection 1177
Regulated Pollutant Parameters 1178
Pretreatment Standards 1179
XIII BEST CONVENTIONAL POLLUTANT CONTROL TECHNOLOGY 1241
XIV ACKNOWLEDGMENT 1243
XV REFERENCES 1245
XVI GLOSSARY 1261
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TABLES
Section Title
III-l Profile of Aluminum Forming Plants 119
III-2 Plant Age Distribution by Discharge Type 120
III-3 Distribution of Facilities According to Time
Elapsed Since Latest Major Plant Modification 121
V-l Rolling with Neat Oils Spent Lubricants 189
V-2 Frequency of Occurence of Toxic Pollutants
Rolling with Neat Oils Spent Lubricants
Raw Wastewater 190
V-3 Sampling Data Rolling with Neat Oils Spent
Lubricants Raw Wastewater 194
V-4 Rolling with Emulsions Spent Emulsion 196
V-5 Frequency of Occurence of Toxic Pollutants
Rolling with Emulsions Spent Emulsions Raw
Wastewater 197
V-6 Sampling Data Rolling with Emulsions Spent
Emulsions Raw Wastewater 201
V-7 Roll Grinding Spent Lubricant 210
V-8 Frequency of Occurence of Toxic Pollutants Roll
Grinding Spent Emulsion Raw Wastewater 211
V-9 Sampling Data Roll Grinding Spent Emulsions Raw
Wastewater 215
V-10 Extrusion Die Cleaning Bath 220
V-ll Extrusion Die Cleaning Rinse 221
V-l2 Frequency of Occurence of Toxic Pollutants
Extrusion Die Cleaning Bath Raw Wastewater 222
V-l3 Sampling Data Extrusion Die Cleaning Bath Raw
Wastewater 223
V-l4 Frequency of Occurence of Toxic Pollutants
Extrusion Die Cleaning Rinse Raw Wastewater 228
V-l5 Sampling Data Extrusion Die Cleaning Rinse Raw
Wastewater 232
V-l6 Extrusion Die Cleaning Scrubber Liquor 235
V-l7 Frequency of Occurence of Toxic Pollutants Extrusion
Die Cleaning Scrubber Liquor Raw Wastewater 236
V-l8 Sampling Data Extrusion Die Cleaning Scrubber Liquor
Raw Wastewater 240
V-l9 Extrusion Press Scrubber Liquor 241
V-20 Frequency of Occurence of Toxic Pollutants Extrusion
Press Scrubber Liquor Raw Wastewater 242
V-21 Sampling Data Extrusion Press Scrubber Liquor Raw
Wastewater 246
V-22 Extrusion Dummy Block Contact Cooling Water 247
V-23 Frequency of Occurence of Toxic Pollutants Extrusion
Dummy Block Contact Cooling Water Raw Wastewater 248
vi
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TABLES (Continued)
Section Title
V-24 Sampling Data Extrusion Dummy Block Cooling Raw
Wastewater 252
V-25 Drawing with Neat Oils Spent Lubricants 253
V-26 Drawing with Emulsions or Soaps Spent Emulsion 254
V-27 Frequency of Occurence of Toxic Pollutants Drawing
with Emulsions or Soaps Spent Emulsion Raw
Wastewater 255
V-28 Sampling Data Drawing with Emulsions or Soaps Spent
Emulsions Raw Wastewater 259
V-29 Sawing Spent Lubricant 260
V-30 Frequency of Occurence of Toxic Pollutants Sawing
Spent Lubricant Raw Wastewater 261
V-31 Sampling Data Sawing Spent Lubricant Raw Wastewater 265
V-32 Frequency of Occurence of Toxic Pollutants Degreasing
Spent Solvents Raw Wastewater 269
V-33 Sampling Data Degreasing Spent Solvents Raw Wastewater 273
V-34 Annealing Atmosphere Scrubber Liquor 274
V-35 Frequency of Occurence of Toxic Pollutants Annealing
Atmosphere Scrubber Liquor Raw Wastewater 275
V-36 Sampling Data Annealing Atmosphere Scrubber Liquor
Raw Wastewater 279
V-37 Rolling Solution Heat Treatment Contact Cooling Water 280
V-38 Frequency of Occurence of Toxic Pollutants Rolling
Solution Heat Treatment Contact Cooling Water Raw
Wastewater 281
V-39 Sampling Data Rolling Solution Heat Treatment Contact
Cooling Water Raw Wastewater 285
V-40 Extrusion Press Heat Treatment Contact Cooling Water 288
V-41 Frequency of Occurence of Toxic Pollutants Extrusion
Press Heat Treatment Contact Cooling Water Raw
Wastewater 289
V-42 Sampling Data Extrusion Press Heat Treatment Contact
Cooling Water Raw Wastewater 293
V-43 Extrusion Solution Heat Treatment Contact Cooling
Water 299
V-44 Frequency of Occurence of Toxic Pollutants Extrusion
Solution Heat Treatment Contact Cooling Water Raw
Wastewater 300
V-45 Sampling Data Extrusion Solution Heat Treatment
Contact Cooling Water Raw Wastewater 304
V-46 Forging Solution Heat Treatment Contact Cooling Water 307
V-47 Frequency of Occurence of Toxic Pollutants Forging
Solution Heat Treatment Contact Cooling Water
Raw Wastewater 308
VII
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TABLES (Continued)
Section Title Page
V-48 Sampling Data Forging Solution Heat Treatment Contact
Cooling Water Raw Wastewater 312
V-49 Drawing Solution Heat Treatment Contact Cooling Water 317
V-50 Frequency of Occurence of Toxic Pollutants Drawing
Solution Heat Treatment Contact Cooling Water
Raw Wastewater 318
V-51 Sampling Data Drawing Solution Heat Treatment Contact
Cooling Water Raw Wastewater 322
V-52 Cleaning or Etching Bath 326
V-53 Frequency of Occurence of Toxic Pollutants Cleaning
or Etching Bath Raw Wastewater 328
V-54 Sampling Data Cleaning or Etching Bath Raw Wastewater 332
V-55 Cleaning or Etching Rinse 349
V-56 Frequency of Occurence of Toxic Pollutants Cleaning
or Etching Rinse Raw Wastewater 351
V-57 Sampling Data Cleaning or Etching Rinse Raw
Wastewater 355
V-58 Cleaning or Etching Scrubber Liquor 391
V-59 Frequency of Occurence of Toxic Pollutants Cleaning
or Etching Scrubber Liquor Raw Wastewater 392
V-60 Sampling Data Cleaning or Etching Scrubber Liquor
Raw Wastewater 396
V-61 Forging Scrubber Liquor 397
V-62 Frequency of Occurence of Toxic Pollutants Forging
Scrubber Liquor Raw Wastewater 398
V-63 Sampling Data Forging Scrubber Liquor Raw Wastewater 402
V-64 Direct Chill Casting Contact Cooling Water
(Aluminum Forming Plants) 404
V-65 Direct Chill Casting Contact Cooling Water (Primary
Aluminum Subcategory) 406
V-66 Frequency of Occurence of Toxic Pollutants Direct
Chill Casting Contact Cooling Water Raw Wastewater 408
V-67 Sampling Data Direct Chill Casting Cooling Water
Raw Wastewater 412
V-68 Continuous Rod Casting Contact Cooling Water
(Aluminum Forming Plants) 426
V-69 Continuous Rod Casting Contact Cooling Water (Primary
Aluminum Plants) 427
V-70 Continuous Rod Casting Spent Lubricant 428
V-71 Continuous Sheet Casting Spent Lubricant 429
V-72 Degassing Scrubber Liquor (Primary Aluminum Plants) 430
V-73 Frequency of Occurence of Toxic Pollutants Degassing
Scrubber Liquor Raw Wastewater 431
V-74 Sampling Data Degassing Scrubber Liquor Raw Wastewater 435
vi i i
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TABLES (Continued)
Section
Title
V-75
V-76
V-77
V-78
V-79
V-80
V-81
V-82
V-83
V-84
V-85
V-86
V-87
V-88
V-89
V-90
V-91
V-92
V-93
V-94
V-95
VI-1
VI-2
VI-3
VI-4
VII-1
VII-2
VII-3
VII-4
VII-5
VII-6
VII-7
VII-8
VII-9
VII-10
VII-11
Extrusion Press Hydraulic Fluid Leakage 436
Frequency of Occurence of Toxic Pollutants Extrusion
Press Hydraulic Fluid Leakage Raw Wastewater 437
Sampling Data Extrusion Press Hydraulic Fluid Leakage
Raw Wastewater 441
Sampling Data Additional Wastewater Raw Wastewater 445
Miscellaneous Nondescript Wastewater 460
Sampling Data Plant B Treated Wastewater 461
Sampling Data Plant C Treated Wastewater 465
Sampling Data Plant D Treated Wastewater 466
Sampling Data Plant E Treated Wastewater 471
Sampling Data Plant H Treated Wastewater 479
Sampling Data Plant J Treated Wastewater 481
Sampling Data Plant K Treated Wastewater 483
Sampling Data Plant L Treated Wastewater 485
Sampling Data Plant P Treated Wastewater 486
Sampling Data Plant Q Treated Wastewater 488
Sampling Data Plant U Treated Wastewater 490
Sampling Data Plant V Treated Wastewater 494
Sampling Data Plant AA Treated Wastewater 596
Sampling Data Plant BB Treated Wastewater 500
Sampling Data Plant DD Treated Wastewater 504
Sampling Data Plant EE Treated Wastewater 510
List of 129 Toxic Pollutants 675
Priority Pollutant Disposition Core Operations 681
Priority Pollutant Disposition Ancillary Operations 685
Priority Pollutant Disposition by Subcategpry 692
pH Control Effect on Metals Removal 788
Effectiveness of Sodium Hydroxide for Metals
Removal 789
Effectiveness of Lime and Sodium Hydroxide for
Metals Removal 790
Theoretical Solubilities of Hydroxides and
Sulfides of Selected Metals in Pure Water 791
Sampling Data from Sulfide Precipitation-
Sedimentation Systems 792
Sulfide Precipitation-Sedimentation Performance 793
Ferrite Co-precipitation Performance 794
Concentration of Total Cyanide (mg/1) 795
Multimedia Filtration Performance 796
Performance of Selected Settling Systems 797
Skimming Performance 798
IX
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TABLES (Continued)
Section Title Page
VII-12 Trace Organic Removal by Skimming API Plus
Belt Skimmers (From Plant 06058) 799
VII-13 Combined Metals Data Etfluent Values (mg/1) 800
VII-14 L&S Performance Additional Pollutants 801
VII-15 Combined Metals Data Set - Untreated Wastewater 802
VII-16 Maximum Pollutant Level in Untreated Wastewater
Additional Pollutants (mg/1) 803
VII-17 Precipitation-Settling-Filtration (LS&F)
Performance Plant A 804
VII-18 Precipitation-Settling-Filtration (LS&F)
Performance Plant B 805
VII-19 Precipitation-Settling-Filtration (LS&F)
Performance Plant C 806
VII-20 Summary of Treatment Effectiveness (mg/1) 807
VII-21 Chemical Emulsion Breaking Efficiencies 808
VII-22 Treatability Rating of Priority Pollutants
Utilizing Carbon Adsorption 809
VII-23 Classes of Organic Compounds Adsorbed on
Carbon 810
Vll-24 Ion Exchange Performance (all values mg/1) 811
VII-25 Peat Adsorption Performance 812
VII-26 Membrane Filtration System Effluent 813
VII-27 Ultrafiltration Performance 814
VIII-1 Major Differences Between Cost Methodologies 902
VIII-2 Cost Equations for Recommended Treatment and
Control Technologies - Pre-Proposal 903
VIII-3 Oily Sludge Production Associated with Aluminum
Forming 909
VIII-4 Lime Dosage Requirements and Lime Sludge
Production Associated with Aluminum Forming 910
VIII-5 Carbon Exhaustion Rates Associated with
Aluminum Forming 911
VIII-6 Cost Equations for Recommended Treatment and
Control Technologies - Post-Proposal 912
VIII-7 Components of Total Capital Investment -
Post-Proposal 916
VIII-8 Components of Total Annualized Costs - Post-
Proposal 91 7
VIII-9 Wastewater Sampling Frequency - Post-Proposal 918
VIII-10 Cost Program Pollutant Parameters 919
VIII-11 Aluminum Forming Category Cost of Compliance
($1982) 920
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TABLES (Continued)
Section Title Page
VIII-12 Characteristics of the Rolling with Neat Oils
Subcategory Normal Plant Used for Costing 921
VIII-13 Characteristics of the Rolling with Emulsion
Subcategory Normal Plant Used for Costing 922
VIII-14 Characteristics of the Extrusion Subcategory
Normal Plant Used for Costing 923
VIII-15 Characteristics of the Forging Subcategory
Normal Plant Used for Costing 924
VIII-16 Characteristics of the Drawing with Neat Oils
Subcategory Normal Plant Used for Costing 925
VIII-17 Characteristics of the Drawing with Emulsions
or Soaps Subcategory Normal Plant Used for
Costing 926
VIII-18 Summary of the Aluminum Forming Normal Plant
Cost ($1982) 927
IX-1 Production Operations-Rolling with Neat Oils 998
Subcategory
IX-2 Comparison of Wastewater Discharge Rates From
Cleaning or Etching Rinse Streams 1000
IX-3 Concentration Range of Pollutants Considered for
BPT Regulation in Core and Ancillary Waste
Streams - Rolling with Neat Oils Subcategory 1001
XI-4 BPT Mass Limitations for the Rolling with Neat
Oils Subcategory 1003
IX-5 Production Operations-Rolling with Emulsions
Subcategory 1007
IX-6 Concentration Range of Pollutants Considered for
BPT Regulation in Core and Ancillary Waste
Streams - Rolling with Emulsions Subcategory 1008
IX-7 BPT Mass Limitations for the Rolling with
Emulsions Subcategory 1010
IX-8 Production Operations - Extrusion Subcategory 1013
IX-9 Concentration Range of Pollutants Considered for
BPT Regulation in Core and Ancillary Waste
Streams - Extrusion Subcategory 1014
IX-10 BPT Mass Limitations for the Extrusion Subcategory 1016
IX-11 Production Operations - Forging Subcategory 1020
IX-12 Concentration Range of Pollutants Considered for
BPT Regulation in Core and Ancillary Waste Streams
- Forging Subcategory 1021
IX-13 BPT Mass Limitations for the Forging Subcategory 1023
IX-14 Production Operations - Drawing with Neat Oils
Subcategory 1026
xi
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TABLES (Continued)
Section
Title
IX-15
IX-16
IX-17
IX-18
IX-19
IX-20
IX-21
IX-22
X-l
X-2
X-3
X-4
X-5
X-6
X-7
X-8
X-9
X-10
X-l 1
X-l 2
X-l 3
Concentration Range of Pollutants Considered for
BPT Regulation in Core and Ancillary Waste
Streams - Drawing with Neat Oils Subcategory
BPT Mass Limitations for the Drawing with Neat
Oils Subcategory
Production Operations - Drawing with Emulsions or
Soaps Subcategory
Comparison of Wastewater Discharge Rates From
Drawing with Emulsion or Soap Streams
Concentration Range of Pollutants Considered for
BPT Regulation in Core and Ancillary Waste
Streams - Drawing with Emulsions or Soaps
Subcategory
BPT Mass Limitations for the Drawing with Emulsions
or Soaps Subcategory
Allowable Discharge Calculations for Plant X in
Example 1
Allowable Discharge Calculations for Plant Y in
Example 2
Capital and Annual Cost Estimates for BAT Options
Total Subcategory
Capital and Annual Cost Estimates for BAT Options
Direct Dischargers
Pollutant Reduction Benefits - Rolling with Neat
Oils Subcategory
Pollutant Reduction Benefits - Rolling with
Emulsions Subcategory
Pollutant Reduction Benefits
Pollutant Reduction Benefits
Pollutant Reduction Benefits
Subcategory
Pollutant Reduction Benefits - Drawing with Emulsions
or Soaps Subcategory
Pollutant Reduction Benefits - Direct Dischargers -
Rolling with Neat Oils Subcategory
Pollutant Reduction Benefits - Direct Dischargers -
Rolling with Emulsions Subcategory
Pollutant Reduction Benefits - Direct Dischargers -
Extrusion Subcategory
Pollutant Reduction Benefits - Direct Dischargers -
Drawing with Neat Oils Subcategory
Pollutant Reduction Benefits - Direct Dischargers -
Drawing with Emulsions or Soaps Subcategory
Extrusion Subcategory
Forging Subcategory
Drawing with Neat Oils
1027
1029
1033
1034
1035
1037
1041
1042
1074
1075
1076
1078
1080
1082
1085
1087
1089
1091
1093
1095
1097
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TABLES (Continued;
Section
Title
X-14
X-15
X-16
X-17
X-18
X-19
X-20
X-21
X-22
X-23
X-24
X-25
X-26
X-27
X-28
X-29
X-30
X-31
X-32
X-33
X-34
X-35
X-36
X-37
Pollutant Reduction Benefits - Normal Plant -
Rolling with Neat Oils Subcategory 1099
Pollutant Reduction Benefits - Normal Plant -
Rolling with Emulsions Subcategory 1100
Pollutant Reduction Benefits - Normal Plant -
Extrusion Subcategory 1101
Pollutant Reduction Benefits - Normal Plant -
Forging Subcategory 1102
Pollutant Reduction Benefits - Normal Plant -
Drawing with Neat Oils Subcategory 1103
Pollutant Reduction Benefits - Normal Plant -
Drawing with Emulsions or Soaps Subcategory 1104
Rolling with Neat Oils Subcategory
Treatment Performance - Normal Plant 1105
Rolling with Emulsions Subcategory
Treatment Performance - Normal Plant 1106
Extrusion Subcategory Treatment
Performance - Normal Plant 1107
Forging Subcategory Treatment Performance -
Normal Plant 1108
Drawing with Neat Oils Subcategory
Treatment Performance - Normal Plants 1109
Drawing with Emulsions Subcategory
Treatment Performance - Normal Plant 1110
TTO - Evaluation of Oil Treatment Effectiveness
on Toxics Removal 1111
Production Operations - Rolling with Neat Oils
Subcategory 1112
BAT Mass Limitations for the Rolling with Neat
Oils Subcategory 1113
Production Operations - Rolling with Emulsions
Subcategory 1118
BAT Mass Limitations for the Rolling with
Emulsions Subcategory 1119
Production Operations - Extrusion Subcategory 1122
BAT Mass Limitations for the Extrusion Subcategory 1123
Production Operations - Forging Subcategory 1127
BAT Mass Limitations for the Forging Subcategory 1128
Production Operations - Drawing with Neat Oils
Subcategory 1131
BAT Mass Limitations for the Drawing with Neat
Oils Subcategory 1132
Production Operations - Drawing with Emulsions or
Soaps Subcategory 1136
Xlll
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TABLES (Continued!
Section
Title
X-38
XI-1
XI-2
XI-3
XI-4
XI-5
XI-6
XII-1
XII-2
XII-3
XII-4
XII-5
XII-6
XII-7
XII-8
XII-9
XII-10
XII-11
XII-12
XII-13
XII-14
XII-15
XII-16
XII-17
XII-18
XII-19
XII-20
BAT Mass Limitations for the Drawing with Emulsions
or Soaps Subcategory 1137
NSPS for the Rolling with Neat Oils Subcategory 1151
NSPS for the Rolling with Emulsions Subcategory 1155
NSPS for the Extrusion Subcategory 1158
NSPS for the Forging Subcategory 1162
NSPS for the Drawing with Neat Oils Subcategory 1165
NSPS for the Drawing with Emulsions or Soaps
Subcategory 1169
POTW Removals of the Toxic Pollutants Found in
Aluminum Forming Wastewater 1180
Capital and Annual Cost Estimates for BAT Options
Indirect Dischargers ($1982) 1182
Pollutant Reduction Benefits - Indirect Dischargers
- Rolling with Neat Oils Subcategory 1183
Pollutant Reduction Benefits - Indirect Dischargers
- Rolling with Emulsions Subcategory 1185
Pollutant Reduction Benefits - Indirect Dischargers
- Extrusion Subcategory 1187
Pollutant Reduction Benefits - Indirect Dischargers
- Forging Subcategory 1189
Pollutant Reduction Benefits - Indirect Dischargers -
Drawing with Neat Oils Subcategory 1192
Pollutant Reduction Benefits - Indirect Dischargers
- Drawing with Emulsions or Soaps Subcategory 1194
PSES for the Rolling with Neat Oils Subcategory 1196
PSES for the Rolling with Emulsions Subcategory 1200
PSES for the Extrusion Subcategory 1203
PSES for the Forging Subcategory 1207
PSES for the Drawing with Neat Oils Subcategory 1210
PSES for the Drawing with Emulsions or Soaps
Subcategory 1214
PSNS for the Rolliwg with Neat Oils Subcategory 1219
PSNS for the Rolling with Emulsions Subcategory 1222
PSNS for the Extrusion Subcategory 1225
PSNS for the Forging Subcategory 1229
PSNS for the Drawing with Neat Oils Subcategory 1232
PSNS for the Drawing with Emulsions or Soaps
Subcategory 1236
xiv
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FIGURES
Section
III-l
II1-2
III-3
III-4
III-5
III-6
III-l
III-8
in-y
111-10
III-ll
111-12
111-13
V-l
V-2
V-3
V-4
V-5
V-6
V-7
V-8
V-9
V-10
V-ll
V-l 2
V-13
V-14
V-15
V-l 6
V-17
V-18
V-19
V-20
V-21
V-2 2
V-2 3
V-24
V-25
VII-1
VII-2
VII-3
VII-4
Title
Aluminum Forming Products
Geographical Distribution of Aluminum Forming
Plants
Common Rolling Mill Configurations
Geographical Distribution of Plants with Hot
or Cold Rolling
Direct Extrusion
Geographical Distribution of Plants with Extrusion
Forging
Geographical Distribution of Plants with Forging
Tube Drawing
Geographical Distribution of Plants with Tube, Wire,
Rod and Bar Drawing
Direct Chill Casting
Continuous Casting
Vapor Degreasing
Wastewater
Wastewater
Wastewater
Wastewater
Wastewater
Wastewater
Wastewater
Wastewater
Wastewater
Wastewater
Wastewater
Wastewater
Wastewater
Wastewater
Wastewater
Wastewater
Wastewater
Wastewater
Wastewater
Wastewater
Wastewater
Wastewater
Wastewater
Wastewater
Wastewater
Comparative Solubilities of Metal Hydroxides
and Sulfide as a Function of pH
Lead Solubility in Three Alkalies
Effluent Zinc Concentration vs. Minimum Effluent pH
Hydroxide Precipitation Sedimentation Effectiveness
-Cadmium
Sources
Sources
Sources
Sources
Sources
Sources
Sources
Sources
Sources
Sources
Sources
Sources
Sources
Sources
Sources
Sources
Sources
Sources
Sources
Sources
Sources
Sources
Sources
Sources
Sources
at
at
at
at
at
at
at
at
at
at
at
at
at
at
at
at
at
at
at
at
at
at
at
at
at
Plant
Plant
Plant
Plant
Plant
Plant
Plant
Plant
Plant
Plant
Plant
Plant
Plant
Plant
Plant
Plant
Plant
Plant
Plant
Plant
Plant
Plant
Plant
Plant
Plant
A
B
C
D
E
F
G
H
J
K
L
N
P
Q
R
S
T
U
V
W
AA
BB
CC
DD
EE
Page
122
123
124
125
126
127
128
129
130
131
132
133
134
516
517
518
519
520
521
522
523
524
525
526
527
528
529
530
531
532
533
534
535
536
537
538
539
540
815
816
817
818
xv
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Section
FIGURES (Continued)
Title
VII-5
VII-6
VII-7
VII-8
VII-9
VII-10
VII-11
VII-12
VII-13
VII-14
VII-15
VII-16
VII-17
VII-18
VII-19
VII-20
VII-21
VII-22
VII-23
VII-24
VII-25
VII-26
VII-27
VII-28
VII-29
VII-30
VII-31
VII-32
VII-33
VII-34
VII-35
VII-36
VII-37
VII-38
Sedimentation Effectiveness
Sedimentation Effectiveness
Sedimentation Effectiveness
Sedimentation Effectiveness
Sedimentation Effectiveness
Precipitation Sedimentation Effectiveness
Sedimentation Effectiveness
Hydroxide Precipitation
- Chromium
Hydroxide Precipitation
- Copper
Hydroxide Precipitation
- Lead
Hydroxide Precipitation
- Nickel and Aluminum
Hydroxide Precipitation
- Zinc
Hydroxide
- Iron
Hydroxide Precipitation Sedimentation Effectiveness
- Manganese
Hydroxide Precipitation
- TSS
Hexavalent Chromium Reduction with Sulfur
Dioxide
Granular Bed Filtration
Pressure Filtration
Representative Types of Sedimentation
Activated Carbon Adsorption Column
Centrifugation
Treatment of Cyanide Waste by Alkaline Chlorination
Typical Ozone Plant for Waste Treatment
UV/Ozonation
Types of Evaporation Equipment
Dissolved Air Flotation
Gravity Thickening
Ion Exchange with Regeneration
Simplified Reverse Osmosis Schematic
Reverse Osmosis Membrane Configurations
Sludge Drying Bed
Simplified Ultrafiltration Flow Schematic
Vacuum Filtration
Flow Diagram for Emulsion Breaking with Chemicals
Filter Configurations
Gravity Oil-Water Separation
Flow Diagram for a Batch Treatment Ultrafiltration
System
Flow Diagram of Activated Carbon Adsorption with
Regeneration
Flow Diagram for Recycling with a Cooling Tower
Counter Current Rinsing (Tanks)
Effect of Added Rinse Stages on Water Use
819
820
821
822
823
824
825
826
827
828
829
830
831
832
833
834
835
835
837
838
839
840
841
842
843
844
845
846
847
848
849
850
851
852
xvi
-------
Section
FIGURES (Continued)
Title
VII-39
VIII-1
VIII-2
VIII-3
VIII-4
VIII-5
VIII-6
VIII-7
VIII-8
VIII-9
VIII-10
VIII-1 1
VIII-12
VIII-13
VIII-14
VIII-15
VIII-16
VIII-17
VIII-18
VIII-19
VIII-20
VIII-21
VIII-22
VIII-23
VIII-24
VIII-25
VIII-26
VIII-27
VIII-28
VIII-29
VIII-30
IX-1
Schematic Diagram of Spinning Nozzle Aluminum
Refining Process 853
Costs of Oil Skimming (Pre-Proposal) 928
Costs of Chemical Emulsion Breaking
(Pre-Proposal) 929
Costs of Dissolved Air Flotation (Pre-Proposal) 930
Costs of Thermal Emulsion Breaking (Pre-Proposal) 931
Costs of Multimedia Filtration (Pre-Proposal) 932
Costs of pH Adjustment with Acid (Pre-Proposal) 933
Costs of pH Adjustment with Caustic (Pre-Proposal) 934
Costs of Lime and Settle (Pre-Proposal) 935
Costs of Chromium Reduction (Pre-Proposal) 936
Costs of Cyanide Oxidation (Pre-Proposal) 937
Costs of Activated Carbon Adsorption (Pre-Proposal) 938
Costs of Vacuum Filtration (Pre-Proposal) 939
Costs of Contract Hauling (Pre-Proposal) 940
Costs of Flow Equalization (Pre-Proposal) 941
Costs of Pumping (Pre-Proposal) 942
Costs of Holding Tanks (Pre-Proposal) 943
Costs of Recycling (Pre-Proposal) 944
General Logic Diagram of Computer Cost Model 945
Logic Diagram of Module Design Procedure 946
Logic Diagram of the Costing Routine 947
Costs of Chemical Precipitation and Gravity
Settling (Post-Proposal) 948
Costs of Vacuum Filtration (Post-Proposal) 949
Costs of Flow Equalization (Post-Proposal) 950
Costs of Cartridge/Multimedia Filtration
(Post-Proposal) 951
Costs of Chemical Emulsion Breaking (Post-
Proposal) 952
Costs of Oil Skimming (Post-Proposal) 953
Costs of Chromium Reduction (Post-Proposal) 954
Costs of Recycling via Cooling Towers/Holding
Tanks (Post-Proposal) 955
Cost of Countercurrent Cascade Rinsing (Post-
Proposal) 956
Costs of Contract Hauling (Post-Proposal) 957
BPT Treatment Train for the Rolling with Neat Oils
xvi i
-------
Section
FIGURES (Continued)
Title
IX-2
IX-3
IX-4
IX-5
IX-6
X-l
X-2
X-3
X-4
X-5
X-6
Subcategory
BPT Treatment
Subcategory
BPT Treatment
BPT Treatment
BPT Treatment
Subcategory
BPT Treatment
Train for the Rolling with Emulsions
Train for the Extrusion Subcategory
Train for the Forging Subcategory
Train for the Drawing with Neat Oils
Train for the Drawing with Emulsions
or Soaps Subcategory
BAT Treatment
BAT Treatment
BAT Treatment
BAT Treatment
BAT Treatment
BAT Treatment
Train
Train
Train
Train
Train
Train
for
for
for
for
for
for
Option
Option
Option
Option
Option
Option
1
2
3
4
5
6
1043
1044
1045
1046
1047
1048
1 141
1142
1143
1 144
1145
1146
XVlll
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SECTION I
SUMMARY AND CONCLUSIONS
Pursuant to Sections 301, 304, 306, 307, 308, and 501 of the
Clean Water Act and 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), modified by orders dated October 26, 1982 and
August 2, 1983, EPA has collected and analyzed data for plants in
the Aluminum Forming Point Source Category. There are no
existing effluent limitations or performance standards for this
industry. This document and the administrative record provide
the technical basis for promulgating effluent limitations
guidelines for existing direct dischargers, pretreatment
standards for new and existing indirect dischargers, and
standards of performance for new source direct dischargers.
Summary of the Category
Two hundred seventy-one plants employing approximately 31,200
people comprise this category. Of the 271 plants, 59 discharge
directly to rivers, lakes, or streams; 72 discharge to publicly
owned treatment works (POTW); and 140 do not discharge process
wastewater. Most of the zero discharge plants employ a combina-
tion of forming and ancillary operations which do not generate
process wastewater. The aluminum forming category has a total
production estimated at 5,000,000 kkg ( 5,500,000 tons) per year,
with individual production ranging from less than 10 kkg (22,000
pounds) to more than 259,000 kkg (570 million pounds) per year.
Aluminum forming processes are those manufacturing operations in
which aluminum or aluminum alloys are shaped into semi-finished
or mill products by hot and cold working. These operations,
called core operations, include rolling, extruding, forging, and
drawing of aluminum. Associated processes, called ancillary
operations, are practiced to achieve desired aluminum product
characteristics or finishes, and include the casting of aluminum
alloys for subsequent forming, heat treatment, and all surface
treatment operations performed as an integral part of aluminum
forming (called cleaning or etching).
Products manufactured by aluminum forming operations generally
serve as stock for subsequent fabricating operations. Cast
ingots and billets are the starting point for making sheet and
plate, extrusions, and forgings, as well as rod, for use in
drawing operations. Rolled aluminum sheet and plate can be used
as stock for stampings, can blanks, and roll formed products.
Extrusions can be used as raw stock for forging and drawing; to
fabricate final products, such as bumpers, window frames, and
light standards; or can be sold as final products. Forgings are
-------
either sold as consumer products or as parts in the production of
machinery, aircrafts, and engines.
Pollutants found in significant amounts in aluminum forming waste
streams include: cadmium, chromium, copper, lead, nickel,
selenium, zinc, and aluminum, oil and grease, suspended solids,
cyanide, and specific toxic organics.
The Agency developed a data collection portfolio (dcp) to collect
information regarding plant size, age, production, the production
processes used, the quantity of process wastewater used and dis-
charged, wastewater treatment in-place, and disposal practices at
plants practicing aluminum forming. The dcp's were sent to 580
firms known or believed to perform aluminum forming; 95 percent
of these firms responded.
EPA sampled the raw (untreated) and treated process wastewater at
25 aluminum forming plants. Screen sampling was performed at
four facilities, each representing one of the core processes.
Samples were collected from wastewater sources associated with
the core processes, as well as any associated processes, includ-
ing cleaning, etching, solution heat treatment, annealing, and
other wastewater streams. Each of the samples was analyzed to
determine the presence or absence, and if present, the concen-
tration of 129 toxic priority pollutants, plus conventional and
selected nonconventional pollutants. The remaining 21 plants
were sampled to verify the findings of the screen sampling
effort, to determine flow characteristics of a number of waste
streams commonly associated with aluminum forming, and to
strengthen the data base.
The Agency examined the rate of production and wastewater genera-
tion reported in the dcp's for each aluminum forming operation.
These data combined with the wastewater characteristics deter-
mined during sampling became the principal bases for subcatego-
rizing this category. Based on these data, the most appropriate
approach to subcategorizing this category is by the major manu-
facturing processes. In addition, a review of the use of lubri-
cants in rolling and drawing showed that these operations needed
to be segmented according to whether neat oils or soaps and emul-
sions are used. A neat oil is a pure oil which when spent of its
lubricating properties, can be hauled to an oil reclaimer or used
as fuel in the plant. Emulsions and soaps are mixtures of oils
and water. When these lubricants are spent, plants can contract
haul them to a disposal site, or treat them to remove the oil and
discharge or reuse the water. The aluminum forming category is
subcategorized based on manufacturing processes and wastewater
characteristics, resulting in six subcategories: rolling with
neat oils, rolling with emulsions, extrusion, forging, drawing
with neat oils, and drawing with emulsions or soaps.
-------
Each subcategory is divided into two segments. The individual
core operations listed previously comprise the first segment of
each subcategory. The core operations also include operations
that may be found in conjunction with the forming process or are
present at every facility. Some of the operations included in
the core do not discharge wastewater. The effluent flow from the
core operations for each of the subcategories is production
normalized or related to the mass of aluminum processed through
the forming operation, and the limitations at BPT and BAT are
based on the production normalized flow and the treatment
effectiveness.
The second segment of each subcategory consists of the ancillary
operations that generate wastewater and when practiced are an
integral part of the aluminum forming process. These ancillary
operations, such as solution heat treatment, cleaning or etching,
and casting, are practiced to achieve desired characteristics or
finishes on the aluminum products and can be characterized by the
generation of large volumes of wastewater. Because they are not
found at every plant in a subcategory and they are not always
unique to a specific subcategory, they are not included in the
core. Instead, a separate limitation is proposed for the waste
streams generated by these ancillary operations and normalized by
the mass of aluminum processed through the ancillary operation.
An aluminum forming plant would be permitted to discharge
pollutants equivalent to the sum of the limitations established
for the core and the ancillary operation(s) practiced at the
plant.
Using the subcategories to study the characteristics of the
untreated wastewater, EPA identified several distinct control and
treatment technologies (both in-plant and end-of-pipe} for use in
treating the pollutants found in aluminum forming wastewaters.
The following end-of-pipe technologies were selected for study by
the Agency:
Chemical precipitation and sedimentation (lime and
settle),
Oil skimming,
Chromium reduction,
Cyanide oxidation or precipitation,
Multimedia filtration,
Carbon adsorption,
Reverse osmosis,
-------
Chemical emulsion breaking, and
Thermal emulsion breaking.
EPA also studied various types of in-plant controls reported in
the dcp's and observed during sampling. The in-plant controls
studied included:
Recycle of contact cooling water and scrubber liquor,
Countercurrent cascade rinsing,
Hauling or regeneration of chemical baths for cleaning
or etching,
Alternative fluxing and degassing methods which do not
require wet scrubbing, and
Recycle of extrusion press hydraulic fluid leakage.
Engineering costs were prepared for each of the treatment options
considered for each plant in the category. These costs were then
used by the Agency to estimate the impact of implementing the
various options on the industry. For each subcategory for each
control and treatment option, the number of potential closures,
number of employees affected, and impact on price were estimated.
These results are reported in the EPA document titled: Economic
Impact Analysis of Effluent Limitations and Standards for the
Aluminum Forming Industry EPA 440/2-83-010.
Based on consideration of the above factors, EPA identified var-
ious control and treatment technologies which formed the basis
for BPT and selected control and treatment appropriate for each
set of standards and limitations. The mass limitations and
standards for BPT, BAT, NSPS, PSES, and PSNS are presented in
Section II. The limitations and standards are discussed briefly
below.
BPT
In general, the BPT level represents the average of the best
existing performances of plants of various ages, sizes, processes
or other common characteristics. Where existing performance is
uniformly inadequate, BPT may be transferred from a different
subcategory or category. In balancing costs in relation to
effluent reduction benefits, EPA considers the volume and nature
of existing discharges, the volume and nature of discharges
expected after application of BPT, the general environmental
-------
effects of the pollutants, and cost and economic impact of the
required pollution control level.
EPA is promulgating BPT mass limitations based on model end-of-
pipe treatment, which consists of oil skimming and lime precipi-
tation and settling, and, where necessary, preliminary treatment
consisting of chemical emulsion breaking, and hexavalent chromium
reduction. Cyanide removal, where appropriate, is also included
in the model BPT technology. The cyanide limitations are based
on the application of cyanide precipitation technology which is
transferred from the coil coating category. However, the Agency
recommends product substitution as the most effective means of
cyanide control.
The pollutants selected for limitation at BPT are-. chromium,
cyanide, zinc, aluminum, oil and grease, total suspended solids
(TSS), and pH.
Fifty-nine plants are direct dischargers. The Agency estimates
that investment costs in 1982 dollars for these plants would be
$48.4 million and that total annual costs would be $37.9 million.
Removal of toxic pollutants over estimates of current removals
would be 94,250 kg/yr (207,350 Ibs/yr). In addition, BPT will
result in the removal of 15.6 million kg/yr (34.3 million Ibs/yr)
of total pollutants including 1.73 million kg/yr (3.80 million
Ibs/yr) of the pollutant aluminum. The analysis of economic
impact concluded that there are two potential plant closures and
221 job losses associated with compliance with the BPT treatment
option. Total loss in industry production is expected to be
about 0.1 percent, with the cost of production increasing by
about 0.3 percent. If average compliance costs incurred by the
plants in the category were passed on to consumers, price
increases would range from 0 to 0.7 percent. The Agency has
determined that the effluent reduction benefits associated with
compliance with BPT limitations justify the costs.
BAT
The BAT technology level represents the best economically achiev-
able performance of plants of various ages, sizes, processes or
other shared characteristics. As with BPT, where existing per-
formance is uniformly inadequate, BAT may be transferred from a
different subcategory or category. BAT may include feasible pro-
cess changes or internal controls, even when not common industry
practice.
In developing BAT, EPA has given substantial weight to the
reasonableness of costs. The Agency considered the volume and
nature of discharges, the volume and nature of discharges
expected after application of BAT, the general environmental
-------
effects of the pollutants, and the costs and economic impacts of
the required pollution control levels. Despite this considera-
tion of costs, the primary determinant of BAT is still effluent
reduction capability.
The direct dischargers are expected to move directly to compli-
ance with BAT limitations from existing treatment because the
flow reduction used to meet BAT limitations would allow the use
of smaller and less expensive lime and settle equipment
than would be used to meet BPT limitations without flow
reduction.
The pollutants selected for regulation at BAT are: chromium,
cyanide, zinc, and aluminum.
Implementation of the BAT limitations will remove annually an
estimated 124,500 kg (273,900 Ibs) of toxic metal and organic
pollutants (from estimated current discharge) at a capital cost,
above equipment in place, of $48.2 million and a total annual
cost of $25.1 million ($1982).
BAT will remove 16,000 kg/yr (35,200 Ib/yr) of toxic pollutants
(metals and organics) and 19,400 kg/yr (42,680 Ib/yr) of the
pollutant aluminum incrementally above BPT. Total annual costs
for BAT are less than BPT because the lower flows allow for
smaller equipment and thereby smaller operating and maintenance
costs. The Agency projects no additional plant or line closures
as a result of these costs. If the average compliance cost
incurred by the plants in the industry were passed on to consum-
ers, price increases would range from 0 to 0.8; not significantly
greater than the BPT increases. Thus EPA has determined that BAT
is economically achievable.
NSPS
NSPS (new source performance standards) are based on the best
available demonstrated technology (BDT), including process
changes, in-plant control, and end-of-pipe treatment technologies
which reduce pollution to the maximum extent feasible.
EPA is establishing the best available demonstrated technology
for the aluminum forming category to be equivalent to BAT tech-
nology with the addition of filtration prior to discharge. The
Agency recognizes that new sources have the opportunity to imple-
ment more advanced levels of treatment without incurring the
costs of retrofitting equipment, the costs of partial or complete
shutdown to install new equipment and the costs to start up and
stabilize the treatment system as existing systems would have to
do.
-------
Filtration is an appropriate technology for NSPS because it is
demonstrated in this category and because compliance with NSPS
will be approximately the same as the cost for an existing plant
to comply with the BAT limitations. EPA does not believe that
NSPS will constitute a barrier to entry for new sources, prevent
major modifications to existing sources, or produce other adverse
economic effects.
The pollutants selected for regulation are: chromium, cyanide,
zinc, aluminum, oil and grease, TSS, and pH.
All of the flow allowances established for NSPS are equivalent to
the BAT allowances with the exception of extrusion press
hydraulic fluid leakage. The NSPS flow allowance is based on
reported flow data from extrusion presses designed and built to
allow for the recirculation of the hydraulic fluid leakage.
PSES
PSES (pretreatment standards for existing sources) are designed
to prevent the discharge of pollutants which pass through, inter-
fere with, or are otherwise incompatible with the operation of
POTW. Pretreatment standards are technology-based and analogous
to the best available technology for removal of toxic pollutants.
EPA is promulgating PSES based on the application of technology
equivalent to BAT, which consists of end-of-pipe treatment com-
prised of oil skimming and lime precipitation and settling, and
preliminary treatment, where necessary, consisting of hexavalent
chromium reduction, chemical emulsion breaking, and cyanide
removal.
In the aluminum forming category, the Agency has concluded that
the toxic metals regulated under these standards (chromium,
cyanide, and zinc) pass through the POTW. The nationwide average
percentage of these same toxic metals removed by a well operated
POTW meeting secondary treatment requirements is about 50 percent
(ranging from 20 to 65 percent), whereas the percentage that can
be removed by an aluminum forming direct discharger applying the
best available technology economically achievable is about 91
percent (ranging from 79 to 97 percent). Accordingly, these
pollutants pass through a POTW and are being regulated at PSES.
In addition to pass through of toxic metals, the Agency has
determined that there would be pass through of toxic organic
pollutants associated with oil waste streams. The PSES technol-
ogy will remove 97 percent of the toxic organics, whereas the
POTW national average removal of these same toxic organics by a
well operated POTW meeting secondary treatment requirements is 71
percent. At BAT, the Agency has determined that toxic organics
will be adequately controlled by the oil and grease limitation.
-------
Oil and grease standards are not appropriate at PSES and there-
fore it is necessary to specifically control toxic organics at
PSES. Toxic organics are regulated as total toxic organics (TTO)
which is all those toxic organics that were found to be present
in sampled aluminum forming wastewaters at concentrations greater
than the analytical quantification level of 0.01 mg/1.
The analysis of wastewaters for toxic organics is costly and
requires sophisticated equipment, therefore the Agency has
retained the alternative to monitoring for TTO that was; proposed.
Data indicate that the toxic organics are much more soluble in
oil and grease than in water and that the removal of the oil and
grease will substantially remove the toxic organics. Therefore,
a monitoring parameter for oil and grease based on the applica-
tion of oil and grease removal has been provided as an alterna-
tive to monitoring for TTO at PSES.
The PSES set forth in this regulation are expressed in terms of
mass per unit of production rather than as concentration stan-
dards. Regulation on the basis of concentration only is not
appropriate because concentration-based standards do not restrict
the total quantity of pollutants discharged. Flow reduction is a
significant part of the model technology for pretreatment because
it results in more concentrated waste streams which further
result in more effective pollutant removal. Thus, mass based
standards are necessary to reflect the pollutant removal achiev-
able by the model treatment technology.
The pollutants selected for regulation are: chromium, cyanide,
zinc, and TTO. Aluminum is not limited because aluminum is com-
monly used by a POTW as a flocculant to aid in the settling and
removal of suspended solids.
Implementation of the PSES will remove annually an estimated
119,500 kg (263,000 Ibs) of toxic metal and organic pollutants
(from estimated current discharge) at a capital cost, above
equipment in place, of $26.1 million and a total annual cost of
$16.7 million ($1982). The Agency's estimate of potential plant
closures indicates that there are three potential closures
associated with PSES. In terms of employment, these potential
closures could affect approximately 276 employees. Total loss in
industry production is expected to be about 0.2 percent, with the
cost of production increasing about 1 percent. Therefore, the
Agency has determined that PSES is economically achievable.
The Agency has set the PSES compliance date at three years after
promulgation of this regulation.
-------
PSNS
Like PSES, PSNS (pretreatment standards for new sources) are
established to prevent the discharge of pollutants which pass-
through, interfere with, or are otherwise incompatible with the
operation of the POTW. New indirect dischargers, like new direct
dischargers, have the opportunity to incorporate the best
available demonstrated technologies including process changes,
in-plant controls, and end-of-pipe treatment technologies, and to
use plant site selection to ensure adequate treatment system
installation.
This regulation establishes mass-based PSNS for the aluminum
forming category. The treatment technology basis for the PSNS
being promulgated is identical to the treatment technology set
forth as the basis for the NSPS being promulgated.
The pollutants regulated under PSNS an
and TTO. Aluminum is not limited b<
hydroxide form, is commonly used by a
in the settling and removal of suspend
oil and grease has been establishec
monitoring for TTO as discussed under P
Nonwater Quality Environmental Impacts
Eliminating or reducing one form of
environmental problems. Sections 304(fc
require EPA to consider the nonwate
impacts (including energy requirements
In compliance with these provisions, we
this regulation on air pollution, solid
scarcity, and energy consumption. This
for review by EPA personnel responsible
grams. While it is difficult to
against each other and against energy u
regulation will best serve often compet
chromium, cyanide, zinc,
cause aluminum, in its
as a flocculant to aid
d solids. Monitoring for
as an alternative to
ES.
pollution may cause other
) and 306 of the Act
quality environmental
of certain regulations.
considered the effect of
waste generation, water
regulation was circulated
for nonwater quality pro-
alance pollution problems
we believe that this
rig national goals.
The Agency considered the solid wastes tiat would be
suggest
?d treatment
generated by the
aluminum forming plants by the
and believes that except for the sludges
ment of cyanide, these sludges are not hazardous under
3001 of the Resource Conservation and Recovery Act (RCRA)
judgement is made based on the recommended technology
precipitation. By the addition of a small excess of lime
treatment, similar sludges, specifically toxic metal
sludges generated by other categories such as the iron and
generated at
technologies
treat-
Section
This
of lime
during
bearing
steel
category,
33084 (May
passed the
19, 1980)).
EP toxicity test. See 40 CFR 261.24 (45 FR
-------
Only wastewater treatment sludge generated by cyanide precipita-
tion technology is likely to be hazardous under the regulations
implementing subtitle C of the Resource Conservation and Recovery
Act (RCRA). Under those regulations generators of these wastes
must test the wastes to determine if the wastes meet any of the
characteristics of hazardous waste (see 40 CFR 262.11, 45 FR
33142-33143, May 19, 1980). Wastewater sludge generated by
cyanide precipitation treatment of aluminum forming solution heat
treatment contact cooling water may contain cyanides and may
exhibit extraction procedure (EP) toxicity. Therefore, these
wastes may require disposal as a hazardous waste. Wastewater
treatment sludge from cyanide precipitation of a process waste
stream is generated separately from lime and settle sludge and
may be disposed of separately.
Treatment and control technologies that require extensive
recycling and reuse of water may require cooling mechanisms.
Evaporative cooling mechanisms can cause water loss and contrib-
ute to water scarcity problemsa primary concern in arid and
semi-arid regions. While this regulation assumes water reuse,
the overall amount of reuse through evaporative cooling mechan-
isms is low and the quantity of water involved is not signifi-
cant. In addition, most aluminum forming plants are located east
of the Mississippi where water scarcity is not a problem. We
conclude that the consumptive water loss is insignificant and
that the pollution reduction benefits of recycle technologies
outweigh their impact on consumptive water loss.
EPA estimates that the achievement of BPT effluent limitations
will result in a net increase in electrical energy consumption of
approximately 65 million kilowatt-hours per year. The BAT
effluent technology should not substantially increase the energy
requirements of BPT because reducing the flow reduces the pumping
requirements, the agitation requirement for mixing wastewater,
and other volume-related energy requirements. Therefore, the BAT
limitations are assumed to require an equivalent energy consump-
tion to that of the BPT limitations. To achieve the BPT and BAT
effluent limitations, a typical direct discharger will increase
total energy consumption by less than one percent of the energy
consumed for production purposes.
The Agency estimates that PSES will result in a net increase in
electrical energy consumption of approximately 50 million
kilowatt-hours per year. To achieve PSES, a typical existing
indirect discharger will increase energy consumption by less than
one percent of the total energy consumed for production purposes.
NSPS and PSNS will not significantly add to total energy consump-
tion of the industry. A normal plant for each subcategory was
used to estimate the energy requirements for new sources. A new
10
-------
source wastewater treatment system will add approximately one
million kilowatt-hours per year to the total industry energy
requirements.
1 l
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SECTION II
RECOMMENDATIONS
1. EPA has divided the aluminum forming category into six
subcategories for the purpose of effluent limitations and
standards. These subcategories are:
- Rolling With Neat Oils
Rolling With Emulsions
Extrusion
Forging
Drawing With Neat Oils
- Drawing With Emulsions or Soaps
Each subcategory is regulated by core and ancillary operations.
The core is composed of those operations that always occur with
the subcategory or are dry operations. Operations not included
in the core are classified as ancillary operations and may or may
not be present at any one facility.
2. BPT is being promulgated based on the model treatment tech-
nology of flow equalization, oil skimming, and chemical
precipitation and sedimentation (lime and settle) technology, and
where appropriate, chemical emulsion breaking, chromium
reduction, and cyanide removal. The following BPT effluent
limitations are being promulgated for existing sources:
13
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A. BPT MASS LIMITATIONS FOR THE ROLLING WITH NEAT OILS
SUBCATEGORY
(a) Rolling with Neat Oils - Core Waste Streams Without An
Annealing Furnace Scrubber
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum
Monthly
for
Average
mg/off-kg (Ib/million off-lbs) of aluminum rolled with neat oils
Chromium
Cyanide
Zinc
Aluminum
Oil & Grease
Total Suspended Solids
PH
0.0244
0.0161
0.0808
0.356
1.11
2.27
(1)
0.010
0.0067
0.0338
0. 174
0.664
I .079
(1)
(1) Within the range of 7.0 to 10.0 at all times.
Rolling With Neat Oils - Core Waste Streams With An
Annealing Furnace Scrubber
Pollutant or
Pollutant Property
Maximum for
Any One Day
Max imum
Monthly
for
Average
mg/off-kg (Ib/million off-lbs) of aluminum rolled with neat oils
Chromium
Cyanide
Zinc
Aluminum
Oil & Grease
Total Suspended Solids
PH
0.
0.
0.
0.
1.
3.
(1
0360
0237
1 19
525
634
348
0.
0.
0.
0.
0.
1 .
(1
0147
0098
0498
257
980
593
(1) Within the range of 7.0 to 10.0 at all times,
14
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(c)
Continuous Sheet Casting - Spent Lubricant
Pollutant
Pollutant
or
Property
Maximum
Any One
for
Day
Maximum
Monthly
for
Average
mg/off-kg
methods
(Ib/million off-lbs) of aluminum cast by continuous
Chromium
Cyanide
Zinc
Aluminum
Oil & Grease
Total Suspended Solids
pH
0.00086
0.00057
0.0029
0.0127
0.0393
0.0805
(1 )
0.00035
0.00024
0.0012
0.0063
0.0236
0.0383
(1 )
(1) Within the range of 7.0 to 10.0 at all times.
(d) Solution Heat Treatment - Contact Cooling Water
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum
Monthly
for
Average
mg/off-kg (Ib/million off-lbs) of aluminum quenched
Chromium
Cyanide
Zinc
Aluminum
Oil & Grease
Total Suspended Solids
pH
3.
2.
1 1 .
49.
154.
315.
(1
39
24
25
55
10
91
1 .
0.
4.
24.
92.
150.
(1
39
93
70
66
46
25
(1) Within the range of 7.0 to 10.0 at all times,
15
-------
!e) Cleaning or Etching - Bath
Pollutant or Maximum for Maximum tor
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.079 0.032
Cyanide 0.052 0.022
Zinc 0.262 0.110
Aluminum 1.15 0.573
Oil & Grease 3.58 2.15
Total Suspended Solids 7.34 3.49
pH ( 1 ) ( 1 )
(1) Within the range of 7.0 to 10.0 at all times.
(f) Cleaning or Etching - Rinse
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 6.12 2.51
Cyanide 4.04 1 .67
Zinc 20.31 8.49
Aluminum 89.46 44.52
Oil & Grease 278.24 166.95
Total Suspended Solids 570.39 271.29
pH ( 1 ) ( 1 )
(1) Within the range of 7.0 to 10.0 at all times.
16
-------
(g) Cleaning or Etching - Scrubber Liquor
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 7.00 2.86
Cyanide 4.61 1.91
Zinc 23.22 9.70
Aluminum 102.24 50.88
Oil & Grease 318.00 190.80
Total Suspended Solids 651.90 310.05
pH ( 1 ) ( 1 )
(a) Within the range of 7.0 to 10.0 at all times.
B. BPT MASS LIMITATIONS FOR THE ROLLING WITH EMULSIONS
SUBCATEGORY
(a) Rolling With Emulsions - Core Waste Streams
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum rolled with emulsions
Chromium 0.057 0.024
Cyanide 0.038 0.016
Zinc 0.19 0.079
Aluminum 0.84 0.416
Oil & Grease 2.60 1.56
Total Suspended Solids 5.33 2.53
pH ( 1 ) ( 1 )
(1) Within the range of 7.0 to 10.0 at all times.
17
-------
(b) Direct Chill Casting - Contact Cooling Water
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cast by direct chill
methods
Chromium 0.59 0.24
Cyanide 0.39 0.16
Zinc 1 .94 0.81
Aluminum 8.55 4.26
Oil & Grease 26.58 15.95
Total Suspended Solids 54.49 25.92
pH ( 1 ) ( 1 )
(1) Within the range of 7.0 to 10.0 at all times.
(c) Solution Heat Treatment - Contact Cooling Water
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum quenched
Chromium 3.39 1 .39
Cyanide 2.24 0.93
Zinc 11.25 4.70
Aluminum 49.55 24.66
Oil & Grease 154.10 92.46
Total Suspended Solids 315.91 150.25
pH ( 1 ) ( 1 )
(1) Within the range of 7.0 to 10.0 at all times.
18
-------
(d) Cleaning or Etching - Bath
Pollutant
Pollutant
or
Property
Maximum for
Any One Day
Maximum
Monthly
for
Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium
Cyanide
Zinc
Aluminum
Oil & Grease
Total Suspended Solids
PH
0.079
0.052
0.262
1.15
3.58
7.34
(1 )
0.032
0.022
0. 109
0.573
2. 15
3.49
(1 )
(1) Within the range of 7.0 to 10.0 at all times,
(e) Cleaning or Etching - Rinse
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium
Cyanide
Zinc
Aluminum
Oil & Grease
Total Suspended Solids
PH
6.
4.
20.
89.
278.
570.
(1
12
04
31
46
24
39
2.
1
8
44
166
271
51
67
49
52
95
29
1
1) Within the range of 7.0 to 10.0 at all times,
19
-------
(f) Cleaning or Etching - Scrubber Liquor
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 7.00 2.86
Cyanide 4.61 1 ..91
Zinc 23.22 9,70
Aluminum 102.24 50.88
Oil & Grease 318.00 190.80
Total Suspended Solids 651.90 310.05
pH (1 ) ( 1 )
(1) Within the range of 7.0 to 10.0 at all times.
C. BPT MASS LIMITATIONS FOR THE EXTRUSION SUBCATEGORY
(a) Extrusion - Core Waste Streams
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum extruded
Chromium 0.16 0.066
Cyanide 0.11 0.044
Zinc 0.53 0.22
Aluminum 2.34 1.16
Oil & Grease 7.32 4.39
Total Suspended Solids 15.0 7.13
pH ( 1 ) ( 1 )
(a) Within the range of 7.0 to 10.0 at all times.
20
-------
(b) Direct Chill Casting - Contact Cooling Water
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cast by direct chill
methods
Chromium 0.59 0.24
Cyanide 0.39 0.16
Zinc 1.94 0.81
Aluminum 8.55 4.26
Oil & Grease 26.58 15.95
Total Suspended Solids 60.60 25.92
pH (1) ( 1 )
(1) Within the range of 7.0 to 10.0 at all times.
(c) Solution and Press Heat Treatment - Contact Cooling Water
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum quenched
Chromium 3 . 39 1 . 39
Cyanide 2.24 0.93
Zinc 11.25 4.70
Aluminum 49.55 24.66
Oil & Grease 154.10 92.46
Total Suspended Solids 315.91 150.25
pH ( 1 ) ( 1 )
(1) Within the range of 7.0 to 10.0 at all times.
21
-------
(d) Cleaning or Etching - Bath
Pollutant
Pollutant
or
Property
Maximum
Any One
for
Day
Maximum for
Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium
Cyanide
Zinc
Aluminum
Oil & Grease
Total Suspended Solids
pH
0.079
0.052
0.26
1.15
3.58
7.34
(1 )
0,
0,
0.
0
2
3
032
022
109
573
15
49
(1 )
(1) Within the range of 7.0 to 10.0 at all times,
(e) Cleaning or Etching - Rinse
Pollutant
Pollutant
or
Property
Maximum
Any One
for
Day
Maximum
Monthly
for
Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium
Cyanide
Zinc
Aluminum
Oil & Grease
Total Suspended Solids
pH
6.
4.
20.
89.
278.
570.
(1
12
04
31
46
24
39
2.
1 .
8.
44.
166.
271 .
(1
51
67
49
52
95
29
(1) Within the range of 7.0 to 10.0 at all times.
22
-------
Cleaning or Etching - Scrubber Liquor
Pollutant
Pollutant
or
Property
Maximum
Any One
for
Day
Maximum
Monthly
for
Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium
Cyanide
Zinc
Aluminum
Oil & Grease
Total Suspended Solids
pH
7.
4.
23.
102.
318.
651 .
(1
00
61
22
24
00
90
2
1
9
50
190
310
86
91
70
88
80
05
(1 )
(1) Within the range of 7.0 to 10.0 at all times.
(g) Degassing - Scrubber Liquor
Pollutant
Pollutant
or
Property
Maximum
Any One
for
Day
Maximum
Monthly
for
Average
mg/off-kg (Ib/million off-lbs) of aluminum degassed
Chromium
Cyanide
Zinc
Aluminum
Oil & Grease
Total Suspended Solids
PH
1 .
0.
3.
16.
52.
106.
(1
15
76
81
78
18
97
0.
0.
1 .
8.
31 .
50.
(1
47
32
59
35
31
88
(1) Within the range of 7.0 to 10.0 at all times,
23
-------
Extrusion Press Leakage
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of hard alloy aluminum extruded
Chromium 0.65 0.27
Cyanide 0.43 0.18
Zinc 2.16 0.90
Aluminum 9.51 4.73
Oil & Grease 29.56 17.74
Total Suspended Solids 60.60 28.82
pH ( 1 ) ( 1 )
(1) Within the range of 7.0 to 10.0 at all times.
D. BPT MASS LIMITATIONS FOR THE DRAWING WITH NEAT OILS
SUBCATEGORY
(a) Drawing With Neat Oils - Core Waste Streams
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum drawn with neat oils
Chromium 0.022 0.0090
Cyanide 0.015 0.0050
Zinc 0.073 0.031
Aluminum 0.32 0.160
Oil & Grease 0.97 0.598
Total Suspended Solids 2.04 0.972
pH ( 1 ) ( 1 )
(1) Within the range of 7.0 to 10.0 at all times.
24
-------
(b) Continuous Rod Casting - Contact Cooling Water
Pollutant
Pollutant
or
Property
Maximum
Any One
for
Day
Maximum
Monthly
for
Average
mg/off-kg
methods
(Ib/million off-lbs) of aluminum cast by continuous
Chromium
Cyanide
Zinc
Aluminum
Oil & Grease
Total Suspended Solids
PH
0,
0,
2
10
31
63
684
451
271
00
10
76
(1 )
0.28
0. 187
0.949
4.976
18.66
30.322
(1 )
(1) Within the range of 7.0 to 10.0 at all times
(c) Continuous Rod Casting - Spent Lubricant
Pollutant
Pollutant
or
Property
Maximum
Any One
for
Day
Maximum for
Monthly Average
mg/off-kg
methods
(Ib/million off-lbs) of aluminum cast by continuous
Chromium
Cyanide
Zinc
Aluminum
Oil & Grease
Total Suspended Solids
PH
00086
00057
00287
01263
03928
08052
1 )
(1) Within the range of 7.0 to 10.0 at all times,
0
0,
0
0,
0
0,
00035
00024
00120
00628
02357
03830
(1 )
25
-------
(d) Solution Heat Treatment - Contact Cooling Water
Pollutant
Pollutant
or
Property
Maximum
Any One
for
Day
Maximum
Monthly
for
Average
mg/off-kg (Ib/million off-lbs) of aluminum quenched
Chromium
Cyanide
Zinc
Aluminum
Oil & Grease
Total Suspended Solids
PH
3.
2.
1 1 .
49.
154.
315.
(1
39
24
25
55
10
91
1 .39
0.93
4.70
24.66
92.46
150.25
(1)
(1) Within the range of 7.0 to 10.0 at all times.
(e) Cleaning or Etching - Bath
Pollutant
Pollutant
or
Property
Maximum
Any One
for
Day
Maximum
Monthly
for
Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium
Cyanide
Zinc
Aluminum
Oil & Grease
Total Suspended Solids
PH
0.
0.
0.
1.
3.
7.
(1
079
052
26
150
58
34
(1) Within the range of 7.0 to 10.0 at all times,
032
022
1 1
57
15
49
26
-------
f) Cleaning or Etching - Rinse
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/off-kg (Ib/million otf-lbs) of aluminum cleaned or etched
Chromium
Cyanide
Zinc
Aluminum
Oil & Grease
Total Suspended Solids
pH
6. 12
4.04
20.31
89.46
278.24
570.39
(1 )
2.51
1 .67
8.49
44.52
166.95
271.29
(1)
(1) Within the range of 7.0 to 10.0 at all times,
(g) Cleaning or Etching - Scrubber Liquor
Pollutant
Pollutant
or
Property
Maximum
Any One
for
Day
Maximum
Monthly
for
Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium
Cyanide
Zinc
Aluminum
Oil & Grease
Total Suspended Solids
pH
7
4
23
102
318
651
,00
.61
.22
,24
,00
,90
2
1
9
50
198
310
,86
,91
.70
,88
.80
.05
(1)
(1 )
(1) Within the range of 7.0 to 10.0 at all times
27
-------
E. BPT MASS LIMITATIONS FOR THE DRAWING WITH EMULSIONS OR
SOAPS SUBCATEGORY
(a) Drawing With Emulsions or Soaps - Core Waste Streans
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum drawn with emulsions
or soaps
Chromium 0.205 0.084
Cyanide 0.135 0.056
Zinc 0.680 0.285
Aluminum 3.00 1.50
Oil & Grease 9.33 5. 60
Total Suspended Solids 19.12 9.10
pH ( 1 ) ( 1 )
(1) Within the range of 7.0 to 10.0 at all times.
(b) Continuous Rod Casting - Contact Cooling Water
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cast by continuous
methods
Chromium 0.684 0.28
Cyanide 0.450 0.187
Zinc 2.27 0.949
Aluminum 10.00 4.976
Oil & Grease 31.10 1 8.66
Total Suspended Solids 63.76 30.323
pH ( 1 ) ( 1 )
(1) Within the range of 7.0 to 10.0 at all times.
28
-------
(c) Continuous Rod Casting - Spent Lubricant
Pollutant or Maximum for Maximum for
Pollutant Property _ Any One Day _ Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cast by continuous
methods
Chromium 0.0009 0.0004
Cyanide 0.0006 0.0003
Zinc 0.0029 0.001
Aluminum 0.013 0.006
Oil & Grease 0.040 0.024
Total Suspended Solids 0.081 0.039
pH ( 1 ) ( 1 )
(1) Within the range of 7.0 to 10.0 at all times.
(d) Solution Heat Treatment - Contact Cooling Water
Pollutant or Maximum for Maximum for
Pollutant Property _ Any One Day _ Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum quenched
Chromium 3.39 1 . 39
Cyanide 2.24 0.93
Zinc 11.25 4.70
Aluminum 49.55 24.66
Oil & Grease 154. 10 92.46
Total Suspended Solids 315.91 150.25
pH ( 1 ) ( 1 )
(1) Within the range of 7.0 to 10.0 at all times.
29
-------
(e) Cleaning or Etching - Bath
Pollutant
Pollutant
or
Property
Maximum for
Any One Day
Maximum
Monthly
for
Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium
Cyanide
Zinc
Aluminum
Oil & Grease
Total Suspended Solids
pH
0.079
0.052
0.262
15
58
34
1 .
3
7
(1 )
(1) Within the range of 7.0 to 10.0 at all times,
(f) Cleaning or Etching - Rinse
0
0
0,
0
2
3
032
022
109
573
15
49
(1)
Pollutant
Pollutant
or
Property
Maximum for
Any 0ne Day
Maximum for
Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium
Cyanide
Zinc
Aluminum
Oil & Grease
Total Suspended Solids
PH
6.
4.
20.
89.
278.
570.
(1
12
04
31
46
24
39
2
1
8
44
166
271
51
67
49
519
95
29
(1)
(1
Within the range of 7.0 to 10.0 at all times,
30
-------
(g) Cleaning or Etching - Scrubber Liquor
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminim cleaned or etched
Chromium 7.00 2.86
Cyanide 4.61 1.91
Zinc 23.22 9.70
Aluminum 102.24 50.88
Oil & Grease 318.00 190.80
Total Suspended Solids 651.90 310.05
pH ( 1 ) ( 1 )
(1) Within the range of 7.0 to 10.0 at all times.
3. BAT is being promulgated based on the model treatment tech-
nology of oil skimming, chemical precipitation, and sedimentation
(lime and settle) technology and in-process flow reduction
control methods, and where applicable, chemical emulsion
breaking, chromium reduction, and cyanide removal. The following
BAT effluent limitations are being promulgated for existing
sources:
A. BAT MASS LIMITATIONS FOR THE ROLLING WITH NEAT OILS
SUBCATEGORY
(a) Rolling With Neat Oils - Core Waste Streams Without An
Annealing Furnace Scrubber
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum rolled with neat oils
Chromium 0.025 0.010
Cyanide 0.016 0.0067
Zinc 0.081 0.034
Aluminum 0.356 0.174
31
-------
(b) Rolling With Neat Oils - Core Waste Streams With An
Annealing Furnace Scrubber
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum rolled with neat oils
Chromium 0.036 0.015
Cyanide 0.024 0.0098
Zinc 0.119 0.050
Aluminum 0.525 0.257
(c) Continuous Sheet Casting - Spent Lubricant
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cast by continuous
methods
Chromium 0.00086 0.00035
Cyanide 0.00057 0.00024
Zinc 0.00287 0.0012
Aluminum 0.0127 0.0062
(d) Solution Heat Treatment - Contact Cooling Water
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum quenched
Chromium 0.897 0.367
Cyanide 0.591 0.245
Zinc 2.974 1.243
Aluminum 13.10 6.518
(e) Cleaning or Etching - Bath
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.079 0.032
Cyanide 0.052 0.022
Zinc 0.262 0.109
Aluminum 1.151 0.573
32
-------
f) Cleaning or Etching - Rinse
Pollutant or Maximum for Maximum for
Pollutant Property Any One 'Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.612 0.251
Cyanide 0.404 0.167
Zinc 2.031 0.849
Aluminum 8.944 4.45
(g) Cleaning or Etching - Scrubber Liquor
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.851 0.348
Cyanide 0.561 0.232
Zinc 2.822 1.179
Aluminum 12.43 6.186
B. BAT MASS LIMITATIONS FOR THE ROLLING WITH EMULSIONS
SUBCATEGORY
(a) Rolling With Emulsions - Core Waste Streams
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum rolled with emulsions
Chromium 0.057 0.024
Cyanide 0.038 0.016
Zinc 0.19 0.079
Aluminum 0.84 0.42
33
-------
(b) Direct Chill Casting - Contact Cooling Water
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cast by direct chill
methods
Chromium 0.59 0.24
Cyanide 0.39 0.16
Zinc 1.94 0.81
Aluminum 8.55 4.26
(c) Solution Heat Treatment - Contact Cooling Water
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum quenched
Chromium 0.90 0.37
Cyanide 0.59 0.25
Zinc 2.98 1.25
Aluminum 13.10 6.52
(d) Cleaning or Etching - Bath
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.079 0.032
Cyanide 0.052 0.022
Zinc 0.26 0.109
Aluminum 1.15 0.573
(e) Cleaning or Etching - Rinse
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.61 0.25
Cyanide 0.41 0.17
Zinc 2.03 0.85
Aluminum 8.95 4.45
34
-------
(f) Cleaning or Etching - Scrubber Liquor
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.85 0.35
Cyanide 0.56 0.23
Zinc 2.82 1.18
Aluminum 12.43 6.19
C. BAT MASS LIMITATIONS FOR THE EXTRUSION SUBCATEGORY
(a) Extrusion - Core Waste Streams
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum extruded
119 Chromium 0.15 0.061
121 Cyanide 0.098 0.041
128 Zinc 0.49 0.21
Aluminum 2.19 1.09
(b) Direct Chill Casting - Contact Cooling Water
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cast by direct chill
methods
Chromium 0.59 0.24
Cyanide 0.39 0.16
Zinc 1.94 0.81
Aluminum 8.55 4.26
(c) Solution or Press Heat Treatment Contact Cooling
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum quenched
Chromium 0.90 0.37
Cyanide 0.59 0.25
Zinc 2.98 1.25
Aluminum 13.10 6.52
35
-------
(d) Cleaning or Etching - Bath
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.079 0.032
Cyanide 0.052 0.022
Zinc 0.262 0.109
Aluminum 1.15 0.58
(e) Cleaning or Etching - Rinse
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.61 0.25
Cyanide 0.41 0.17
Zinc 2.03 0.85
Aluminum 8.95 4.45
(f) Cleaning or Etching - Scrubber Liquor
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.85 0.35
Cyanide 0.56 0.23
Zinc 2. 82 1 . 1! 8
Aluminum 12.43 6.19
(g) Extrusion Press Leakage
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of hard alloy aluminum extruded
Chromium 0.65 0.27
Cyanide 0.43 0.18
Zinc 2.16 0.90
Aluminum 9.51 4.73
36
-------
D. BAT MASS LIMITATIONS FOR THE DRAWING WITH NEAT OILS
SUBCATEGORY
(a) Drawing With Neat Oils - Core Waste Streams
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum drawn with neat oils
Chromium 0.022 0.009
Cyanide 0.015 0.006
Zinc 0.073 0.031
Aluminum 0.321 0.16
(b) Continuous Rod Casting - Contact Cooling Water
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cast by continuous
methods
Chromium 0.086 0.035
Cyanide 0.056 0.024
Zinc 0.283 0.118
Aluminum 1.247 0.621
(c) Continuous Rod Casting - Spent Lubricant
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cast by continuous
methods
Chromium 0.00086 0.0004
Cyanide 0.0006 0.0002
Zinc 0.0029 0.0012
Aluminum 0.0127 0.0063
37
-------
(d) Solution Heat Treatment - Contact Cooling Water
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum quenched
Chromium 0.896 0.367
Cyanide 0.591 0.245
Zinc 2.974 1.243
Aluminum 13.10 6.519
(e) Cleaning or Etching - Bath
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.079 0.032
Cyanide 0.052 0.022
Zinc 0.262 0.109
Aluminum 1.151 0.563
(f) Cleaning or Etching - Rinse
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.612 0.251
Cyanide 0.404 0.167
Zinc 2.031 0.849
Aluminum 8.944 4.451
(g) Cleaning or Etching - Scrubber Liquor
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.851 0.348
Cyanide 0.561 0.232
Zinc 2.82 1.179
Aluminum 12.43 6.19
38
-------
E. BAT MASS LIMITATIONS FOR THE DRAWING WITH EMULSIONS
OR SOAPS SUBCATEGORY
(a) Drawing With Emulsions or Soaps - Core Waste Streams
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum drawn with emulsions
or soaps
Chromium 0.205 0.084
Cyanide 0.135 0.056
Zinc 0.681 0.285
Aluminum 3.00 1.49
(b) Continuous Rod Casting - Contact Cooling Water
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cast by continuous
methods
Chromium 0.086 0.035
Cyanide 0.056 0.024
Zinc 0.283 0.118
Aluminum 1 .25 0.62
(c) Continuous Rod Casting - Spent Lubricant
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cast by continuous
methods
Chromium 0.0009 0.0004
Cyanide 0.0006 0.0003
Zinc 0.0029 0.0012
Aluminum 0.013 0.0063
39
-------
(d) Solution Heat Treatment - Contact Cooling Water
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum quenched
Chromium 0.897 0.37
Cyanide 0.591 0.25
Zinc 2.98 1.24
Aluminum 13.10 6.52
(e) Cleaning or Etching - Bath
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.079 0.032
Cyanide 0.052 0.022
Zinc 0.262 0.11
Aluminum 1.15 0.57
(f) Cleaning or Etching - Rinse
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.612 0.251
Cyanide 0.404 0.167
Zinc 2.03 0.849
Aluminum 8.95 4.45
(g) Cleaning or Etching - Scrubber Liquor
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.85 0.348
Cyanide 0.561 0.232
Zinc 2.82 1.18
Aluminum 12.43 6.19
40
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4. NSPS is being promulgated based on the model treatment tech-
nology of oil skimming, chemical precipitation, sedimentation and
filtration (lime, settle, and filter) technology and in-process
flow reduction control methods, and where applicable, chemical
emulsion breaking, chromium reduction, and cyanide removal. The
following effluent standards are being promulgated for new
sources:
A. NSPS FOR THE ROLLING WITH NEAT OILS SUBCATEGORY
(a) Rolling With Neat Oils - Core Waste Streams Without An
Annealing Furnace Scrubber
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
g/off-kg (Ib/million off-lbs) of aluminum rolled with neat oils
m
Chromium
Cyanide
Zinc
Aluminum
Oil & Grease
Total Suspended Solids
pH
0.021
0.01 1
0.057
0.338
0.553
0.830
1)
0.0083
0.0044
0.023
0. 150
0.553
0.664
1 )
(1) Within the range of 7.0 to 10.0 at all times.
(b) Rolling With Neat Oils - Core Waste Streams With An
Annealing Furnace Scrubber
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum rolled with neat oils
Chromium
Cyanide
Zinc
Aluminum
Oil & Grease
Total Suspended Solids
PH
0.030
0.016
0.084
0.499
0.817
1 .225
(1)
0.0123
0.0065
0.0343
0.221
0.817
0.980
(1 )
(1) Within the range of 7.0 to 10.0 at all times.
41
-------
(c) Continuous Sheet Casting - Spent Lubricant
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cast by continuous
methods
Chromium 0.00073 0.00029
Cyanide 0.00039 0.00016
Zinc 0.0020 0.00082
Aluminum 0.012 0.0053
Oil & Grease 0.0197 0.019
Total Suspended Solids 0.0295 0.022
pH ( 1 ) ( 1 )
(1) Within the range of 7.0 to 10.0 at all times.
(d) Solution Heat Treatment - Contact Cooling Water
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum quenched
Chromium 0.76 0.31
Cyanide 0.41 0.17
Zinc 2.08 0.86
Aluminum 12.45 5.52
Oil & Grease 20.37 20.37
Total Suspended Solids 30.56 24.45
pH ( 1 ) ( 1 )
(1) Within the range of 7.0 to 10.0 at all times.
42
-------
Cleaning or Etching - Bath
Pollutant or Maximum for
Pollutant Property Any
One Day
mg/off-kg (Ib/million off-lbs) of aluminum
Chromium
Cyanide
Zinc
Aluminum
Oil & Grease
Total Suspended Solids
pH
(1) Within the range of 7.
(f) Cleaning or Etching -
Pollutant or Max
Pollutant Property Any
mg/off-kg (Ib/million off-1
Chromium
Cyanide
Zinc
Aluminum
Oil & Grease
Total Suspended Solids
PH
(1) Within the range of 7.
(g) Cleaning or Etching -
Pollutant or Max
Pollutant Property Any
mg/off-kg (Ib/million off-1
Chromium
Cyanide
Zinc
Aluminum
Oil & Grease
Total Suspended Solids
pH
0.066
0.036
0. 183
1 .094
1 .79
2.69
(1 )
0 to 10.0 at all
Rinse
imum for
One Day
bs) of aluminum
0. 52
0. 28
1 .42
8.50
13.91
20.87
(1 )
0 to 10.0 at all
Scrubber Liquor
imum for
One Day
bs) of aluminum
0.715
0.387
1 .97
11.81
19.33
29.00
(1 )
Maximum for
Monthly Average
cleaned or etched
0.027
0.015
0.075
0.485
1 .79
2.15
(1 )
times .
Maximum for
Monthly Average
cleaned or etched
0.21
0. 1 1
0. 59
3.70
13.91
16.69
(1 )
times.
Maximum for
Monthly Average
cleaned or etched
0.29
0. 16
0.81
5.24
19.33
23.20
(1 )
(1) Within the range of 7.0 to 10.0 at all times.
43
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B. NSPS FOR THE ROLLING WITH EMULSIONS SUBCATEGORY
(a) Rolling With Emulsions - Core Waste Streams
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum rolled with emulsions
Chromium 0.048 0.020
Cyanide 0.026 0.011
Zinc 0.133 0.055
Aluminum 0.80 0.35
Oil & Grease 1.30 1.30
Total Suspended Solids 1.95 1.56
pH (1 ) ( 1 )
(1) Within the range of 7.0 to 10.0 at all times.
(b) Direct Chill Casting - Contact Cooling Water
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cast by direct chill
methods
Chromium 0.49 0.20
Cyanide 0.27 0.11
Zinc 1.36 0.59
Aluminum 8.12 3.60
Oil & Grease 13.29 1 3 . 29
Total Suspended Solids 19.94 15.95
pH (1 ) ( 1 )
(1) Within the range of 7.0 to 10.0 at all times.
44
-------
(c) Solution Heat Treatment - Contact Cooling Water
Pollutant or Maximum for Maximum for
Pollutant Property _ Any One Day _ Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum quenched
Chromium
Cyanide
Zinc
Aluminum
Oil & Grease
Total Suspended Solids
pH
(1) Within the range of
(d) Cleaning or Etching
0.76
0.41
2.08
12.45
20.37
30.56
(1 )
7.0 to 10.0 at all times.
- Bath
0
0
0
5
20
24
(1
.31
. 17
.86
.52
.37
.45
)
Pollutant or Maximum for Maximum for
Pollutant Property _ Any One Day _ Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium
Cyanide
Zinc
Aluminum
Oil & Grease
Total Suspended Solids
PH
( 1 ) Within the range of
(e) Cleaning or Etching
0.067
0.036
0. 183
1 .094
1 .79
2.69
(1)
7.0 to 10.0 at all times.
- Rinse
0.027
0.015
0.075
0.485
1 .79
2. 15
(1 )
Pollutant or Maximum for Maximum for
Pollutant Property _ Any One Day _ Monthly Average
mg/kg (Ib/million Ibs) of aluminum cleaned or etched
Chromium 0.52 0.21
Cyanide 0.28 0.11
Zinc 1.42 0.59
Aluminum 8.50 3.77
Oil & Grease 13.91 13.91
Total Suspended Solids 20.87 16.70
pH ( 1 ) ( 1 )
(1) Within the range of 7.0 to 10.0 at all times.
45
-------
(f) Cleaning or Etching - Scrubber Liquor
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.72 0.29
Cyanide 0.39 0.16
Zinc 1.97 0.81
Aluminum 11.81 5,. 24
Oil & Grease 19.33 19.. 33
Total Suspended Solids 29.00 23.20
pH ( 1 ) ( 1 )
(1) Within the range of 7.0 to 10.0 at all times.
C. NSPS FOR THE EXTRUSION SUBCATEGORY
(a) Extrusion - Core Waste Streams
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum extruded
Chromium 0.13 0.051
Cyanide 0.068 0.027
Zinc 0.35 0.14
Aluminum 2.07 0.92
Oil & Grease 3.39 3.39
Total Suspended Solids 5.10 4.07
pH (1 ) (1 )
(1) Within the range of 7.0 to 10.0 at all times.
46
-------
(b) Direct Chill Casting - Contact Cooling Water
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cast by direct chill
methods
Chromium 0.49 0.20
Cyanide 0.27 0.11
Zinc 1.36 0.56
Aluminum 8.12 3.60
Oil & Grease 13.29 13.29
Total Suspended Solids 19.24 15.95
pH (1) (1)
(1) Within the range of 7.0 to 10.0 at all times.
(c) Solution and Press Heat Treatment - Contact Cooling
Water
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum quenched
Chromium 0.76 0.31
Cyanide 0.41 0.17
Zinc 2.08 0.86
Aluminum 12.45 5.52
Oil & Grease 20.37 20.37
Total Suspended Solids 30.56 24.45
pH ( 1 ) ( 1 )
(1) Within the range of 7.0 to 10.0 at all times.
47
-------
(d) Cleaning or Etching - Bath
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.067 0.027
Cyanide 0.036 0.015
Zinc 0.183 0.075
Aluminum 1.094 0.485
Oil & Grease 1.79 1 .79
Total Suspended Solids 2.69 2.15
pH ( 1 ) ( 1 )
(1) Within the range of 7.0 to 10.0 at all times.
(e) Cleaning or Etching - Rinse
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.52 0.21
Cyanide 0.28 0.11
Zinc 1 .42 0.59
Aluminum 8.50 3.77
Oil & Grease 13.91 13.91
Total Suspended Solids 20.87 16.70
pH (1 ) ( 1 }
(1) Within the range of 7.0 to 10.0 at all times.
(f) Cleaning or Etching - Scrubber Liquor
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.72 0.29
Cyanide 0.39 0.16
Zinc 1.97 0.81
Aluminum 11.81 5.24
Oil & Grease 19.33 19.33
Total Suspended Solids 29.00 23.20
pH ( 1 ) ( 1 )
(1) Within the range of 7.0 to 10.0 at all times.
48
-------
!g) Extrusion Press Leakage
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of hard alloy aluminum extruded
Chromium 0.11 0.045
Cyanide 0.060 0.024
Zinc 0.31 0.126
Aluminum 1.82 0.81
Oil & Grease 2.98 2.98
Total Suspended Solids 4.47 3.58
pH ( 1 ) ( 1 )
(1) Within the range of 7.0 to 10.0 at all times.
D. NSPS FOR THE FORGING SUBCATEGORY
(a) Forging - Core Waste Streams
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum forged
Chromium 0.019 0.008
Cyanide 0.010 0.004
Zinc 0.051 0.021
Aluminum 0.305 0.135
Oil & Grease 0.50 0.50
Total Suspended Solids 0.75 0.60
pH ( 1 ) ( 1 )
(1) Within the range of 7.0 to 10.0 at all times.
49
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(b) Forging - Scrubber Liquor
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/mi11 ion off-lbs) of aluminum forged
Chromium 0.035 0.014
Cyanide 0.019 0.008
Zinc 0.096 0.04
Aluminum 0.576 0.256
Oil & Grease 0.943 0.95
Total Suspended Solids 1.42 1.13
pH ( 1 ) ( 1 )
(1) Within the range of 7.0 to 10.0 at all times.
(c) Solution Heat Treatment - Contact Cooling Water
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum quenched
Chromium 0.76 0.31
Cyanide 0.41 0.163
Zinc 2.08 0.86
Aluminum 12.45 5.52
Oil & Grease 20.37 20.37
Total Suspended Solids 30.56 24.45
pH (1 ) (!)
(1) Within the range of 7.0 to 10.0 at all times.
(d) Cleaning or Etching - Bath
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.066 0.027
Cyanide 0.036 0.015
Zinc 0.183 0.075
Aluminum 1.094 0.485
Oil & Grease 1.79 1.79
Total Suspended Solids 2.69 2.15
pH (1 ) ( 1 )
(1) Within the range of 7.0 to 10.0 at all times.
50
-------
(e) Cleaning or Etching - Rinse
Pollutant or Maximum for
Pollutant Property Any One Day
mg/off-kg (Ib/million off-lbs) of aluminum
Chromium 0.52
Cyanide 0.28
Zinc 1.42
Aluminum 8.5
Oil & Grease 13.91
Total Suspended Solids 20.87
pH (1 )
(1) Within the range of 7.0 to 10.0 at all
(f) Cleaning or Etching - Scrubber Liquor
Pollutant or Maximum for
Pollutant Property Any One Day
mg/off-kg (Ib/million off-lbs) of aluminum
Chromium 0.72
Cyanide 0.39
Zinc 1.97
Aluminum 11.81
Oil & Grease 19.33
Total Suspended Solids 29.00
pH (1 )
Maximum for
Monthly Average
cleaned or etched
0. 21
0. 1 1
0.59
3.77
13.91
16.69
(1 )
times.
Maximum for
Monthly Average
cleaned or etched
0.29
0. 155
0.812
5.24
19.33
23.20
(1)
(1
Within the range of 7.0 to 10.0 at all times,
51
-------
m
E. NSPS FOR THE DRAWING WITH NEAT OILS SUBCATEGORY
(a) Drawing With Neat Oils - Core Waste Streams
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
g/off-kg (Ib/million off-lbs) of aluminum drawn with neat oils
Chromium 0.019 0.008
Cyanide 0.010 0.004
Zinc 0.051 0.021
Aluminum 0.304 0.135
Oil & Grease 0.498 0.498
Total Suspended Solids 0.747 0.598
pH (1) ( 1 )
(1) Within the range of 7.0 to 10.0 at all times.
(b) Continuous Rod Casting - Contact Cooling Water
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cast by continuous
methods
Chromium 0.072 0.. 029
Cyanide 0.039 0..016
Zinc 0.198 0.082
Aluminum 1.185 0.526
Oil & Grease 1.939 1.939
Total Suspended Solids 2.909 2.327
pH (1 ) ( 1 )
(1) Within the range of 7.0 to 10.0 at all times.
52
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(c) Continuous Rod Casting - Spent Lubricant
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cast by continuous
methods
Chromium 0.0008 0.0003
Cyanide 0.0004 0.0002
Zinc 0.002 0.008
Aluminum 0.012 0.006
Oil & Grease 0.02 0.02
Total Suspended Solids 0.03 0.024
pH (1) ( 1 )
(1) Within the range of 7.0 to 10.0 at all times.
(d) Solution Heat Treatment - Contact Cooling Water
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum quenched
Chromium 0.754 0.306
Cyanide 0.408 0.163
Zinc 2.08 0.856
Aluminum 12.45 5.52
Oil & Grease 20.37 20.37
Total Suspended Solids 30.56 24.45
pH ( 1 ) (1 )
(1) Within the range of 7.0 to 10.0 at all times.
53
-------
e) Cleaning or Etching - Bath
Pollutant or Maximum for
Pollutant Property Any One Day
mg/off-kg (Ib/million off-lbs) of aluminum
Chromium 0.066
Cyanide 0.036
Zinc 0.183
Aluminum 1 . 094
Oil & Grease 1 . 79
Total Suspended Solids 2.69
pH (1 )
(1) Within the range of 7.0 to 10.0 at all
(f) Cleaning or Etching - Rinse
Pollutant or Maximum for
Pollutant Property Any One Day
mg/off-kg (Ib/million off-lbs) of aluminum
Chromium 0.515
Cyanide 0.278
Zinc 1 .42
Aluminum 8.50
Oil & Grease 13.91
Total Suspended Solids 20.87
pH (1 )
(1) Within the range of 7.0 to 10.0 at all
(g) Cleaning or Etching - Scrubber Liquor
Pollutant or Maximum for
Pollutant Property Any One Day
mg/off-kg (Ib/million off-lbs) of aluminum
Chromium 0.715
Cyanide 0.387
Zinc 1.97
Aluminum 11.81
Oil & Grease 19.33
Total Suspended Solids 29.00
PH
Maximum for
Monthly Average
cleaned or etched
0.027
0. 015
0.075
0.485
1 ..79
2. 15
(1 )
times.
Maximum for
Monthly Average
cleaned or etched
0.209
0.111
0. 584
3.77
13.91
16.70
(1 )
times.
Maximum for
Monthly Average
cleaned or etched
0.290
0. 155
0.812
5.24
19.33
23.20
(1) Within the range of 7.0 to 10.0 at all times,
54
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F. NSPS FOR THE DRAWING WITH EMULSIONS OR SOAPS SUBCATEGORY
(a) Drawing With Emulsions or Soaps - Core Waste Streams
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum drawn with emulsions
or soaps
Chromium 0.173 0.070
Cyanide 0.094 0.038
Zinc 0.476 0.196
Aluminum 2.85 1 .27
Oil & Grease 4.67 4.67
Total Suspended Solids 7.00 5.60
pH (1 ) ( 1 )
(1) Within the range of 7.0 to 10.0 at all times.
(b) Continuous Rod Casting - Contact Cooling Water
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cast by continuous
methods
Chromium 0.072 0.029
Cyanide 0.039 0.016
Zinc 0.198 0.081
Aluminum 1.184 0.526
Oil & Grease 1.940 1.940
Total Suspended Solids 2.91 2.33
pH (1 ) ( 1 )
(1) Within the range of 7.0 to 10.0 at all times.
55
-------
(c) Continuous Rod Casting - Spent Lubricant
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cast by continuous
methods
Chromium 0.0008 0.0003
Cyanide 0.0004 0.0002
Zinc 0.0020 0.0008
Aluminum 0.012 0.0053
Oil & Grease 0.020 0.020
Total Suspended Solids 0.030 0.024
pH ( 1 ) ( 1 )
(1) Within the range of 7.0 to 10.0 at all times.
(d) Solution Heat Treatment - Contact Cooling Water
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum quenched
Chromium 0.754 0.31
Cyanide 0.408 0.16
Zinc 2.08 0.86
Aluminum 12.450 5.52
Oil & Grease 20.37 20.37
Total Suspended Solids 20.56 24.45
pH ( 1 ) ( 1 )
(1) Within the range of 7.0 to 10.0 at all times.
56
-------
(e) Cleaning or Etching - Bath
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.066 0.027
Cyanide 0.036 0.015
Zinc 0.183 0.075
Aluminum 1.094 0.49
Oil & Grease 1.79 1.79
Total Suspended Solids 2.69 2.15
pH ( 1 ) ( 1 )
(1) Within the range of 7.0 to 10.0 at all times.
(f) Cleaning or Etching - Rinse
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.515 0.21
Cyanide 0.278 0.11
Zinc 1.42 0.59
Aluminum 8.50 3.77
Oil & Grease 13.91 13.91
Total Suspended Solids 20.87 16.70
pH ( 1 ) ( 1 )
(1) Within the range of 7.0 to 10.0 at all times.
(g) Cleaning or Etching - Scrubber Liquor
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.72 0.290
Cyanide 0.387 0.155
Zinc 1.97 0.812
Aluminum 1.18 5.24
Oil & Grease 19.33 19.33
Total Suspended Solids 29.00 23.20
pH ( 1 ) ( 1 )
(1) Within the range of 7.0 to 10.0 at all times.
57
-------
5. PSES is being promulgated based on the model treatment tech-
nology of oil skimming and chemical precipitation and sedi-
mentation (lime and settle) technology and in-process flow
reduction control methods, and where applicable, chemical
emulsion breaking, chromium reduction, and cyanide removal. The
following pretreatment standards are being promulgated for
existing sources:
A. PSES FOR THE ROLLING WITH NEAT OILS SUBCATEGORY
(a) Rolling With Neat Oils - Core Waste Streams Without An
Rolling With Neat Oils - Cc
Annealing Furnace Scrubber
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum rolled with neat oils
Chromium 0.025
Cyanide 0.016
Zinc 0.081
Total Toxic Organics (TTO) 0.038
Oil & Grease* 1.11
(b) Rolling With Neat Oils - Core Waste
Annealing Furnace Scrubber
0
0
0
0
Streams With
.010
.007
.034
--
.67
An
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum rolled with neat oils
Chromium 0.036 0.015
Cyanide 0.024 0.010
Zinc 0.119 0.050
Total Toxic Organics (TTO) 0.057
Oil & Grease* 1.64 0.98
58
-------
(c) Continuous Sheet Casting - Spent Lubricant
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/kg (Ib/million Ibs) of aluminum cast by continuous methods
Chromium 0.00086 0.00035
Cyanide 0.00057 0.00024
Zinc 0.0029 0.0012
Total Toxic Organics (TTO) 0.0014
Oil & Grease* 0.040 0.024
*Alternate monitoring limit - oil and grease may be substituted
for TTO.
(d) Solution Heat Treatment - Contact Cooling Water
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum quenched
Chromium 0.90 0.37
Cyanide 0.59 0.25
Zinc 2.98 1.25
Total Toxic Organics (TTO) 1.41
Oil & Grease* 40.74 24.45
(e) Cleaning or Etching - Bath
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.079 0.032
Cyanide 0.052 0.022
Zinc 0.262 0.109
Total Toxic Organics (TTO) 0.124
Oil & Grease* 3.58 2.15
59
-------
Cleaning or Etching - Rinse
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/mil1 ion off-lbs) of aluminum cleaned or etched
Chromium 0.61 0.25
Cyanide 0.41 0.17
Zinc 2.03 0.85
Total Toxic Organics (TTO) 0.96
Oil & Grease* 27.82 16.69
*Alternate monitoring limit - oil and grease may be substituted
for TTO.
(g) Cleaning or Etching - Scrubber Liquor
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.85 0.35
Cyanide 0.56 0.23
Zinc 2.82 1.18
Total Toxic Organics (TTO) 1.34
Oil & Grease* 38.7 23.20
B. PSES FOR THE ROLLING WITH EMULSIONS SUBCATEGORY
(a) Rolling With Emulsions - Core Waste Streams
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum rolled with emulsions
Chromium 0.057 0.024
Cyanide 0.038 O.Olt^
Zinc 0.190 O.O"^
Total Toxic Organics (TTO) 0.090
Oil & Grease* 2.60
60
-------
(b) Direct Chill Casting - Contact Cooling Water
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cast by direct chill
methods
Chromium 0.59 0.24
Cyanide 0.39 0.16
Zinc 1.94 0.81
Total Toxic Organics (TTO) 0.92
Oil & Grease* 26.58 15.95
^Alternate monitoring limit - oil and grease may be substituted
for TTO.
(c) Solution Heat Treatment - Contact Cooling Water
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum quenched
Chromium 0.90 0.37
Cyanide 0.56 0.25
Zinc 2.98 1.24
Total Toxic Organics (TTO) 1.41
Oil & Grease* 40.74 24.44
(d) Cleaning or Etching - Bath
Pollutant orMaximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.079 0.032
Cyanide 0.052 0.022
Zinc 0.262 0.109
Total Toxic Organics (TTO) 0.124
Oil & Grease* 3.58 2.15
61
-------
(e) Cleaning or Etching - Rinse
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/mi11 ion Ibs) of aluminum cleaned or etched
Chromium 0.61 0.25
Cyanide 0.41 0.17
Zinc 2.03 0.85
Total Toxic Organics (TTO) 0.96
Oil & Grease* 27.82 16.69
*Alternate monitoring limit - oil and grease may be substituted
for TTO.
(f) Cleaning or Etching - Scrubber Liquor
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.85 0.35
Cyanide 0.56 0.23
Zinc 2.83 1.18
Total Toxic Organics (TTO) 1.34
Oil & Grease* 38.66 23.20
C. PSES FOR THE EXTRUSION SUBCATEGORY
(a) Extrusion - Core Waste Streams
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum extruded
Chromium 0.15 0.061
Cyanide 0.098 0.041
Zinc 0.49 0.21
Total Toxic Organics (TTO) 0.23
Oil & Grease* 6.80 4.07
62
-------
(b) Direct Chill Casting - Contact Cooling Water
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cast by direct chill
methods
Chromium 0.59 0.24
Cyanide 0.39 0.16
Zinc 1.94 0.81
Total Toxic Organics (TTO) 0.92
Oil & Grease* 26.58 15.95
*Alternate monitoring limit - oil and grease may be substituted
for TTO.
(c) Solution and Press Heat Treatment - Contact Cooling
Water
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum quenched
Chromium 0.90 0.37
Cyanide 0.59 0.25
Zinc 2.98 1.25
Total Toxic Organics (TTO) 1.41
Oil & Grease* 40.74 24.45
(d) Cleaning or Etching - Bath
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.079 0.032
Cyanide 0.052 0.022
Zinc 0.26 0.109
Total Toxic Organics (TTO) 0.124
Oil & Grease* 3.58 2.15
63
-------
(e) Cleaning or Etching - Rinse
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.61 0.25
Cyanide 0.41 0.17
Zinc 2.03 0.85
Total Toxic Organics (TTO) 0.96
Oil & Grease* 27.82 16.69
*Alternate monitoring limit - oil and grease may be substituted
for TTO.
(f) Cleaning or Etching - Scrubber Liquor
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.85 0.35
Cyanide 0.56 0.23
Zinc 2.82 1.18
Total Toxic Organics (TTO) 1.34
Oil & Grease* 38.66 23.20
(g) Extrusion Press Leakage
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of hard alloy aluminum extruded
Chromium 0.65 0.27
Cyanide 0.43 0.18
Zinc 2.16 0.90
Total Toxic Organics (TTO) 1.02
Oil & Grease* 29.56 17.74
64
-------
D. PSES FOR THE FORGING SUBCATEGORY
(a) Forging - Core Waste Streams
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum forged
Chromium 0.022 0.009
Cyanide 0.015 0.006
Zinc 0.073 0.031
Total Toxic Organics (TTO) 0.035
Oil & Grease* 1 . 00 0.60
*Alternate monitoring limit - oil and grease may be substituted
for TTO.
(b) Forging - Scrubber Liquor
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum forged
Chromium 0.042 0.017
Cyanide 0.028 0.011
Zinc 0.14 0.058
Total Toxic Organics (TTO) 0.065
Oil & Grease* 1.89 1.13
(c) Solution Heat Treatment - Contact Cooling Water
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum quenched
Chromium 0.897 0.37
Cyanide 0.591 0.25
Zinc 2.98 1.24
Total Toxic Organics (TTO) 1.41
Oil & Grease* 40.74 24.45
65
-------
(d) Cleaning or Etching - Bath
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.079 0.032
Cyanide 0.052 0.022
Zinc 0.26 0.11
Total Toxic Organics (TTO) 0.123
Oil & Grease* 3. 58 2.15
*Alternate monitoring limit - oil and grease may be substituted
for TTO.
(e) Cleaning or Etching - Rinse
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.61 0.25
Cyanide 0.40 0.17
Zinc 2.03 0.85
Total Toxic Organics (TTO) 0.96
Oil & Grease* 27.82 16.70
(f) Cleaning or Etching - Scrubber Liquor
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.851 0.35
Cyanide 0.561 0.23
Zinc 2.82 1.18
Total Toxic Organics (TTO) 1.34
Oil & Grease* 38.66 23.20
66
-------
E. PSES FOR THE DRAWING WITH NEAT OILS SUBCATEGORY
(a) Drawing With Neat Oils - Core Waste Streams
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum drawn with neat oils
Chromium 0.022 0.009
Cyanide 0.015 0.006
Zinc 0.073 0.031
Total Toxic Organics (TTO) 0.035
Oil & Grease* 1.00 0.60
*Alternate monitoring limit - oil and grease may be substituted
for TTO.
(b) Continuous Rod Casting - Contact Cooling Water
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cast by continuous
methods
Chromium 0.086 0.035
Cyanide 0.057 0.023
Zinc 0.283 0.118
Total Toxic Organics (TTO) 0.133
Oil & Grease* 3.878 2.327
(c) Continuous Rod Casting - Spent Lubricant
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cast by continuous
methods
Chromium 0.0009 0.0004
Cyanide 0.0006 0.0003
Zinc 0.0029 0.0012
Total Toxic Organics (TTO) 0.0014
Oil & Grease* 0.040 0.024
67
-------
(d) Solution Heat Treatment - Contact Cooling Water
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum quenched
Chromium 0.896 0.367
Cyanide 0.591 0.245
Zinc 2.98 1.24
Total Toxic Organics (TTO) 1.41
Oil & Grease* 40.74 24.45
*Alternate monitoring limit - oil and grease may be substituted
for TTO.
(e) Cleaning or Etching - Bath
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.079 0.033
Cyanide 0.052 0.022
Zinc 0.262 0.109
Total Toxic Organics (TTO) 0.124
Oil & Grease* 3.58 2.15
(f) Cleaning or Etching - Rinse
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.612 0.251
Cyanide 0.404 0.17
Zinc 2.03 0.85
Total Toxic Organics (TTO) 0.96
Oil & Grease* 27.82 16.70
68
-------
(g) Cleaning or Etching - Scrubber Liquor
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.851 0.348
Cyanide 0.561 0.232
Zinc 2.82 1.18
Total Toxic Organics (TTO) 1.34
Oil & Grease* 38.66 23.20
*Alternate monitoring limit - oil and grease may be substituted
for TTO.
F. PSES FOR THE DRAWING WITH EMULSIONS OR SOAPS SUBCATEGORY
(a) Drawing With Emulsions or Soaps - Core Waste Streams
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum drawn with emulsions
or soaps
Chromium 0.205 0.084
Cyanide 0.135 0.056
Zinc 0.681 0.285
Total Toxic Organics (TTO) 0.32
Oil & Grease* 9.33 5.60
(b) Continuous Rod Casting - Contact Cooling Water
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cast by continuous
methods
Chromium 0.086 0.035
Cyanide 0.056 0.024
Zinc 0.283 0.119
Total Toxic Organics (TTO) 0.134
Oil & Grease* 3.88 2.33
69
-------
(c) Continuous Rod Casting - Spent Lubricant
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cast by continuous
methods
Chromium 0.0009 0.0004
Cyanide 0.0006 0.0003
Zinc 0.0029 0.0012
Total Toxic Organics (TTO) 0.0014
Oil & Grease* 0.040 0.024
*Alternate monitoring limit - oil and grease may be substituted
for TTO.
(d) Solution Heat Treatment - Contact Cooling Water
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum quenched
Chromium 0.896 0.367
Cyanide 0.591 0.245
Zinc 2.98 1.25
Total Toxic Organics (TTO) 1.41
Oil & Grease* 40.74 24.44
(e) Cleaning or Etching - Bath
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.079 0.032
Cyanide 0.052 0.022
Zinc 0.262 0.11
Total Toxic Organics (TTO) 0.124
Oil & Grease* 3.58 2.15
70
-------
(f) Cleaning or Etching - Rinse
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.612
Cyanide 0.404
Zinc 2.03
Total Toxic Organics (TTO) 0.96
Oil & Grease* 27.82
0.251
0. 167
0.849
16.69
*Alternate monitoring limit - oil and grease may be substituted
for TTO.
(g) Cleaning or Etching - Scrubber Liquor
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.851
Cyanide 0.561
Zinc 2.82
Total Toxic Organics (TTO) 1.34
Oil & Grease* 38.66
0.348
0.232
1.18
23.20
6. PSNS is being promulgated based on the model treatment tech-
nology of oil skimming and chemical precipitation, sedimentation
and filtration (lime, settle, and filter) technology and in-
process flow reduction control methods, and where applicable,
chemical emulsion breaking, chromium reduction, and cyanide
removal. The following pretreatment standards are being
promulgated for new sources:
71
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A. PSNS FOR THE ROLLING WITH NEAT OILS SUBCATEGORY
(a) Rolling With Neat Oils - Core Waste Streams Without An
Annealing Furnace Scrubber
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs} of aluminum rolled with neat oils
Chromium 0.021 0.009
Cyanide 0.011 0.005
Zinc 0.057 0.024
Total Toxic Organics (TTO) 0.038
Oil & Grease* ' 0.54 0.54
*Alternate monitoring limit - oil and grease may be substituted
for TTO.
(b) Rolling With Neat Oils - Core Waste Streams With An
Annealing Furnace Scrubber
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum rolled with neat oils
Chromium 0.030 0.013
Cyanide 0.017 0.007
Zinc 0.084 0.035
Total Toxic Organics (TTO) 0.057
Oil & Grease* 0.817 0.817
(c) Continuous Sheet Casting - Spent Lubricant
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cast by continuous
methods
Chromium 0.00073 0.00029
Cyanide 0.00039 0.00016
Zinc 0.0020 0.00082
Total Toxic Organics (TTO) 0.0014
Oil & Grease* 0.020 0.020
72
-------
(d) Solution Heat Treatment - Contact Cooling Water
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum quenched
Chromium 0.76 0.31
Cyanide 0.41 0.17
Zinc 2.08 0.86
Total Toxic Organics (TTO) 1.41
Oil & Grease* 20.37 20.37
*Alternate monitoring limit - oil and grease may be substituted
for TTO.
(e) Cleaning or Etching - Bath
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.067 0.027
Cyanide 0.036 0.015
Zinc 0.183 0.075
Total Toxic Organics (TTO) 0.124
Oil & Grease* 1.79 1 .79
(f) Cleaning or Etching - Rinse
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.52 0.21
Cyanide 0.28 0.11
Zinc 1.42 0.59
Total Toxic Organics (TTO) 0.96
Oil & Grease* 13.91 13.91
73
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(g) Cleaning or Etching - Scrubber Liquor
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.72 0.29
Cyanide 0.39 0.16
Zinc 1 .97 0.81
Total Toxic Organics (TTO) 1.34
Oil & Grease* 19.33 19.33
*Alternate monitoring limit - oil and grease may be substituted
for TTO.
B. PSNS FOR THE ROLLING WITH EMULSIONS SUBCATEGORY
(a) Rolling With Emulsions - Core Waste Streams
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum rolled with emulsions
Chromium 0.048 0.020
Cyanide 0.026 0.011
Zinc 0.133 0.055
Total Toxic Organics (TTO) 0.090
Oil & Grease* 1.30 1.30
(b) Direct Chill Casting - Contact Cooling Water
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cast by direct chill
methods
Chromium 0.49 0.20
Cyanide 0.27 0.11
Zinc 1 .36 0. 56
Total Toxic Organics (TTO) 0.92
Oil & Grease* 13.29 13.29
74
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(c) Solution Heat Treatment - Contact Cooling Water
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum quenched
Chromium 0.76 0.31
Cyanide 0.41 0.17
Zinc 2.08 0.86
Total Toxic Organics (TTO) 1.41
Oil & Grease* 20.37 20.37
*Alternate monitoring limit - oil and grease may be substituted
for TTO.
(d) Cleaning or Etching - Bath
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.079 0.032
Cyanide 0.052 0.022
Zinc 0.26 0.109
Total Toxic Organics (TTO) 0.00 0.00
Oil & Grease* 0.00 0.00
(e) Cleaning or Etching - Rinse
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.52 0.21
Cyanide 0.28 0.11
Zinc 1.42 0.59
Total Toxic Organics (TTO) 0.96
Oil & Grease* 13.91 13.91
75
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(f) Cleaning or Etching - Scrubber Liquor
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.72 0.29
Cyanide 0.39 0.16
Zinc 1.97 0.81
Total Toxic Organics (TTO) 1.34
Oil & Grease* 19.33 19.33
*Alternate monitoring limit - oil and grease may be substituted
for TTO.
C. PSNS FOR THE EXTRUSION SUBCATEGORY
(a) Extrusion - Core Waste Streams
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/mil1 ion off-lbs) of aluminum extruded
Chromium 0.13 0.05
Cyanide 0.07 0.03
Zinc 0.35 0.15
Total Toxic Organics (TTO) 0.24
Oil & Grease* 3.40 3.40
(b) Direct Chill Casting - Contact Cooling Water
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cast by direct chill
methods
Chromium 0.49 0.05
Cyanide 0.27 0.03
Zinc 1.36 0.13
Total Toxic Organics (TTO) 0.92
Oil & Grease* 13.29 2.98
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(c) Solution and Press Heat Treatment - Contact Cooling
Water
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum quenched
Chromium 0.76 0.31
Cyanide 0.41 0.17
Zinc 2.08 0.86
Total Toxic Organics (TTO) 1.41
Oil & Grease* 20.37 20.37
*Alternate monitoring limit - oil and grease may be substituted
for TTO.
(d) Cleaning or Etching - Bath
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.067 0.027
Cyanide 0.036 0.015
Zinc 0.183 0.075
Total Toxic Organics (TTO) 0.00 0.00
Oil & Grease* 1.79 1.79
(e) Cleaning or Etching - Rinse
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.52 0.21
Cyanide 0.28 0.11
Zinc 1.42 0.59
Total Toxic Organics (TTO) 0.96
Oil & Grease* 13.91 13.91
77
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f) Cleaning or Etching - Scrubber Liquor
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.72
Cyanide 0.39
Zinc 1.97
Total Toxic Organics (TTO) 1.34
Oil & Grease* 19.33
0.29
0. 16
0.81
19.33
*Alternate monitoring limit - oil and grease may be substituted
for TTO.
(g) Extrusion Press Leakage
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/off-kg (Ib/million off-lbs) of hard alloy aluminum extruded
Chromium 0.11
Cyanide 0.06
Zinc 0.31
Total Toxic Organics (TTO) 0.21
Oil & Grease* 2.98
D. PSNS FOR THE FORGING SUBCATEGORY
(a) Forging - Core Waste Streams
0.05
0.03
0.13
2.98
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum forged
Chromium 0.019
Cyanide 0.010
Zinc 0.051
Total Toxic Organics (TTO) 0.035
Oil & Grease* 0.50
0.008
0.004
0.021
0.50
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(b) Forging - Scrubber Liquor
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum forged
Chromium 0.035 0.014
Cyanide 0.019 0.008
Zinc 0.096 0.040
Total Toxic Organics (TTO) 0.065
Oil & Grease* 0.95 0.95
*Alternate monitoring limit - oil and grease may be substituted
for TTO.
(c) Solution Heat Treatment - Contact Cooling Water
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum quenched
Chromium 0.76 0.31
Cyanide 0.41 0.16
Zinc 2.08 0.86
Total Toxic Organics (TTO) 1.41
Oil & Grease* 20.37 20.37
(d) Cleaning or Etching - Bath
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.066 0.027
Cyanide 0.036 0.015
Zinc 0.183 0.075
Total Toxic Organics (TTO) 0.124
Oil & Grease* 1.79 1.79
79
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» Cleaning or Etching - Rinse
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.52
Cyanide 0.28
Zinc 1.42
Total Toxic Organics (TTO) 0.96
Oil & Grease* 13.91
0 . 21
0. 1 1
0. 59
13.91
*Alternate monitoring limit - oil and grease may be substituted
for TTO.
(f) Cleaning or Etching - Scrubber Liquor
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/off-kg (Ib/mi11 ion off-lbs) of aluminum cleaned or etched
Chromium 0.72
Cyanide 0.39
Zinc 1.97
Total Toxic Organics (TTO) 1.34
Oil & Grease* 19.33
E. PSNS FOR THE DRAWING WITH NEAT OILS SUBCATEGORY
(a) Drawing With Neat Oils - Core Waste Streams
0. 29
0. 16
0. 812
19.33
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum drawn with neat oils
Chromium 0.019
Cyanide 0.010
Zinc 0.051
Total Toxic Organics (TTO) 0.035
Oil & Grease* 0.50
0. 008
0.004
0.021
0.50
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(b) Continuous Rod Casting - Contact Cooling Water
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cast by continuous
methods
Chromium 0.072 0.029
Cyanide 0.039 0.016
Zinc 0.198 0.082
Total Toxic Organics (TTO) 0.134
Oil & Grease* 1 .94 1 .94
*Alternate monitoring limit - oil and grease may be substituted
for TTO.
(c) Continuous Rod Casting - Spent Lubricant
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cast by continuous
methods
Chromium 0.0007 0.0003
Cyanide 0.0004 0.0002
Zinc 0.0020 0.0008
Total Toxic Organics (TTO) 0.0014
Oil & Grease* 0.020 0.020
(d) Solution Heat Treatment - Contact Cooling Water
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum quenched
Chromium 0.76 0.306
Cyanide 0.41 0.163
Zinc 2.08 0.856
Total Toxic Organics (TTO) 1.41
Oil & Grease* 20.37 20.37
81
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!e) Cleaning or Etching - Bath
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.067
Cyanide 0.036
Zinc 0.183
Total Toxic Organics (TTO) 0.124
Oil & Grease* 1.79
0.027
0.015
0.075
1 .79
*Alternate monitoring limit - oil and grease may be substituted
for TTO.
(f) Cleaning or Etching - Rinse
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.52 0.21
Cyanide 0.28 0.11
Zinc 1.42 0.59
Total Toxic Organics (TTO) 0.96
Oil & Grease* 13.91 13.91
(g) Cleaning or Etching - Scrubber Liquor
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.72
Cyanide 0.39
Zinc 1.97
Total Toxic Organics (TTO) 1.34
Oil & Grease* 19.33
0.29
0. 16
0. 812
1 9 ,. 3 3
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F. PSNS FOR THE DRAWING WITH EMULSIONS OR SOAPS SUBCATEGORY
(a) Drawing With Emulsions or Soaps - Core Waste Streams
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum drawn with emulsions
or soaps
Chromium 0.173 0.070
Cyanide 0.094 0.038
Zinc 0.48 0.196
Total Toxic Organics (TTO) 0.32
Oil & Grease 4.67 4.67
*Alternate monitoring limit - oil and grease may be substituted
for TTO.
(b) Continuous Rod Casting - Contact Cooling Water
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cast by continuous
methods
Chromium 0.072 0.029
Cyanide 0.039 0.016
Zinc 0.198 0.082
Total Toxic Organics (TTO) 0.134
Oil & Grease* 1.94 1.94
(c) Continuous Rod Casting - Spent Lubricant
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cast by continuous
methods
Chromium 0.0007 0.0003
Cyanide 0.0004 0.0002
Zinc 0.0020 0.0008
Total Toxic Organics (TTO) 0.0014
Oil & Grease* 0.020 0.020
83
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(d) Solution Heat Treatment - Contact Cooling Water
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum quenched
Chromium 0.76 0.306
Cyanide 0.41 0.163
Zinc 2.08 0.856
Total Toxic Organics (TTO) 1.41
Oil & Grease* 20.37 20.37
*Alternate monitoring limit - oil and grease may be substituted
for TTO.
(e) Cleaning or Etching - Bath
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.067 0.027
Cyanide 0.036 0.015
Zinc 0.183 0.075
Total Toxic Organics (TTO) 0.124
Oil & Grease* 1.79 1.79
(f) Cleaning or Etching - Rinse
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.52 0.21
Cyanide 0.28 0.11
Zinc 1.42 0.59
Total Toxic Organics (TTO) 0.96
Oil & Grease* 13.91 13.91
84
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(g) Cleaning or Etching - Scrubber Liquor
Pollutant or Maximum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/off-kg (Ib/million off-lbs) of aluminum cleaned or etched
Chromium 0.715 0.290
Cyanide 0.387 0.155
Zinc 1.97 0.812
Total Toxic Organics (TTO) 1.34
Oil & Grease* 19.33 19.33
*Alternate monitoring limit - oil and grease may be substituted
for TTO.
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SECTION III
INTRODUCTION
LEGAL AUTHORITY
The Federal Water Pollution Control Act Amendments of 1972
established a comprehensive program to "restore and maintain the
chemical, physical, and biological integrity of the Nation's
waters" (Section 101(a)). To implement the Act, EPA was to issue
effluent limitations guidelines, pretreatment standards, and new
source performance standards for industry dischargers.
The Act included a timetable for issuing these standards. How-
ever, EPA was unable to meet many of the deadlines and, as a
result, in 1976, it was sued by several environmental groups.
In settling this lawsuit, EPA and the plaintiffs executed a
court-approved "Settlement Agreement." This Agreement required
EPA to develop a program and adhere to a schedule in promulgating
effluent limitations guidelines, new source performance stan-
dards, and pretreatment standards for 65 "priority" pollutants
and classes of pollutants for 21 major industries. See Natural
Resources Defense Council, Inc. v. Train, 8 ERC 2120 (D.D.C.
1976), modified, 12 ERC 1833 (D.D.C. 1979), modified by Orders
dated October 26, 1982 and August 2, 1983.
Many of the basic elements of this Settlement Agreement program
were incorporated into the Clean Water Act of 1977. Like the
Agreement, the Act stressed control of toxic pollutants, includ-
ing the 65 "priority" pollutants. In addition to strengthening
the toxic control program, Section 304(e) of the Act authorizes
the Administrator to prescribe "best management practices" (BMP)
to prevent the release of toxic and hazardous pollutants from
plant site runoff, spillage or leaks, sludge or waste disposal,
and drainage from raw material storage associated with, or ancil-
lary to, the manufacturing or treatment process.
The purpose of this document is to provide the supporting techni-
cal data regarding water use, pollutants, and treatment technolo-
gies for BPT, BAT, NSPS, PSES, and PSNS effluent limitations that
EPA is promulgating for the aluminum forming category under
Sections 301, 304, 306, 307, 308, and 501 of the Clean Water Act.
DATA COLLECTION AND UTILIZATION
EPA gathered and evaluated technical data in the course of
developing these guidelines in order to perform the following
tasks:
87
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1. To profile the category with regard to the production,
manufacturing processes, geographical distribution,
potential wastewater streams, and discharge mode of
aluminum forming plants.
2. To subcategorize, if necessary, in order to permit
regulation of the aluminum forming category in an
equitable and manageable way. This was done by taking
all of the factors mentioned above plus others into
account.
3. To characterize wastewater, detailing water use, waste-
water discharge, and the occurrence of priority,
conventional, and nonconventional pollutants, in waste
streams from aluminum forming processes..
4. To select pollutant parametersthose priority, conven-
tional, and nonconventional pollutants present at
significant concentrations in wastewater streamsthat
should be considered for regulation.
5. To consider control and treatment technologies and
select alternative methods for reducing pollutant dis-
charge in this category.
6. To consider the costs of implementing the alternative
control and treatment technologies.
7. To present possible regulatory alternatives.
Sources of Industry Data
Data on the aluminum forming category were gathered from previous
EPA studies, literature studies, inquiries to federal and state
environmental agencies, raw material manufacturers and suppliers,
trade association contacts, and the aluminum forming manufac-
turers themselves. Additionally, meetings were held with indus-
try representatives and the EPA. All known aluminum formers were
sent a data collection portfolio (dcp) requesting specific infor-
mation concerning each facility. Finally, a sampling program was
carried out at 25 plants. The sampling program consisted of
screen sampling and analysis at four facilities to determine the
presence of a broad range of pollutants and verification at 21
plants to quantify the pollutants present in aluminum forming
wastewater. Specific details of the sampling program and infor-
mation from the above data sources are presented in Section V.
After proposal on November 22, 1982, a large number of public
comments were received on the proposed regulation and supporting
documents, many containing additional data about the category.
88
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The Agency sent out requests for additional information and data
to 13 commenters and visited six facilities; sampling and analy-
ses were performed at five of those plants. On July 27, 1983, a
notice was published in the Federal Register (49 FR 34079)
announcing the availability of additional data for review and
comment. All additional information obtained since proposal
which arrived in a timely manner and all comments on the proposed
regulation were considered in preparing the final regulation.
Literature Review. EPA reviewed and evaluated existing
literature for background information to clarify and define
various aspects of the aluminum forming category and to determine
general characteristics and trends in production processes and
wastewater treatment technology. Review of current literature
continued throughout the development of these guidelines.
Plant Survey and Evaluation. The aluminum forming plants were
surveyed to gather information regarding plant size, age and
production, the production processes used, and the quantity,
treatment, and disposal of wastewater generated at these plants.
This information was requested in dcp's mailed to all companies
known or believed to be involved in the forming of aluminum or
aluminum alloys. The original mailing list was compiled from the
following sources:
U.S. Department of Commerce, Directory of Aluminum
Suppliers in the United States, Revised January 1978.
Architectural Aluminum Manufacturers Association,
Membership Directory, 1977.
- Aluminum Foil Container Manufacturers Association,
Membership Roster as of May 1, 1978.
- Dun & Bradstreet, Inc., Million Dollar Directory, 1978.
In all, dcp's were sent to 580 firms. Approximately 95 percent
of the companies responded to the survey. In many cases, compa-
nies contacted were not actually members of the aluminum forming
category as it is defined by the Agency. Where firms had alumi-
num forming operations at more than one location, a dcp was
requested from each plant. A total of 279 dcp's applicable to
the aluminum forming category were returned. Two plants had
ceased aluminum forming operations before proposal and a total of
277 plants were included in the data base at proposal. Subse-
quent to proposal, the Agency became aware of three plants which
have closed and three additional plants which have ceased alumi-
num forming operations. Therefore, a total of 271 plants are
included in the data base. In cases where the dcp responses were
89
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incomplete or unclear, additional information was requested by
telephone or letter.
The dcp responses were interpreted individually, and the follow-
ing data were documented for future reference and evaluation:
Company name, plant address, and name of the contact
listed in the dcp.
Plant discharge status as direct (to surface water),
indirect (to POTW), or zero discharge.
Production process streams present at the plant, as well
as associated flow rates; production rates; operating
hours; wastewater treatment, reuse, or disposal methods;
the quantity and nature of process chemicals; and the
percent of any soluble oil used in emulsified mixtures.
Capital and annual treatment costs.
Availability of pollutant monitoring data provided by the
plant.
The summary listing of this information provided a consistent,
systematic method of evaluating and summarizing the dcp
responses. In addition, procedures were developed to simplify
subsequent analyses. The procedures developed had the following
capabi1ities:
Selection and listing of plants containing specific pro-
duction process streams or treatment technologies.
Summation of the number of plants containing specific
process stream and treatment combinations.
Calculation of the percent recycle present for specific
streams and summation of the number of plants recycling
this stream within various percent recycle ranges.
Calculation of annual production values associated with
each process stream and summation of the number of plants
with these process streams having production values
within various ranges.
Calculation of water use and blowdown from individual
process streams.
In addition to industry data obtained from dcp's, telephone con-
tacts were made with plants in the aluminum forming category to
expand the Agency's information on extrusion die cleaning baths,
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rinses, and scrubbers, and on the roll grinding operations.
Telephone contacts also served to clarify information contained
in the dcp's.
The calculated information and summaries were important and fre-
quently used in the development of this guideline. Summaries
were used in the category profile, evaluation of subcategoriza-
tion, and analysis of in-place treatment and control technolo-
gies. Calculated information was used in the determination of
water use and discharge values for the conversion of pollutant
concentrations to mass loadings.
Utilization of_ Industry Data
Data collected from the previously listed sources are used
throughout this report in the development of a base for BPT and
BAT limitations and NSPS and pretreatment standards. Previous
EPA studies as well as the literature provided the basis for the
aluminum forming subcategorization discussed in Section IV. Raw
wastewater characteristics for each subcategory presented in Sec-
tion V were obtained from the screening and verification sam-
pling. Selection of pollutant parameters for control (Section
VI) was based on verification and screening sampling results.
These provided information on both the pollutants which the plant
personnel felt were in their wastewater discharges and those
pollutants specifically found in aluminum forming wastewaters as
the result of sampling. Based on the selection of pollutants
requiring control and their levels, applicable treatment technol-
ogies were identified and these are described in Section VII of
this document. Actual wastewater treatment technologies utilized
by aluminum forming plants (as identified in the dcp responses
and observed at the sampled plants) were also used to identify
applicable treatment technologies. The costs of treatment (both
individual technologies and systems) were based primarily on data
from equipment manufacturers and literature and are contained in
Section VIII of this document. Finally, dcp data, sampling data,
and estimated treatment system performance are utilized in
Sections IX, X, XI, and XII (BPT, BAT, NSPS, and pretreatment,
respectively) in the selection of applicable treatment systems;
the presentation of achievable effluent levels; and the presen-
tation of actual effluent levels obtained for each aluminum
forming subcategory.
DATA COLLECTION SINCE PROPOSAL
After proposal of the Aluminum Forming Regulation, EPA provided a
75 day comment period, which closed on February 8, 1983. EPA
received approximately 1,000 individual comments from 24 differ-
ent commenters. The Agency gathered additional data after
91
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proposal to
regulation.
clarify data and to provide further support for the
Under authority of Section 308 of the Clean Water Act, the Agency
requested specific additional information and data from 13 com-
menters to clarify and support their individual comments. The
Agency's request for information asked each commenter to provide
specific information supporting their particular comments.
Responses were received from all of the 13 commenters. The
additional data and information received related primarily to
wastewater sources not specifically considered by the proposed
regulation; space limitations and retrofit problems involved with
the installation of two-stage countercurrent rinsing; and the
classification and disposal costs of solid wastes generated by
wastewater treatment. We received flow and production data for
additional waste streams as well as information on treatment and
characteristics of these streams. Plan view diagrams were sub-
mitted by two companies to show space availability for counter-
current cascade rinsing. We also received information regarding
operating schedules for surface treatment lines. Cost informa-
tion was submitted for solid waste disposal as well as copies of
correspondence with disposal companies and state or local author-
ities. We also received new technical information' on the
regeneration of cleaning and etching baths.
To supplement existing data regarding treatment-in-place and the
long-term performance of that treatment, we collected discharge
monitoring report (DMR) data from state or EPA Regional offices
for direct dischargers. DMR data are self-monitoring data sup-
plied by permit holders to meet state or EPA permit requirements.
These data were available from 30 aluminum forming plants;
however, the data vary widely in character and nature due to the
dissimilar nature of the monitoring and reporting requirements
placed on aluminum forming plants by the NPDEIS permit issuing
authority. These data were not used in the actuail development of
the final limitations but DMR data from 11 plants that have lime
and settle treatment were used as a check on the achievability of
the treatment effectiveness values used to establish limitations
and standards. A discussion on these DMR data arid a comparison
of them to the treatment effectiveness values used in this regu-
lation is found in the administrative record to this rulemaking.
The existing treatment effectiveness data were reviewed thor-
oughly following proposal. As a result of this review, minor
additions and deletions were made to the Agency's treatment
effectiveness data base. These changes are documented in the
record along with responses to comments. Following the changes,
statistical analyses performed prior to proposal were repeated.
Conclusions reached prior to proposal were unchanged and little
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or no effect on the
changes in the data.
final limitations occurred as a result of
Additional data were obtained from 17 plants that perform anodiz-
ing and conversion coating operations as an integral part of
their aluminum forming extrusion operations. These data,
obtained by site visits, telephone contacts, and letter requests,
were used to expand the process configuration, production, and
wastewater flow information obtained during the Agency's 1978
data collection effort with regard to plants which perform
anodizing and conversion coating. These data were used to
characterize wastewater flows and subsequently estimate cost of
compliance for these plants.
Since proposal, the Agency made engineering visits to six alumi-
num forming plants to determine the flow characteristics of 12
wastewater streams (sawing spent lubricant, roll grinding spent
lubricant, die cleaning baths, extrusion press hydraulic leakage,
detergent cleaning baths and rinses, anodizing baths and rinses,
dye baths and rinses, and sealing baths and rinses). Addition-
ally, we collected samples for chemical analysis at five of these
plants to determine the nature of the above wastewater streams
and the effectiveness of end-of-pipe treatment in removing pollu-
tants, primarily aluminum. In addition to the wastewater streams
listed above, we sampled a variety of process wastewaters to
characterize treatment effectiveness.
A notice of data availability was published in the Federal
Register on July 27, 1983 and the comment period for this notice
ended on August 11, 1983.
The data described above were analyzed and incorporated with the
data collected prior to proposal, and were used in the develop-
ment of the final effluent limitations guidelines and standards
delineated in this document. A further discussion of how these
additional data were used is presented in the appropriate
sections of this document.
DESCRIPTION OF THE ALUMINUM FORMING CATEGORY
The aluminum forming industry is generally included within SIC
3353, 3354, 3355, and 3463 of the Standard Industrial Classifica-
tion Manual, prepared in 1972 and supplemented in 1977 by the
Office of Management and Budget, Executive Office of the
President.
Aluminum forming is the deformation of aluminum or aluminum
alloys into specific shapes by hot or cold working such as roll-
ing, extrusion, forging, and drawing. Also included are a number
of ancillary operations such as casting, heat treatment, and sur-
93
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face treatment that are an integral part of aluminum forming pro-
cesses and that can contribute significantly to the wastewaters
discharged from aluminum forming plants. For the purposes of
this regulation, surface treatment is considered to be a part of
aluminum forming whenever it is performed as an integral part of
aluminum forming. All surface treatment of aluminum is consid-
ered to be an integral part of aluminum forming whenever it is
performed at the same plant site at which aluminum is formed.
The manufacture of aluminum powders and the forming of parts from
aluminum or aluminum alloy powders will be regulated under the
nonferrous metals forming regulation. Casting done at a plant
which manufactures aluminum and also does aluminum forming will
be subject to the casting limitations for the aluminum manufac-
turing subcategories of the nonferrous metals category if they
cast the aluminum without cooling. If the aluminum is a remelted
primary aluminum product and is cast at a facility for subsequent
forming of aluminum, then the casting of remelted aluminum will
be subject to the aluminum forming limitations.
Historical
The dcp responses indicate that 156 companies own 271 aluminum
forming plants. Five of the companies own 22 percent of the
plants, and 16 companies own 42 percent of the production
facilities.
Employment data is given in the dcp responses for 248 plants (89
percent of the total). These plants report a total of 28,557
workers involved in aluminum forming. Employment at the indi-
vidual sites ranges from one to 2,100 people. The employment
distribution of aluminum forming workers at the 248 plants is: 69
percent employ fewer than 100 people in aluminuir forming
operations; 83 percent employ fewer than 200 people in this
capacity; and 95 percent employ fewer than 500 people.
Aluminum forming plants are not limited to any one geographical
location. As shown in Figure 111-2, plants are found throughout
most of the United States, but the majority are located east of
the Mississippi River. Population density is not a limiting
factor in plant location. Aluminum forming plants tend to be
more common in urban areas, but they are frequently found in
rural areas as well.
The majority of the aluminum forming plants (55 percent) that
reported the age of their facility indicated they were built
since 1957. Table III-2 shows the age distribution of aluminum
forming plants according to their classification as direct,
indirect, and zero discharge type. The dates of most recent
modification were reported by 230 plants. The distribution of
facilities according to time elapsed since their last major plant
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modification is given in Table III-3. Of the 271 aluminum
forming plants, 44 percent have been modified since 1972.
Product Description
There are a number of advantages to using aluminum in a wide
variety of products. Chief among these are that aluminum is
lightweight, tough, resistant to corrosion, and has high elec-
trical conductivity. The major uses of aluminum are in the
building and construction industry, transportation industries,
the electrical products industry, and in container and package
manufacturing.
Products manufactured by aluminum forming operations generally
serve as stock for subsequent fabricating operations, as shown in
Figure III-l. Cast ingots and billets are the starting point for
making sheet and plate, extrusions, and forgings, as well as rod,
for use in drawing operations. Rolled aluminum sheet and plate
can be used as stock for stampings, can blanks, and roll formed
products; as finished products in building, ship and aircraft
construction; or as foil. Extrusions can be used as raw stock
for forging and drawing; to fabricate final products, such as
bumpers, window frames, or light standards; or can be sold as
final products, such as beams or extruded tubing. Forgings are
either sold as consumer products or used as parts in the
production of machinery, aircraft, and engines.
The variety and type of products produced at one location has a
large influence on the production capacity of the forming plant,
the number of people employed, and the amount of water used. The
capital intensive investment, large source of energy required,
and specialized labor force involved in making aluminum sheet,
strip, foil, and plate products limit the number of facilities
available to meet the demand for these sheet products. Most
sheet products are made at a few large plants owned by major com-
panies. Table III-l summarizes data about these and other prod-
ucts of aluminum forming. A variety of sheet products are often
produced at the same location. Other products, such as billets
and extrusions, are frequently made in conjunction with the
rolled products at these plants.
Tubes, rod, cable, and wire are produced at sites that range in
size from very large to small. On a mass basis most drawn
products are produced by a few large companies or factories,
while the remainder are produced by a number of smaller firms.
Employment varies from a few to several hundred people.
Extrusion and forging processes, which produce a wide variety of
products, do not require large facilities. Consequently, extru-
sion and forging products are formed at many sites by a number of
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companies. Production and employment at facilities using either
type of process range from small plants with few workers to large
plants with hundreds of employees. Some extrusion plants have
other forming operations as well. Forging, however, is usually
performed by plants that are not involved in other processes.
Casting in the aluminum forming category, both continuous and
direct chill, is done prior to another operation, such as rolling
or extrusion. Aluminum billets or ingots are rarely cast at
aluminum forming plants for sale to other industries or firms.
Stationary casting in this industry usually involves only melted
in-plant scrap aluminum. The ingots, frequently called pigs or
sows, produced from stationary casting are normally remelted and
used as stock for continuous or direct chill casting.
Reported production of formed aluminum at individual plant sites
ranged from .09 kkg (0.1 ton) to almost 360,000 kkg (400,000
tons) during 1977. The aluminum forming production distribution
for the 249 plants, for which 1977 production data were availa-
ble, is summarized as fellows: 75 percent produced less than
9,000 kkg (10,000 tons); 96 percent produced less than 45,000 kkg
(50,000 tons); and 98 percent- produced less than 180,000 kkg
(200,000 tons).
One hundred forty plants indicated that no wastewater from alumi-
num forming operations is discharged to either surface waters or
a POTW. Of the remaining 131, 59 discharge an effluent from
aluminum forming directly to surface waters, and 72 discharge
indirectly, sending aluminum forming effluent through a POTW.
The volume of aluminum forming wastewater discharged by plants in
this category ranges from 0 to 2,896,000 liters per hour (0 to
765,000 gal/hr). The mean volume is approximately 74,000 liters
per hour (19,540 gal/hr) for those plants having discharges. Two
hundred fifty-nine plants supplied wastewater data. This is less
than the total number of aluminum forming plants in the category
because several plants did not provide enough information to cal-
culate the flows. Of these 259 plants, over 50 percent reported
no wastewater discharge from aluminum forming operations; 90 per-
cent discharge less than 19,000 liters per hour (5,000 gal/hr);
and 98 percent discharge less than 190,000 liters per hour
(50,000 gal/hr). There is no correlation between overall water
use and total aluminum production for a plant as a whole;
however, correlations can be developed between water use or
wastewater discharge and production on a process basis. This is
discussed further in Section V.
Sixty plants reported some form of treatment for wastewater from
aluminum forming processes. Another 13 plants mentioned treat-
ment only for wastes not covered under the aluminum forming
category. The most common forms of wastewater treatment are pH
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adjustment, clarification, gravity oil separation (skimming), and
lagoons. Recirculation including in-line filtration and cooling
towers are frequently used as wastewater controls. Other flow
reduction techniques demonstrated include countercurrent cascade
and spray rinsing. Oily wastes are separated into oil and water
fractions by emulsion breaking using heat or chemicals. Gravity
separation is frequently used to separate neat oil and broken
emulsions from the water fraction. The oil portion is usually
removed by a contractor, although some plants dispose of it by
land application, incineration, or lagooning. Wastewater
treatment sludges generally are not thickened, but are disposed
of without treatment; however, vacuum and pressure filters, cen-
trifuges, and drying beds are occasionally used. Sludge disposal
methods include landfill and contractor removal. Disposal of
wastewater is being accomplished by discharge to surface waters
or a POTW, by contractor removal, or by land application.
DESCRIPTION OF ALUMINUM FORMING PROCESSES
Aluminum forming processes, for the purpose of this guideline,
are those manufacturing operations in which aluminum or aluminum
alloys are shaped into semifinished or mill products by hot or
cold working. An aluminum alloy is defined, for the purposes of
this regulation, as any metal in which aluminum is the major
component by percent composition. Frequently used alloying
materials include silicon, zinc, copper, manganese, iron, magne-
sium, titanium, and nickel. The content of these alloying mate-
rials in aluminum generally ranges from 3 to 12 percent. Alloys
are formulated to produce a metal with improved characteristics
such as good machinability, hardness, strength, high resistance
to corrosion, and good castability.
The manufacturing operations, called core operations (see Section
IV), include rolling, extruding, forging and drawing of aluminum.
Associated processes, called ancillary operations, such as the
casting of aluminum alloys for subsequent forming, heat
treatment, cleaning, and etching are also included.
Water is used in combination with oil lubricants, surface pro-
cessing chemicals, and in contact cooling as a part of these
operations in order to achieve specified desired metal character-
istics (i.e., tensile strength, malleability, specific surface
properties). Water may also be used in wet air pollution control
devices (i.e., wet scrubbers, electrostatic precipitators) to
collect fumes and particulates. A further discussion of waste-
water sources from aluminum forming processes is presented in
Section V. Regulatory flow allowances for waste streams under
BPT, BAT, NSPS, and pretreatment standards are presented and
discussed in Sections IX, X, XI, and XII respectively.
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EPA recognizes that plants sometimes combine non-aluminum forming
process and nonprocess wastewater prior to treatment and dis-
charge. Pollutant discharge allowances will be established only
for aluminum forming process wastewater, not the non-aluminum
process or non-process wastewaters under this regulation. The
flows and wastewater characteristics for these other waste
streams are a function of the plant operations, layout, and water
handling practices. As a result, the pollutant discharge efflu-
ent limitation for non-aluminum forming wastewater streams will
be prepared by the permitting or control authority on a case-by-
case basis. These wastewaters are not further discussed in this
document or covered by the regulation.
Core Operations
Rolling. The rolling process is used to transform cast aluminum
ingot into any one of a number of intermediate or final products.
Pressure exerted by the rollers as aluminum Is passed between
them reduces the thickness in the metal and may cause work
hardening. Square ingots cast by the direct chill method
described previously are often used in the production of wire,
rod, and bar. The ingots are usually reduced by hot rolling to
elongated forms, known as blooms. Additional hot or cold rolling
may be used to produce rod, bar, or wire. Rod is defined as
having a solid round cross section 0.95 cm (3/8 inch) or more in
diameter. Bar is also identified by a cross section with 0.95 cm
(3.8 inch) or more between two parallel sides, but it is not
round. Wire is characterized by a diameter of less than 0.95 cm
(3/8 inch).
Although the design of rolling mills varies considerably, the
principle behind the process is essentially the same, At the
rolling mill, aluminum is passed through a set of rolls that
reduces the thickness of the metal and increases its length. Two
common roll configurations are shown in Figure III-3. Multiple
passes through the rolls are usually required, and mills are
frequently designed to allow rolling in the reverse direction.
For wire, rod, and bar products, grooves in the upper and lower
rolls account for the various reductions in cross sectional area.
At sheet mills, ingots are heated to temperatures ranging from
400° to 500°C and hot rolled to form slabs. Hot rolling is usu-
ally followed by further reduction of thickness on a cold rolling
mill. The hot rolled product is generally limited to plate
typically defined as being greater than or equal to 6.3 mm (0.25
inch) thick. Cold rolled products are classified as sheet from
6.3 to 0.15 mm (0.249 to 0.007 inch) thick and foil below 0.15 mm
(0.006 inch) thick.
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As will be discussed later in this section, heat treatment is
usually required before and between stages of the rolling pro-
cess. Ingots are usually made homogeneous in grain structure
prior to hot rolling in order to remove the effects of casting on
the aluminum's mechanical properties. Annealing is typically
required between passes or after cold rolling to keep the metal
ductile and remove the effects of work hardening. The kind and
degree of heat treatment applied depends on the alloy involved,
the nature of the rolling operation, and the properties desired
in the product.
It is necessary to use a cooling and lubricating compound during
rolling to prevent excessive wear on the rolls, to prevent adhe-
sion of aluminum to the rolls, and to maintain a suitable and
uniform rolling temperature. Oil-in-water emulsions, stabilized
with emulsifying agents such as soaps and other polar organic
materials, are used for this purpose in hot rolling operations.
Emulsion concentrations usually vary between 5 and 10 percent
oil. Evaporation of the lubricant as it is sprayed on the hot
metal serves to cool the rolling process. Mist eliminators may
be used to recover rolling emulsions that are dispersed to the
atmosphere. The emulsions are typically filtered to remove metal
fines and other contaminants and recirculated through the mills.
The use of deionized water to replace evaporative and carryover
losses and the addition of bactericides and antioxidizing agents
are practiced at many plants to increase the life of the emul-
sions. Nevertheless, the emulsions eventually become rancid or
degraded and must be eliminated from circulation either by con-
tinuous bleed or periodic discharge. Most cold rolling opera-
tions use mineral oil or kerosene-based lubricants rather than
water-based compounds to avoid staining the aluminum surface;
however, emulsions are used for cold rolling in other countries
and, to a limited extent, in the United States. As in hot
rolling, mist eliminators are commonly used to collect cold
rolling mists in order to recover the rolling oils for reuse.
The steel rolls used in hot and cold rolling operations require
periodic machining to remove aluminum buildup and to grind away
any cracks or imperfections that appear on the surface of the
rolls. Although the survey of the category indicated that roll
grinding with water is practiced, the use of an oil-in-water
emulsion is much more common. This emulsion is usually recycled
and periodically discharged after treatment with other emulsified
waste streams at the plant. Some plants have demonstrated that
the discharge of roll grinding emulsions can be avoided by in-
line removal using magnetic separation of steel fines from the
emulsion or filtration techniques. With this treatment, the
emulsion can be recycled indefinitely with no bleed stream other
than carryover on the rolls.
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Of the plants surveyed, 57 have rolling operations.
of these discharge wastewater directly to surface
discharge indirectly through a POTW, and 25 do
process wastewater. The geographical location of
Twenty-three
water, nine
not discharge
plants with
aluminum rolling operations is presented in Figure III-4. The
annual production of rolled aluminum at these plants during 1977
varied from 270 to 580,000 kkg (300 to 640,000 tons), with a mean
value of 200,000 kkg (220,000 tons). The production distribution
is summarized as follows: of the 45 rolling operations for which
data were available, 36 percent produced less
20,000 tons) of aluminum and aluminum alloys; 73
less than 90,000 kkg (100,000 tons); and 90
less than 360,000 kkg (400,000 tons).
1977 production
than 18,000 kkg i
percent produced
percent produced
Extrusion. In the extrusion process, high pressures are applied
to a cast billet of aluminum, forcing the metal to flow through a
die orifice. The resulting product is an elongated shape or tube
of uniform cross-sectional area. Extrusions are manufactured
using either a mechanical or a hydraulic extrusion press.
There are two basic methods of extrusion practiced in the
aluminum forming category:
direct extrusion, and
indirect extrusion.
The direct extrusion process is shown schematically in Figure
III-5. A heated cylindrical billet is placed into the ingot
chamber, and the dummy block and ram are placed into position
behind it. Pressure is exerted on the ram by hydraulic or
mechanical means, forcing the metal to flow through the die
opening. The extrusion is sawed off next to the die, and the
dummy block and ingot butt are released. Hollow shapes are
produced with the use of a mandrel positioned in the die opening
so that the aluminum is forced to flow around it. A less common
technique, indirect extrusion, is similar, except that in this
method, the die is forced against the billet extruding the metal
in the opposite direction through the ram stem. A dummy block is
not used in indirect extrusion.
Although aluminum can be extruded cold, it is usually first
heated to a temperature ranging from 375 to 525°C, so that little
work hardening will be imposed on the product. Heat treatment is
frequently used after extrusion to attain the desired mechanical
properties. Heat treatment techniques will be described later in
this section. At some plants, contact cooling of the extrusion,
sometimes called press heat treatment quench, is practiced as the
aluminum leaves the press. This can be done in one of three
ways: with a water spray near the die, by immersion in a water
tank adjacent to the runout table, or by passing the aluminum
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through a water wall. A third wastewater stream which may be
associated with the extrusion process is dummy block cooling
water. Following an extrusion, the dummy block drops from the
press and is cooled before being used again. Air cooling is most
commonly used for this purpose, but water is used at a few plants
to quench the dummy blocks.
The extrusion process requires the use of a lubricant to prevent
adhesion of the aluminum to the die and ingot container walls.
In hot extrusion, limited amounts of lubricant are applied to the
ram and die face or to the billet ends. For cold extrusion, the
container walls, billet surfaces, and die orifice must be lubri-
cated with a thin film of viscous or solid lubricant. The lubri-
cant most commonly used in extrusion is graphite in an oil or
water base. A less common technique, spraying liquid nitrogen on
the billet prior to extrusion, is also used. The nitrogen vapor-
izes during the extrusion process and acts as a lubricant.
Extrusion presses that are used to extrude hard alloys such as
aircraft alloys operate under extremely high pressures. These
presses frequently use an oil-water emulsion as the hydraulic
fluid to reduce the risk of fires instead of neat oil used as the
hydraulic fluid in other presses. Due to the nature of this
hydraulic fluid and the extremely high pressures, these extrusion
presses frequently develop hydraulic fluid leaks which must be
treated and discharged.
The steel dies used in the extrusion process require frequent
dressing and repairing to ensure the necessary dimensional pre-
cision and surface quality of the product. The aluminum that has
adhered to the die orifice is typically removed by soaking the
die in a caustic solution. The aluminum is dissolved and later
precipitated as aluminum hydroxide. The caustic bath is followed
by a water rinse of the dies. The rinse is frequently discharged
as a wastewater stream.
In all, 163 extrusion plants were identified in this survey. Of
these, 85 indicated that no wastewater is discharged from alumi-
num forming operations at the plant; 38 identified themselves as
direct dischargers; and 40 indicated indirect discharge of the
process effluent to a POTW. In subsequent investigation of
extrusion practices, it became apparent that these figures may be
misleading. At many of the extrusion plants contacted, personnel
did not realize that die cleaning rinse water was considered to
be an aluminum forming wastewater stream as defined in this
study. For this reason, some of the plants classified as zero
discharge are believed to be discharging this effluent stream
either to surface waters or to a POTW.
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The geographical locations of the extrusion plants are shown in
Figure II1-6. Annual production of extruded products from these
plants ranged between 6.8 and 68,000 kkg (7.5 and 75,000 tons) in
1977. The production distribution is summarized as follows: of
the 157 extrusion operations for which 1977 production data were
available, 58 percent produced less than 4,500 kkg (5,000 tons)
of aluminum and aluminum alloys; 81 percent produced less than
9,000 kkg (10,000 tons)/ and 92 percent produced less than 18,000
kkg (20,000 tons).
Forging. Forging is a process in which aluminum is formed,
usually hot, into shapes by employing compressive forces. The
actual forging process is a dry operation. There are four basic
methods of forging practiced in the aluminum forming category:
Closed die forging,
Open die forging,
Rolled ring forging, and
Cold impact extruding.
In each of these techniques, pressure is exerted on dies or
rolls, forcing the heated stock to take the desired shape. The
first three methods are shown schematically in Figure III-7.
Closed die forging, the most prevalent method, is accomplished by
hammering or squeezing the aluminum between two steel dies, one
fixed to the hammer or press ram and the other to the anvil.
Forging hammers, mechanical presses, and hydraulic presses can be
used for the closed die forging of aluminum alloys. The heated
stock is placed in the lower die and, by one or more blows of the
ram, forced to take the shape of the die set. In closed-die
forging, aluminum is shaped entirely within the cavity created by
these two dies. The die set comes together to completely enclose
the forging, giving lateral restraining to the flow of the metal.
The process of open die forging is similar to that described
above, but in this method, the shape of the forging is determined
by manually turning the stock and regulating the blows of the
hammer or strokes of the press. Open die forging requires a
great deal of skill and only simple, roughly shaped forgings can
be produced. Its use is usually restricted to items produced in
small quantities and to development work where the cost of making
closed type dies is prohibitive.
The process of rolled ring forging is used in the manufacture of
seamless rings. A hollow cylindrical billet is rotated between a
mandrel and pressure roll to reduce its thickness and increase
its diameter.
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The process of impact extruding is performed by placing a cut-off
piece of aluminum in a bottom die. A top die consisting of a
round or rectangular punch and fastened to the press ram is
driven into the aluminum slug, causing the aluminum to be driven
up around the top punch. Usually, the aluminum adheres to the
punch and must be stripped off as the press ram rises.
Proper lubrication of the dies is essential in forging aluminum
alloys. Collodial graphite in either a water or an oil medium is
usually sprayed onto the dies for this purpose. Particulates and
smoke may be generated from the partial combustion of oil-based
lubricants as they contact the hot forging dies. In those cases,
air pollution controls may be required. Baghouses, wet scrub-
bers, and commercially available dry scrubbers are in use at
aluminum forming facilities.
Forging of aluminum alloys is practiced at 16 plants located as
shown in Figure III-8. Of those plants, 12 discharge aluminum
forming wastewater indirectly to a POTW, and the remaining four
plants have no discharge of process wastewater. The production
distribution is summarized as follows: of the 15 forging opera-
tions for which 1977 production data were available, 67 percent
produced less than 900 kkg (1,000 tons) of aluminum and aluminum
alloys; 80 percent produced less than 4,500 kkg (5,000 tons); and
87 percent produced less than 9,000 kkg (10,000 tons).
Drawing. The term drawing, when it applies to the manufacture of
tube, rod, bar, or wire, refers to the pulling of metal through a
die or succession of dies to reduce its diameter, alter the cross
sectional shape, or increase its hardness. In the drawing of
aluminum tubing, one end of the extruded tube is swaged to form a
solid point and then passed through the die. A clamp, known as a
bogie, grips the swaged end of tubing, as shown in Figure III-9.
A mandrel is then inserted into the die orifice, and the tubing
is pulled between the mandrel and die, reducing the outside
diameter and the wall thickness of the tubing. Wire, rod, and
bar drawing is accomplished in a similar manner, but the aluminum
is drawn through a simple die orifice without using a mandrel.
In order to ensure uniform drawing temperatures and avoid exces-
sive wear on the dies and mandrels used, it is essential that a
suitable lubricant be applied during drawing. A wide variety of
lubricants are used for this purpose. Heavier draws, which have
a higher reduction in diameter, may require oil-based lubricants,
but oil-in-water emulsions are used for many applications. Soap
solutions may also be used for some of the lighter draws. Draw-
ing oils are usually recycled until their lubricating properties
are exhausted.
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Intermediate annealing is frequently required between draws in
order to restore the ductility lost by cold working of the drawn
product. Degreasing of the aluminum may be required to prevent
burning of heavy lubricating oils in the annealing furnaces.
Of the plants surveyed, 77 are involved in the drawing of tube,
wire, rod, and bar. The geographical location of these plants is
shown in Figure 111-10. No aluminum forming wastewater is dis-
charged at 51 of the plants. Of the remainder, 10 discharge
directly to surface water, and 16 discharge indirectly to a POTW.
The production distribution is summarized as follows: of the 57
drawing operations for which 1977 production data were available,
46 percent produced less than 900 kkg (1,000 tons) of aluminum
and aluminum alloys; 74 percent produced less than 4,500 kkg
(5,000 tons); and 82 percent produced less than 9,000 kkg (10,000
tons).
Sawing. Sawing may be required for a number of aluminum forming
processes. Before ingots can be used as stock for rolling or
extrusion, the ingot may require scalping or sawing to a suitable
length. Following processes such as rolling, extrusion, and
drawing, the aluminum products may be sawed. The circular saws
and band saws used generally require a cutting lubricant in order
to minimize friction and act as a coolant. Oil-in-water emul-
sions or mineral-based oils are usually applied to the sides of
the blade as a spray. In some cases, a heavy grease or wax may
be used as a saw lubricant. Normally, saw oils are not dis-
charged as a wastewater stream. The lubricants frequently are
carried over on the product or removed together with the saw
chips for reprocessing. In some cases; however, recycle and dis-
charge of a low-volume saw lubricant stream is practiced.
Swaging. Swaging is a forming operation frequently associated
with drawing. Swaging is often the initial step in drawing tube
or wire. By repeated blows of one or more pairs of opposing
dies, a solid point is formed. The point is then inserted
through the drawing die and gripped. In a few cases, swaging is
used in tube forming without a subsequent drawing operation.
Some lubricants, such as waxes and kerosene, may be used to
prevent adhesion of the metal or oxide on the swaging dies.
Anci1lary Operations
Casting. Before aluminum alloys can be used for rolling or
extrusion, and subsequently for other aluminum forming opera-
tions, they are usually cast into ingots of suitable size and
shape. Although ingots may be prepared at smelters or other
forming plants, 85 of the 277 plants surveyed indicated that
casting is done on site. In addition, 30 of the 31 primary
aluminum plants surveyed in the nonferrous metals study indicated
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that some form of casting is done on site. Nine of these plants
fall into both the aluminum forming and nonferrous metals cate-
gories. Therefore, 106 primary reduction, secondary aluminum and
aluminum forming plants have casting operations on site.
The equipment and methods of casting used at aluminum forming
plants are the same as those employed by primary and many second-
ary plants, and the water requirements and waste characteristics
are also very similar. Casting done at a plant which does both
primary aluminum reduction and aluminum forming will be subject
to the casting limitations for primary aluminum if they cast the
aluminum directly without cooling. If the aluminum is a remelted
primary aluminum product then the casting subsequent to the
remelting will be subject to the aluminum forming limitations.
The aluminum alloys used as the raw materials for casting opera-
tions are sometimes purchased from nearby smelters and trans-
ported to the forming plants in the molten state. Usually, how-
ever, purchased aluminum ingots are charged together with alloy-
ing elements into melting furnaces at the casting plants.
Several types of furnaces can be used, but reverberatory furnaces
are the most common. The melting temperatures used range from
650 to 750°C.
At many plants, fluxes are added to the metal in order to reduce
hydrogen contamination, remove oxides, and eliminate undesirable
trace elements. Solid fluxes, such as hexachloroethane, aluminum
chloride, and anhydrous magnesium chloride, may be used, but it
is more common to bubble gases such as chlorine, nitrogen, argon,
helium, and mixtures of chlorine and inert gases through the
molten metal. Fluxing is accomplished by inserting a long,
perforated "lance" into the molten liquid and pumping the gas
through it. This forces the oxides of aluminum back up to the
surface. The oxides form on top of the molten metal while it
stands in the crucibles and after it is poured into the furnace,
andbeing heavier than pure aluminumthe oxides sink down into
the molten metal. Bubbles in the fluxing material surround the
aluminum oxides and carry them up to the surface, where it can be
skimmed off with big, long-handled rakes.
After alloying and fluxing, the metal is allowed to flow into a
second or "holding" compartment of the furnace, which acts as a
reservoir. When the reservoir of molten metal is sufficiently
full the metal may be drawn off to be cast.
Certain complex reactions occur in the furnace itself and, as a
result, some hydrogen gas is trapped in the molten metal. For
this reason, just before it moves from the charging furnace to
the holding furnaces, the metal is "degassed" by introducing a
combination of nitrogen and chlorine gas, or chlorine gas alone,
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or other chemicals. Although similar to fluxing in its
description, degassing has an entirely different purpose but both
may occur in the same operation.
The fluxing and degassing operations are not the same as the
demagging process used in the manufacture of secondary aluminum.
Like degassing and fluxing, demagging involves bubbling of chlo-
rine gas through molten aluminum, however the constituent to be
removed through demagging is primarily magnesium. Thus, the
demagging process is a refining process which frequently requires
significantly more chlorine than degassing or fluxing and some
type of wet air pollution control.
One of the problems associated with furnace degassing with
chlorine is the need for air pollution control. If the alloy
being treated does not contain magnesium, the chlorine gas will
react to form aluminum chloride, which exists as a dense, white
smoke. The presence of hydrochloric acid in these vapors
necessitates the use of wet scrubbers. For this reason, other
gases or mixtures of gases may be preferred as degassing agents.
In addition, a number of in-line treatment methods that eliminate
the need for fluxing when degassing aluminum have recently been
developed and are being adopted by the industry. For a more
detailed description of these alternatives, see Section VII. One
of the aluminum forming plants and four primary aluminum plants
with casting operations reported using wet air pollution controls
to treat fumes from their melting furnaces. Chlorine was occa-
sionally cited as a degassing agent. If enough metal refining is
taking place that large amounts of gases are being emitted and a
wet scrubber is necessary, this is considered metal manufacturing
and is covered under the primary or secondary aluminum
subcategory of the nonferrous metals manufacturing point source
category.
The casting methods used in aluminum forming can be divided into
three classes:
Direct chill casting,
- Continuous casting, and
Stationary casting.
The process variations among these techniques affe?ct both the
metallic properties of the aluminum that is cast and the
characteristics of associated wastewater streams.
Direct chill casting is performed at 61 aluminum forming plants
and is the most widely used method of casting aluminum for
subsequent forming. Direct chill casting is characterized by
continuous solidification of the metal while it is being poured
The length of an ingot cast using this method is determined b
by
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the vertical distance it is allowed to drop rather than by mold
dimensions.
As shown in Figure 111-11, molten aluminum is tapped from the
melting furnace and flows through a distributor channel into a
shallow mold. Noncontact cooling water circulates within this
mold, causing solidification of the aluminum. The base of the
mold is attached to a hydraulic cylinder which is gradually
lowered as pouring continues. As the solidified aluminum leaves
the mold, it is sprayed with contact cooling water to reduce the
temperature of the forming ingot. The cylinder continues to
descend into a tank of water, causing further cooling of the
ingot as it is immersed. When the cylinder has reached its
lowest position, pouring stops and the ingot is lifted from the
pit. The hydraulic cylinder is then raised and positioned for
another casting cycle.
In direct chill casting, lubrication of the mold is required to
ensure proper ingot quality. Lard or castor oil is usually
applied before casting begins and may be reapplied during the
drop. Much of the lubricant volatilizes on contact with the
molten aluminum, but contamination of the contact cooling water
with oil and oil residues does occur.
The production distribution is summarized as follows: of the 56
direct chill casting operations for which 1977 production data
were available, 52 percent produced less than 23,000 kkg (25,000
tons) of aluminum and aluminum alloys; 73 percent produced less
than 45,000 kkg (50,000 tons); and 89 percent produced less than
180,000 kkg (200,000 tons). Direct chill casting is also per-
formed by 27 primary aluminum plants covered in the nonferrous
metals survey. A comparison of production information was made
using production capacity from the two data sets, since the pri-
mary aluminum data was not from 1977. Of the 18 reduction plants
supplying production capacity data, 28 percent produce less than
90,000 kkg (100,000 tons); 78 percent produce less than 180,000
kkg (200,000 tons); and 94 percent produce less than 227,000 kkg
(250,000 tons).
Continuous casting is practiced at 15 plants in the aluminum
forming category instead of, or in addition to, direct chill
casting methods. Unlike direct chill casting, no restrictions
are placed on the length of the casting, and it is not necessary
to interrupt production to remove the cast product. The use of
continuous casting eliminates or reduces the degree of subsequent
rolling required.
A relatively new technology, continuous casting of aluminum first
came into practice in the late 1950's. Since then, improvements
and modifications have resulted in the increased use of this pro-
107
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cess. Current applications include the casting of plate, sheet,
foil, and rod. Because continuous casting affects the mechanical
properties of the aluminum cast, the use of continuous casting is
limited by the alloys used, the nature of subsequent forming
operations, and the desired properties of the finished product.
In applications where continuous casting can be used, the follow-
ing advantages have been cited:
Increased flexibility in the dimensions of the cast
product;
Low capital costs, as little as 10 to 15 percent of the
cost of conventional direct chill casting and hot rolling
methods; and
Low energy requirements, reducing the amount of energy
required to produce comparable products by direct chill
casting and rolling methods by 35 to 80 percent, depend-
ing on the product being cast.
In addition, the use of continuous casting techniques has been
found to significantly reduce or eliminate the use of contact
cooling water and oil lubricants.
A number of different continuous casting processes are* currently
being used in the category. Although the methods vary somewhat,
they are similar in principle to one of the three processes dia-
grammed schematically in Figure 111-12. The most common method
of continuous sheet casting, shown in Figure III-12A, substitutes
a single casting process for the conventional direct chill cast-
ing, scalping, heating, and hot rolling sequence. The typical
continuous sheet casting line consists of melting and holding
furnaces, a caster, pinch roll, shear, bridle, and coiler.
Molten aluminum flows from the holding furnace through a degas-
sing chamber or filter to the caster headbox. The level of
molten aluminum maintained in the headbox causes the metal to
flow upwards through the top assembly, which distributes it
uniformly across the width of the casting rolls. The aluminum
solidifies as it leaves the tip and is further cooled and solidi-
fied as it passes through the internally water-cooled rolls. It
leaves the caster as a formed sheet and successively passes
through pinch rolls, a shear, and a tension bridle before being
wound into a coil. The cooling water associated with this method
of continuous sheet casting never comes into contact with the
aluminum metal.
Another method of casting continuous aluminum sheet is shown in
Figure III-12B. This process is not very common and is limited
due to the mechanical properties of the sheet produced. Molten
aluminum is poured into a rotating perforated cylinder. The
108
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droplets formed are air cooled and solidify as they fall. At
this point, the pellets may either be removed for temporary stor-
age or charged directly to a preheated chamber, hot rolled into
sheet, and coiled. This unique process design not only elimi-
nates the use of contact cooling water, but also results in con-
siderable reductions in the amount of noncontact cooling water
required in the production of sheet.
Several methods of rod casting, similar to the one shown in
Figure III-12C, are currently being used to produce aluminum rod.
Typically, continuous rod is manufactured on an integrated cast-
ing and rolling line consisting of a wheel belt caster, pinch
roll, shear, rolling trains, and a coiler. A ring mold is set
into the edge of the casting wheel. The mold is bound peripher-
ally by a continuous belt which loops around the casting wheel
and an associated idler wheel. As the casting wheel rotates,
aluminum is poured into the mold and solidifies. After a rota-
tion of approximately 180°, the belt separates from the mold,
releasing the still pliable aluminum bar. The bar then enters
directly into an in-line rolling mill, where it is rolled into
rod and coiled. Noncontact cooling water circulating within the
casting wheel is used to control the temperature of the ring
mold. Cooling of the belt is, for the most part, also accom-
plished by noncontact water, though some plants indicated that
contact with the aluminum bar as it leaves the mold is difficult
to avoid. Some models are actually designed so that cooling
water circulates within the interior of the wheel and then flows
over the freshly cast bar and onto the belt as the belt separates
from the ring mold. Because continuous casting incorporates
casting and rolling into a single process, rolling lubricants may
be required. Frequently, oil emulsions similar to those used in
conventional hot rolling are used for this purpose. Graphite
solutions may be suitable for roll lubrication of some continuous
casting processes. In other instances, aqueous solutions of
magnesia are used.
The production distribution is summarized as follows: of the 14
continuous casting operations for which 1977 production data were
available, 57 percent produced less than 18,000 kkg (20,000 tons)
of aluminum and aluminum alloys; 71 percent produced less than
27,000 kkg (30,000 tons); and 100 percent produced less than
36,000 kkg (40,000 tons). Five plants in the primary aluminum
industry have continuous casting. Production was compared using
the production capacity rather than actual production since 1977
production was not available. Of the four plants supplying pro-
duction capacity data, one plant has a capacity less than 22,700
kkg (25,000 tons); two plants have a capacity of 45,000 kkg
(50,000 tons) or less; and no plant has a capacity above 68,000
kkg (75,000 tons).
109
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Stationary casting of aluminum ingots is practiced at 16 aluminum
plants, usually to recycle in-house aluminum scrap. The
production distribution is summarized as follows: of the 10
stationary casting operations for which 1977 production data were
available, 50 percent produced less than 1,800 kkg (2,000 tons)
of aluminum and aluminum alloys; 70 percent produced less than
4,500 kkg (5,000 tons); and 90 percent produced less than 9,000
kkg (10,000 tons). In the stationary casting method, molten
aluminum is poured into cast iron molds and allowed to air cool.
Lubricants and cooling water are not required. Melting and
casting procedures are dictated by the intended use of the ingots
produced. Frequently, the ingots are used as raw material for
subsequent aluminum forming operations at the plant. Other
plants sell these ingots for reprocessing.
Heat Treatment. Heat treatment is an integral part of aluminum
forming practiced at nearly every plant in the category. It is
frequently used both in process and as a final step in forming to
give the aluminum alloy the desired mechanical properties. The
general types of heat treatment applied are the following:
Homogenizing, to increase the workability and help con-
trol recrystal1ization and grain growth following
casting;
Annealing, to soften work-hardened and heat-treated
alloys, relieve stress, and stabilize properties and
dimensions;
Solution heat treatment, to improve mechanical properties
by maximizing the concentration of hardening constituents
in solid solution; and
Artificial aging, to provide hardening by precipitation
of constituents from solid solution.
Homogenizing, annealing, and aging are dry processes, while solu-
tion heat treatment typically involves significant quantities of
contact cooling water.
In the casting process, large crystals of intermetallic compounds
are distributed heterogeneously throughout the ingot. Homogeni-
zation of the cast ingot provides a more uniform distribution of
the soluble constituents within the alloy. By reducing the brit-
tleness caused by casting, homogenization prepares the ingot for
subsequent forming operations. The need for homogenization and
the time and temperatures required are dependent on the alloy
involved, the ingot size, the method of casting used, and the
nature of the subsequent forming operations. Typically, the
ingot is heated to a temperature ranging between 425 and 650°C
1 10
-------
and held at that temperature for four to 48 hours. The ingots
are then allowed to air cool. One plant does use a water mist to
aid final cooling after homogenizing.
Annealing is used by plants in the aluminum forming category to
remove the effects of strain hardening or solution heat treat-
ment. The alloy is raised to its recrystal1ization temperature,
typically between 350 and 400°C. Nonheat-treatable, strain-
hardened alloys need only be held in the furnace until the
annealing temperature is reached; heat-treatable alloys usually
require a detention time of two or three hours. In continuous
furnaces, the metal is raised to higher temperatures (i.e., 425
to 450°C) and detained in the furnace for 30 to 60 seconds. Once
removed from the annealing furnace, it is essential that the
heat-treatable alloys be cooled to 250°C or lower at a slow,
controlled rate. After annealing, the aluminum is in a ductile,
more workable condition suitable for subsequent forming opera-
tions. One plant reported that a water seal was used on its
annealing furnace to maintain the inert atmosphere in the anneal-
ing furnace. Water circulates through a fibrous material which
provides the seal between the furnace door and the frame. The
purpose of the water is to prevent scorching of the seal mate-
rial. Some of the water does pass through the fibrous material
and contacts the metal; however, this water evaporates on con-
tact. After discussions with the plant and the furnace vendor,
it was concluded that the furnace seal water is a noncontact
cooling water stream.
Solution heat treatment is accomplished by raising the tempera-
ture of a heat-treatable alloy to the eutectic temperature, where
it is held for the required length of time, then quenched
rapidly. As a result of this process, the metallic constituents
in the alloy are held in a super-saturated solid solution,
improving the mechanical properties of the alloy. The metal
temperatures recommended for solution heat treatment of formed
aluminum alloys typically range from 450 to 550° C. The required
length of time the metal must be held at this temperature varies
from one to 48 hours. In the case of extrusion, certain aluminum
alloys can be solution heat treated immediately following the
extrusion process. In this procedure, known as press heat treat-
ment, the metal is extruded at the required temperatures and
quenched with contact cooling water as it emerges from the die or
press.
The quenching techniques used in solution heat treatment are
frequently critical in achieving the desired mechanical proper-
ties. The sensitivity of alloys to quenching varies, but delays
in transferring the product from the furnace to the quench, a
quenching rate that is incorrect or not uniform, and the quality
of the quenching medium used can all have serious detrimental
111
-------
effects. With few exceptions, contact cooling water is used to
quench solution heat treated products. Immersion quenching in
contact cooling water, typically ranging from 65 to 100°C, is
used for most aluminum formed products. Forgings are also
quenched at cooler temperatures (i.e., 60 to 70°C). Spray or
flush quenching is sometimes used to quench thick products.
Solution heat treated forgings of certain alloys can be quenched
using an air blast rather than a water medium. Air quenching can
also be used for certain extrusions following press heat treat-
ment. Immersion quenching using glycol is often found in the
manufacture of high-performance aeronautical components. This
quenching technique is critical for achieving desired mechanical
properties, and its use may increase as the demand for high-
quality parts goes up.
Artificial aging, also known as precipitation heat treatment, is
applied to some aluminum alloys in order to cause precipitation
of super-saturated constituents in the metal. The alloy is
heated to a relatively low temperature (i.e., 120 to 200° C) for
several hours and then air cooled. Artificial aging is fre-
quently used following solution heat treatment to develop the
maximum hardness and ultimate tensile and yield strength in the
metal. For certain alloys, the mechanical properties are maxi-
mized by sequentially applying solution heat treatment, cold
working, and artificial aging.
At elevated temperatures, the presence of water vapors can dis-
rupt the oxide film on the surface of the product, especially if
the atmosphere is also contaminated with ammonia or sulfur com-
pounds. Possible detrimental effects include surface blistering,
porosity, discoloration, and a decrease in tensile properties.
When this occurs, it is necessary to control the atmosphere
within a heat treatment furnace. A number of techniques can be
used to control the atmosphere. At some aluminum forming plants,
natural gas is burned to generate an inert atmosphere. The
resulting flue gases are cooled to remove moisture and are intro-
duced to the heat treatment furnace. Under the proper condi-
tions, the same fuel that heats the furnace can be used for this
purpose. Because of the high sulfur content in most furnace
fuels; however, the off-gases may require treatment by wet
scrubbers before they can be used as inert atmosphere for heat
treatment.
Cleaning or_ Etching. A number of chemical or electrochemical
treatments may be applied after the forming of aluminum or alumi-
num alloy products. Acid and alkaline solutions, and detergents
can be used to clean soils such as oil and grease from the alumi-
num surface. Acid and alkaline solutions can also be used to
etch the product or brighten its surface. Deoxidizing and
desmutting are accomplished with acid solutions. Surface
1 12
-------
treatments and their associated rinses are usually combined in a
single line of successive tanks. Wastewater discharge from these
lines is typically commingled prior to treatment or discharge.
In some cases, rinse water from one treatment is reused in the
rinse of another.
These treatments may be used for cleaning purposes, to provide
the desired finish for an aluminum formed product, or they may
prepare the aluminum surface for subsequent coating. A number of
different terms are commonly used in referring to sequences of
surface treatments (e.g., pickling lines, cleaning lines, etch
lines, preparation lines, and pretreatment lines). The termin-
ology depends, to some degree, on the purpose of the lines, but
usage varies within the industry. In addition, the characteris-
tics of wastewater generated by surface treatment is determined
by the unit components of the treatment lines rather than the
specific purpose of its application. In order to simplify
discussion, the term cleaning or etching is used in this document
to refer to any surface treatment processes other than solvent
cleaning.
Surface treatment operations performed as an integral part of the
forming process are considered to be within the scope of the
aluminum forming category. For the purposes of this regulation,
surface treatment of aluminum is considered to be an integral
part of aluminum forming whenever it is performed at the same
plant site at which aluminum is formed.
Solvent Cleaning. Solvent cleaners are used to remove oil and
grease compounds from the surface of aluminum products. This
process is usually used to remove cold rolling and drawing
lubricants before products are annealed, finished, or shipped.
There are three basic methods of solvent cleaning: vapor
degreasing, cold cleaning, and emulsified solvent degreasing.
Vapor degreasing, the predominant method of solvent cleaning in
the aluminum forming industry, uses the hot vapors of chlorinated
solvents to remove oils, greases, and waxes. In simplest form,
vapor degreasing units consist of an open steel tank similar to
the one shown in Figure III-13A. Solvent is heated at the bottom
of a steel tank and, as it boils, a hot solvent vapor is gener-
ated. Because of its higher density, the vapor displaces air and
fills the tank. Near the top of the tank, condenser coils
provide a cooling zone in which the vapors condense and are
prevented from rising above a fixed level. When cool aluminum
forming products are lowered into the hot vapor, the solvent con-
denses onto the product, dissolving oils present on the surface.
Vapor degreasing units may also incorporate immersion or spraying
of the hot solvent for more effective cleaning. Conveyor systems
1 13
-------
similar to the one shown in Figure III-13B are used in some
applications.
The solvents most commonly used for vapor degreasing in aluminum
forming are trichloroethylene, 1,1,1-trichloroethane, and per-
chloroethylene. Selection of the solvent depends on a number of
factors, including solvent boiling point, product dimension, and
alloy makeup; and the nature of the oil, grease, or wax to be
removed. Stabilizing agents are usually added to the solvents.
Vapor degreasing solvents are frequently recovered by distilla-
tion. Solvents can be distilled either within the degreasing
unit itself or in a solvent recovery still. The sludge residue
generated in the recovery process is toxic and may be flammable.
Suitable handling and disposal procedures must be followed and
are discussed in subsequent sections of this report (principally
in Section VII).
Cold cleaning is another solvent cleaning method and involves
hand wiping, spraying, or immersion of metal parts in organic
solvents to remove oil, grease, and other contaminants from the
surface. A variety of solvents or solvent blends, primarily
petroleums and chlorinated hydrocarbons, are used in cold clean-
ing. These solvents can be reclaimed by distillation either on
site or by an outside recovery service. For highly contaminated
solvents; however, reclamation may not be cost effective, and
contract hauling is the disposal method of choice. In general,
cold cleaning is not as effective as vapor degreasing treatment,
but the costs are considerably lower.
Emulsified solvents can also be used to clean aluminum, but they
are less efficient than pure solvents, and their use is limited
to the removal of light oil and grease. Reclamation of emulsi-
fied solvents is not economically feasible at this time.
Contract hauling of the spent solvents is the disposal method
practiced by plants in the aluminum forming category.
Due to the toxic nature of many cleaning solvents, emission con-
trols may be required.
Alkaline and Acid Cleaning. Alkaline cleaning is the most common
method of cleaning aluminum surfaces. The alkaline solutions
vary in pH and chemical composition. Inhibitors are frequently
added to minimize or prevent attack on the metal. Alkaline
cleaners are able to emulsify vegetable and animal oils and
greases to a certain degree and are effective in the removal of
lard, oil, and other such compounds. Mineral oils and grease, on
the other hand, are not emulsified by alkaline cleaning solutions
and, therefore, are not removed as effectively.
1 14
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Aluminum products can be cleaned with an alkaline solution either
by immersion or spray. The solution is usually maintained at a
temperature ranging between 60 and 80° C. Rinsing, usually with
warm water, should follow the alkaline cleaning process to
prevent the solution from drying on the product.
Acid solutions can also be used for aluminum cleaning, but they
are less effective than either alkaline or solvent cleaning sys-
tems. Their use is generally limited to the removal of oxides
and smut. Acid cleaning solutions usually have a pH ranging from
4.0 to 5.7 and temperatures between room temperature and 80°C.
The solutions typically contain one or two acids (e.g., nitric,
sulfuric, phosphoric, chromic, and hydrofluoric acids).
Chemical and Electrochemical Brightening. The surface of
aluminum or aluminum alloys can be chemically or
electrochemically brightened to improve surface smoothness and
reflectance. Chemical brightening is accomplished by immersing
the product in baths of concentrated or dilute acid solutions.
The acids most commonly used for this purpose are sulfuric;
nitric; phosphoric; acetic; and, to a lesser extent, chromic and
hydrofluoric. Other constituents, such as copper or lead salts,
glycerol, and ethylene glycol, may be added as well.
Aluminum can also be brightened by electrochemical methods. The
product is immersed in an electrolyte bath, through which direct
current is passed. The electrolytic solutions are acidic, con-
taining hydrofluoric, phosphoric, chromic, or sulfuric acid, or
they may be alkaline, containing sodium carbonate or trisodium
phosphate.
Etching. Chemical etchants are used to reduce or eliminate
scratches and other surface imperfections, to remove oxides, or
to provide surface roughness. The most widely used etchant is an
aqueous solution of sodium hydroxide. The concentration and tem-
perature of the caustic bath are carefully controlled to provide
the desired degree of etching. In general, the sodium hydroxide
concentration ranges from 1 to 15 percent, and the solution is
maintained between 50 and 80°C. It is important that products
are rinsed immediately following caustic etching.
As a result of etching with a caustic solution, the surface of
the product may be discolored. Alloying constituents, such as
copper, manganese, and silicon, as well as other impurities in
the metal, are not dissolved in the etchant and form a dark
residual film referred to as smut. In order to alleviate this
problem, caustic etching is frequently followed by desmutting.
For specific aluminum alloys or desired finishes, acid etching
may be used. Aluminum-silicon alloys are frequently etched in a
115
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solution containing nitric and hydrofluoric acids. Fumes
generated by acid etching are corrosive and may constitute a
health hazard requiring suitable air pollution control. In
general, etching with acids is more expensive, but it may result
in less aluminum loss, which can be an economic advantage.
Desmutting and Deoxidizing. Acid solutions are used in
desmutting and deoxidizing aluminum products. Desmutting, a
process frequently applied following caustic etching, is
accomplished by immersion in an acid solution that dissolves the
residual film. Although a number of acid solutions can be used
to remove smut, dilute nitric acid is most commonly employed.
Deoxidizers are acid solutions formulated to remove specific
oxide films and coatings from the aluminum products. The oxides
may have been formed naturally, or they may result from heat
treatment or other surface treatments. Deoxidizing solutions can
be composed of a variety of acids, including chromic, phosphoric,
sulfuric, nitric, and hydrofluoric acid.
Anodizing. Anodizing is either a chemical or an electrolytic
oxidation process which converts the surface of the metal to an
insoluble oxide. These oxide coatings provide corrosion protec-
tion, decorative surfaces, a base for painting and other coating
processes, as well as special electrical and mechanical proper-
ties.
The majority of anodizing is carried out by immersion of racked
parts in tanks. Continuous anodizing may be done on large coils
of aluminum in a manner similar to continuous electroplating.
The formation of the oxide occurs (in electrolytic anodizing)
when the parts are made anodic in dilute sulfuric acid or dilute
chromic acid solutions. The oxide layer begins formation at the
extreme outer surface, and as the reaction proceeds, the oxide
grows into the metal. The last formed oxide, known as the bound-
ary layer, is located at the interface between the aluminum and
the oxide. The boundary is extremely thin and nonporous. The
sulfuric acid process is typically used for all parts subject to
stress or containing recesses in which the sulfuric acid solution
may be retained and attack the aluminum. Chromic acid anodic
coatings are more protective than sulfuric acid coatings and have
a relatively thick boundary layer. For these reasons, a chromic
acid bath is used if a complete rinsing of the part cannot be
achieved.
Chemical Conversion Coating. This manufacturing operation
includes chromating, phosphating, and passivating. These coat-
ings are applied to previously deposited metal or basis material
for increased corrosion protection, lubricity, preparation of the
surface for additional coatings, or formulation of a special
116
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surface appearance. In chromating, a portion of the aluminum is
converted to one of the components of the protective film formed
by the coating solution. This occurs by reaction with aqueous
solutions containing hexavalent chromium and active organic or
inorganic compounds. Most of the coatings are applied by chemi-
cal immersion, although a spray or brush treatment can be used.
Phosphate coatings are used to provide a good base for paints and
other organic coatings, to condition the surfaces for cold form-
ing operations by providing a base for drawing compounds and
lubricants, and to impart corrosion resistance to the aluminum
surface by the coating itself or by providing a suitable base for
rust-preventive oils or waxes. Phosphate conversion coatings are
formed by the immersion of aluminum in a dilute solution of phos-
phoric acid. The method of applying the phosphate coating is
dependent upon the size and shape of the part to be coated.
Small parts frequently are coated in barrels immersed in the
phosphating solution. Large parts may be spray coated or
continuously passed through the phosphating solution.
Coloring or Dyeing. Coloring or dyeing aluminum is frequently
performed on anodized aluminum. The dyeing process involves
impregnating the pores of the anodized aluminum with an organic
material.
Mineral coloring is the precipitation of a pigment in the pores
of the anodic coating before sealing.
Integral color anodizing is a single-step process in which the
color is produced during anodizing. Coloring results from the
occulsion of micro-particles in the coating. The electrolyte
reacts with the micro-constituents and the matrix of the aluminum
alloy.
Another method for coloring is a two-step or electrolytic color-
ing process. Following anodizing with sulfuric acid and rinsing,
the aluminum parts are transferred to an acidic electrolyte which
contains a dissolved metal salt. The metallic pigment is elec-
trodeposited in the pores of the anodic coating by the use of
alternating current.
Sealing. Sealing is the final surface finishing step performed
in conjunction with anodizing. Sealing partially converts the
alumina on the surface to an aluminum monohydroxide. Corrosion
resistance of anodized aluminum is largely dependent on the
effectiveness of the sealing operation. Sealing solutions may
consist of boiling deionized water or nickel acetate.
Precipitation of nickel hydroxide helps in plugging pores left in
the anodized surface.
1 1 7
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Aluminum anodized in sulfuric acid may be sealed in slightly
acidified water (pH 5.5 to 6.5) at about 93 to 100°C (200 to
212°F). Clear anodized aluminum parts may be sealed with hot
nickel acetate followed by rinsing and immersion in a hot dichro-
mate solution.
1 18
-------
Table III-1
PROFILE OF ALUMINUM FORMING PLANTS
PRODUCTION (tons/yr)
EMPLOYMENT
Aluminum
Product
Plate
Sheet
Strip
Foil
Tube
Rod
Wire &
Cable
Extrusions
Forgings
Number
of
Plants
7
16
21
15
25
13
48
141
16
Industry
Total
6.00x1 O4
8. 34x1 O5
7.28x105
2.091x105
7. 08x1 O4
4. 747x1 O4
1 .988x105
9.07x105
1. 856x1 O4
Plant
Average
8. 57x103
5.56x104
3.639x104
1. 394x1 O4
3,078
4, 747
4,229
6.48x103
1 ,547
Plant
Average
852
693
356
294
176
125
43
100
94
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Figure III-3
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134
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SECTION IV
INDUSTRY SUBCATEGORIZATION
Subcategorization should take into account pertinent industry
characteristics, manufacturing process variations, wastewater
characteristics, and other factors. Effluent limitations and
standards establish mass limitations on the discharge of pollu-
tants which are applied, through the permit issuance process, to
specific dischargers. To allow the national standard to be
applied to a wide range of sizes of production units, the mass of
pollutant discharge must be referenced to a unit of production.
This factor is referred to as a production normalizing parameter
and is developed in conjunction with subcategorization.
Division of the category into subcategories provides a mechanism
for addressing process and product variations which result in
distinct wastewater characteristics. The selection of production
normalizing parameters provides the means for compensating for
differences in production rates among plants with similar prod-
ucts and processes within a uniform set of mass-based effluent
limitations and standards.
BASIS FOR SUBCATEGORIZATION
Factors Considered
After considering the nature of the various segments of the
aluminum forming industry and their operations, EPA evaluated
possible bases for subcategorization. These include:
1. Raw Materials Used
2. Manufacturing Processes
3. Wastewater Characteristics
4. Products Manufactured
5. Water Use
6. Water Pollution Control Technology
7. Treatment Costs
8. Solid Waste Generation
9. Size of Plant
10. Age of Plant
11. Number of Employees
12. Total Energy Requirements (Manufacturing Process and
Water Treatment and Control)
13. Nonwater Quality Characteristics
14. Unique Plant Characteristics
135
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Subcategorization Selection
After considering the above factors, it was concluded that the
aluminum forming category consists of separate and distinct pro-
cesses with enough variability in products and wastes to require
the division of the industry into a number of discrete subcatego-
ries. The individual processes, wastewater characteristics, and
applicable treatment technologies comprise the most significant
factors in the Subcategorization of this complex industry. The
remaining factors either served to support and substantiate the
Subcategorization or were shown to be inappropriate bases for
Subcategorization. In evaluating these factors, the following
items were addressed: the nature of the Subcategorization based
on the factor being considered; the positive and negative aspects
of the potential Subcategorization; the potential production
normalizing parameters that could be used in conjunction with
this Subcategorization scheme; and the interrelationship between
different factors. Each factor is discussed below.
Raw Materials. The raw materials used in the aluminum forming
category can be classified as follows:
aluminum and aluminum alloys;
lubricants;
surface treatment, degreasing, and furnace fluxing
chemicals; and
additives to lubricants and cooling water.
In some instances, the same raw material may take on various
effluent characteristics, and these will require different treat-
ment. For example, an oil that is emulsified requires different
treatment than the same oil in a pure state. The proportion of
particular pollutants may differ depending upon the type of alu-
minum alloy being processed. Copper alloyed aluminum may gen-
erate wastewater with higher concentrations of copper than other
aluminum alloys. Due to process variations and the proprietary
nature of many alloys and chemical additives, it is difficult to
establish a production normalizing parameter that directly
relates pollutant discharge to specific alloys or process
chemicals.
Manufacturing Processes. There are four principal manufacturing
processes used in aluminum forming: rolling, extrusion, forging,
and drawing. Since recognition of these separate processes is
common, Subcategorization using these four processes would be
easily understood.
136
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Typically, a company will have only one of these forming opera-
tions at an individual plant site, as tabulated below. Conse-
quently, all the plant operations associated with that facility
would be regulated under one subcategory.
PLANTS HAVING ONLY ONE ALUMINUM FORMING
OPERATION ON-SITE
Number of Plants Percent of Total
With Only This Plants With This
Forming Operation Forming Operation Forming Operation
Rolling 37 65
Extrusion 144 88
Forging 13 81
Drawing 52 68
Subcategorization based on the principal manufacturing processes
does not take into account the wastewater generated by minor or
ancillary production processes. In many cases, the principal
manufacturing process will contribute only a small fraction of
the plant's total process wastewater.
Wastewater Characteristics and Treatment Technologies. Using
wastewater characteristics as a criterion, the following sub-
categorization would result: emulsions; pure oils, also known as
neat oils; oil-in-water (nonemulsified) mixtures; and acidic or
basic wastewaters. The major types of unit operations producing
the identified waste streams are listed below.
137
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Unit Operations Producing
Waste Stream the Waste Stream
Emulsions Hot Rolling
Cold Rolling
Drawing
Extrusion (Press Leakage)
Neat Oils Cold Rolling
Drawing
Oil-in-water (nonemulsified) Casting
mixtures Solution heat treatment
Cleaning or etching
Acidic or basic wastewaters Extrusion die cleaning
Cleaning or etching
Anodizing or conversion coating
This subcategorization scheme reflects the fact that effective
wastewater pollutant removal is dependent on the wastewater
characteristics and treatment system designed for removal of
these pollutants. Treatment of emulsified and oil-in-water (non-
emulsified) wastewaters in the same treatment system is inappro-
priate because additional treatment steps are required to break
emulsions. Wastewaters generated during the cleaning or etching
of aluminum with an acid or base solution may require pH adjust-
ment with metals removal and may not need to be treated for oil
removal. Finally, since spent neat oils are pure oil and contain
no water, they may frequently be disposed of by incineration or
contract hauling, thus requiring no treatment.
Products Manufactured. Another approach to subcategorization is
based on the products manufactured, as listed below:
Associated
Product Manufacturing Process
Plate Rolling
Sheet Rolling
Strip Rolling
Foil Rolling
Rod and bar Rolling, extrusion, drawing
Tubing Extrusion or drawing
Miscellaneous shapes Extrusion or forging
Wire and cable Drawing
Other (L shapes, I-beams, etc.) Drawing or extrusion
The product manufactured would be an appropriate criterion for
subcategorization if the waste characterization and production
138
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process to produce a given item are the same from plant to plant;
however, this approach is not applicable to the manufacture of
many aluminum formed products. For example, rods can be produced
by two different production processes which generate similar
wastewater (i.e., rolling and drawing); however, the mass of
pollutants generated per unit of rod produced by rolling will be
different than the amount generated by drawing the rod. Further-
more, some products produced by the same process may use differ-
ent lubricants, therefore generating a waste with different
characteristics. Strip and sheet, for example, can be produced
by operations which use either neat or emulsified oils as
lubricants.
This approach to subcategorization does not take into account
ancillary operations, such as cleaning or etching, heat treat-
ment, and casting, that may be found at any given plant. All of
these factors make it very difficult to develop an equitable
regulation using products manufactured as a basis for
subcategorization.
Process Water Use. Major differences in water use (volume of
water applied to a process per mass of product) between facili-
ties with large and small production could be considered as a
factor in the development of subcategories.
As will be discussed in Section V, analysis of the data indicated
that production normalized water use (i.e., gallons per ton of
aluminum formed) for a given unit operation is usually indepen-
dent of production volume. For example, a large direct chill
casting operation will use about the same amount of water per ton
of ingot produced as an operation casting much less aluminum by
the same method.
Size. The number of employees and amount of aluminum processed
were used to measure relative sizes of aluminum forming plants.
Wastewaters produced by a production process are largely indepen-
dent of the number of plant employees. Variations in staff occur
for many reasons, including shift differences, clerical and
administrative support, maintenance workers, efficiency of plant
operations, and market fluctuations. Due to these and other fac-
tors, the number of employees is constantly fluctuating, making
it difficult to develop a correlation between the number of
employees and wastewater generation.
Subcategorization based on size in terms of production of alumi-
num would group plants by the off-pounds of extrusions, sheets,
rods, etc. This is a good method of subcategorization for an
economic analysis on this category since plants producing rod
will compete for the same market, and smaller production plants
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may have very different economic characteristics than large
production plants. One drawback to this subcategorization
approach is that it does not account for the ancillary operations
frequently performed in conjunction with the forming operation
and the wastewater they may generate.
Age. Aluminum forming is one of the newest large-volume metal
industries. The demand for aluminum products has grown greatly
since the end of World War II. Thus, aluminum forming plants are
relatively modern; most are less than 30 years old. Furthermore,
to remain competitive, plants must be constantly modernized.
Modernization of production equipment, processes, treatment
systems, and air pollution control equipment is undertaken on a
continuous basis throughout the industry. Data regarding the age
and date of the latest major modification for each plant were
compiled from the dcp responses and summarized in Tables III-2
and III-3 (pp. 120 and 121), respectively.
Unique Plant Characteristics. Aluminum forming plants are unique
on the basis of their physical locations and unit operations. As
discussed later in this section, these unit operations are
necessary to the manufacturing process, but vary from plant to
plant, depending on the product and specifications.
Location. The geographical distribution of the aluminum forming
plants is shown in Figure III-2 (p. 122). The plants are not
limited to any one geographical location, but they are generally
located east of the Mississippi River, with pockets of plants
located in the western states of Washington, California, and
Texas. Although some cost savings may be realized for facilities
located in non-urban settings where land is available to install
lagoons, equivalent control of wastewater pollutant discharge can
be achieved by urban plants with the use of physical and chemical
treatment systems that have smaller land requirements. Since
most plants are located in the eastern part of the United States
(an area where precipitation exceeds evaporation) or in urban
areas, evaporation and land application of the wastewater are not
commonly used. Presently, only 27 of the 271 plants are known to
evaporate or apply wastewater to land.
Unit Operations. The following is a list of the unit operations
performed as part of the aluminum forming process.
140
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Unit Operation
Direct chill casting
Continuous rod casting
Continuous sheet casting
Stationary casting
Hot rolling
Cold rolling
Roll grinding
Degassing
Extrusion die cleaning
Extrusion dummy block cooling
Forging
Drawing
Anneal ing
Press heat treatment
Solution heat treatment
Homogenizing
Artificial aging
Degreasing
Cleaning, etching, or
other surface treatment
Sawing
Swaging
Waste Stream
Contact cooling water
Spent lubricant
Contact cooling water
Spent lubricant
Dry operation
Spent emulsion
Spent neat oil or emulsion
Spent emulsion
Scrubber liquor
Bath caustic solution
Rinse water
Scrubber liquor
Contact cooling water
Scrubber liquor
Spent neat oil, emulsion,
or soap solution
Atmosphere scrubber liquor
Contact cooling water
Contact cooling water
Dry operation
Dry operation
Spent solvents
Bath: caustic, acid, seal,
or detergent solutions
Rinse water
Scrubber liquor
Spent neat oil or emulsion
Dry operation
141
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Included in this list are several operations that either do not
discharge a waste stream or discharge small quantities of waste-
water. Furthermore, for subcategories based on these operations,
this approach to subcategorization does not take into account the
different types of oils used for lubrication. For example, draw-
ing can use a neat oil lubricant or an emulsified oil lubricant.
Waste characteristics and treatment schemes are different for the
two types of oils used.
Subcategory Selection
In selecting the subcategories, the Agency tried to minimize the
number of subcategories, but at the same time provide sufficient
segmentation to account for the differences between processes and
associated wastewater streams. Because the aluminum forming
category encompasses a variety of operations that generate
wastewaters with differing characteristics, it is necessary to
consider a combination of factors when establishing subcategori-
zation.
Each of the factors listed and discussed previously are evaluated
below on the basis of suitability for subcategorizing the
aluminum forming category.
Raw Materials. The pollutants in the wastewater discharged are
dependent on the raw materials; however, the amount of pollutants
discharged does not directly correlate with the nature of raw
materials used. Heavy discharge of some metals may result from
the presence of these particular compounds in the aluminum alloy;
however, the amount of metal that enters the wastewater is much
more highly dependent on the operation performed on the alloy.
For instance, etching the workpiece will result in a higher metal
discharge than rolling the workpiece. Subcategorization solely
on the basis of raw materials was considered inappropriate for
this category because of the difficulty associated with
correlating raw materials with the discharge of pollutants.
Manufacturing Processes. Aluminum forming is widely charac-
terized by the principal manufacturing processes of rolling,
extruding, forging, and drawing. Companies have built plants
around a single production process and are familiar with the
terminology. Pollutant generation can be related to the mass of
production from these processes. On this basis, subcategoriza-
tion based on manufacturing processes is appropriate for this
category; however, the four processes of rolling, extruding,
forging, and drawing do not account for the different lubricants,
requiring different treatments, that can be used for the rolling
and drawing operations. This approach to subcategorization also
fails to consider the unique properties of the aluminum forming
142
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plants in the variety of ancillary unit operations that may be
present, many of which generate large volumes of wastewater.
Therefore, the manufacturing processes by themselves are not
suitable for subcategorizing the aluminum forming category.
Wastewater Characteristics. Wastewater characteristics are very
important in the consideration of appropriate treatment
technology and form the basis for effluent limitations.
Subcategorization based solely on wastewater characteristics is
inappropriate for the aluminum forming category since it is
difficult to develop a production normalizing parameter. More
than one manufacturing process may generate a waste stream with
the same characteristics, such as rolling and drawing which both
can use neat oils and emulsions. Volume of wastewater, or in
this case lubricant generated per the mass of aluminum rolled,
may vary greatly with the volume generated per mass of aluminum
drawn. The purpose of subcategorizing is to allow for equitable
regulations across a category and the subcategories must allow
for a normalizing parameter to establish mass limitations.
Wastewater characteristics alone are inappropriate for
subcategorizing the aluminum forming category.
Products Manufactured. As discussed previously, the same product
can be manufactured by as many as three of the aluminum forming
operations. The mass of pollutant generated per unit of product
will be different depending on the type of forming operation
employed. Subcategorization based on products manufactured does
not account for the ancillary operations, such as cleaning or
etching, heat treatment, and casting, that may be found at any
given plant. These factors make it very difficult to develop a
reliable effluent limitation using products manufactured as a
basis for the Subcategorization. Thus, this is an inappropriate
approach for subcategorizing the aluminum forming category to
establish equitable effluent limitations; however,
Subcategorization on the basis of products manufactured is an
appropriate approach for characterizing the industry for an
economic impact analysis where the emphasis is on a plant's
ability to compete in the marketplace.
Process Water Use. Process water use, when related to the mass
of aluminum processed, is fairly constant regardless of the
production volume. Since no distinct differences in water use
could be identified between plants with large production volumes
and plants with small production volumes, the Agency has
determined that this approach is inappropriate to subcategorize
the aluminum forming category. Flows which are normalized by
some aspect of production are used to establish effluent
limitations; variations in water use or discharge were considered
and are discussed in detail in Sections V and IX.
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Size. Size in terms of employment is considered to be an
inappropriate basis for subcategorization because it cannot be
directly related to the generation of wastewater. Size in terms
of production is also considered to be inappropriate for subcate-
gorizing to establish effluent guidelines, since it does not
account for the wastewaters generated by the ancillary
operations.
Age. Since most aluminum forming plants have been built in the
past 30 years and have been modernized frequently, age is not a
valid basis for subcategorization.
Location. Location does not appear to be a significant factor on
which to base subcategorization. Most aluminum forming plants
are located in urban areas; thus, there is no vast disparity in
land availability between urban and rural plants. In addition,
few plants use land application or evaporation to treat aluminum
forming wastewaters.
Unit Operations. The principal benefit from using unit oper-
ations as a basis for subcategorization is that an appropriate
effluent limitation can be established for each waste stream
generated. For each regulated pollutant, a specific pollutant
mass discharge value could be calculated for each waste stream
present at the facility. These values would be summed to deter-
mine the total mass discharge allowed for that pollutant at that
faci1ity.
The difficulties with this approach are the large number of sub-
categories (approximately 25) and the need for a separate pro-
duction normalizing parameter for each subcategory or unit
operation.
Primarily because of the large number of subcategories and com-
plications associated with it, subcategorization based on unit
operations alone was not considered to be appropriate.
Summary of Subcategorization
The aluminum forming category is not well suited to subcategori-
zation using any one of the factors discussed in this section.
By applying a combination of factors, such as manufacturing
processes, unit operations, raw materials, and wastewater charac-
teristics, the aluminum forming category can be divided into six
subcategories:
1. Rolling with Neat Oils
2. Rolling with Emulsions
3. Extrusion
4. Forging
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5. Drawing with Neat Oils
6. Drawing with Emulsions or Soaps
Each manufacturing process consists of one of the four principal
forming operations plus a number of ancillary operations. Each
of these unit operations must be addressed by the limitations and
standards. Since not all plants with a given manufacturing pro-
cess have the same number of ancillary unit operations, some
method of equating the plants must be developed. In addition to
the principal forming operation, there are some ancillary opera-
tions that are unique to the principal forming operations and
others that are necessary to manufacture the final product. For
the purpose of subcategorization, the forming operation and these
closely related ancillary operations are grouped to comprise a
core operation. Another group of operations is not unique to the
forming operations, is not always necessary in the manufacturing
process, and does not discharge wastewater. For simplification,
these are included with the other operations in the core. The
core thus becomes a distinct regulatory unit that, for the
purpose of establishing limits, is viewed as a single source of
pollutants.
There are still a number of unit operations that do not fit into
the core. These operations are not unique to a forming process,
discharge wastewater (usually large volumes), and are not always
necessary to the manufacturing process. Because these operations
make significant contributions to the pollutant loadings when
they are performed, but they are not performed consistently
throughout the subcategory, they are not included in the core.
Instead, these operations are included in the subcategories as
ancillary operations that, for regulatory purposes, can be added
to the core when they (the ancillary operations) are practiced,
or in order to limit the pollutant discharges from aluminum
forming plants.
Subcategorization on the basis of the core and ancillary opera-
tions as previously defined does not take into account the dif-
ferent types of wastes that can be generated by rolling and
drawing. To account for the two types of wastes generated by
rolling and drawing lubricants, four distinct operations were
specified: rolling that uses neat oils, rolling that uses
emulsions, drawing that uses neat oils, and drawing that uses
emulsions or soaps. These four operations are still identifiable
by the industry and account for the differences in wastewater
generated by the same forming operation. Furthermore, each can
be related to some unit of production to normalize plant prac-
tices and can be applied to the subcategorization scheme of core
and ancillary operations. Thus, the manufacturing processes,
unit operations, raw materials, and wastewater characteristics
145
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all play an important part in subcategorizing the aluminum
forming category.
PRODUCTION NORMALIZING PARAMETER
In order to ensure equitable regulation of the category, effluent
limitations guidelines and standards of performance have been
established on a pollutant mass discharge basis (i.e., mass of
pollutant discharged per unit of production). The unit of pro-
duction specified in these regulations is known as a production
normalizing parameter (PNP). Establishing concentration limita-
tions rather than mass-based limits was considered; however, a
plant that diluted its wastewater would have an advantage in
meeting concentration-based limitations over a plant that con-
served water. Thus, with concentration limitations a plant might
actually be penalized for having good water conservation prac-
tices. To avoid this possibility, the mass of pollutants in the
discharge has been related to a specific PNP to establish a limi-
tation that will limit the pollutant mass discharged proportion-
ate to an amount of production.
The approach used in selecting the appropriate PNP for a given
subcategory or ancillary operation is two-fold: achieving a cor-
relation between production and the corresponding discharge of
pollutants and ensuring feasibility and ease of regulation. Some
of the alternatives considered in specifying the PNP include:
1. Mass of aluminum processed,
2. Number of finished products manufactured,
3. Surface area of aluminum processed, and
4. Mass of process chemicals used.
The evaluation of these alternatives is summarized in the dis-
cussion that follows.
Mass of Aluminum Processed. The aluminum forming industry
typically maintains production records of the pounds of aluminum
processed by an individual unit operation. Availability of these
production data and lack of data for other production parameters,
such as area of aluminum and number of products, makes this the
most convenient parameter to use. The aluminum forming dcp
requested three production values: the capacity production rate
for the unit operation in question, the maximum production rate
achieved in 1977, and the average production rate for 1977, all
in Ib/hr.
Number of End Products Processed. The number of products
processed by a given plant would not account for the variations
in size and shape typical of formed products. Extrusions, for
instance, are produced in a wide range of sizes. It would be
146
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unreasonable to expect the quenching of a large extrusion to use
the same amount of water required for a smaller extruded product.
Surface Area of Aluminum Processed. Surface area may be an
appropriate production normalizing parameter for surface
treatment operations of aluminum such as cleaning or etching. It
would not, however, be appropriate for quench or lubricant and
cooling operations. The surface area of aluminum processed is
not generally kept or known by industry and in some cases, such
as forging of miscellaneous shapes, surface area data would be
difficult to determine.
Mass of Process Chemicals Used. The mass of process chemicals
used (e.g., lubricants, solvents, and cleaning or etching
solutions) is dependent on the processes which the aluminum
undergoes rather than the other raw materials used in the
process.
Selection of the Production Normalizing Parameter
Two of the four parameters considered, number of finished prod-
ucts and mass of process chemicals, are not appropriate PNP's for
the aluminum forming category. The number of finished products
is inappropriate because of the lack of consistency and uniform-
ity in the finished products manufactured by an aluminum forming
plant, particularly by an extrusion or forging plant. Also the
processes vary from plant to plant even when producing essen-
tially the same product. The mass of process chemicals is an
inappropriate PNP because the mass of pollutants discharged is
more directly related to the type of operation using the process
chemicals than the amount of these compounds used, although the
process chemicals frequently enter the wastewater.
The surface area of product as a PNP would relate the mass of
pollutants discharged to the surface area of aluminum that con-
tacts the process wastewater. This parameter may be appropriate
for some aluminum forming operations that produce wastewater,
since the mass of pollutants entering the wastewater may be
related to the area of the aluminum it is contacted with.
However, the Agency is not selecting surface area as a production
normalizing parameter because surface area is not always the most
appropriate parameter, especially in contact cooling situations
where the volume of water used is more closely related to the
mass of product. Aluminum formed products, especially forged
products or extrusions, also come in a wide variety of shapes and
the surface area of these shapes would be difficult to determine.
The fourth parameter considered is the mass of product. The
Agency has selected mass as the most appropriate PNP. The mass
of pollutants can be related to the mass of aluminum processed
147
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and most companies keep production records in terms of mass. The
PNP is based on the average production rates reported in the
dcp's. In most cases, the plants were operating at or near the
capacity production rate for a given piece of equipment. The
average production rate will correlate with the mass of pollu-
tants found in the wastewater. For the six subcategories, the
core operations are closely related to the principal forming
operation and the mass of pollutants generated from each ought to
be dependent on the mass of aluminum processed through the form-
ing operation. Thus, there is only one PNP for each core based
on the mass of pollutants processed through the forming opera-
tion. Each ancillary operation has a separate PNP based on the
mass of aluminum processed through the ancillary operation. An
example of how the PNP's apply when establishing mass discharge
limits is shown in Section IX.
The PNP for aluminum forming is "off-kilograms" or the kilograms
of product removed from a machine at the end of a process cycle.
In the rolling process aluminum ingot enters the mill to be
processed. Following one process cycle which may substantially
reduce the ingot's thickness, the aluminum is removed from the
rolling mill where it may be processed through another operation,
such as annealing, sizing, cleaning, or it may simply be stored
before being brought back to the rolling mill for another process
cycle, further reducing the thickness. The mass of aluminum
removed from the rolling mill after each process cycle multiplied
by the number of process cycles is the PNP for that process. The
core of each subcategory has one PNP which is based on the mass
of aluminum processed through the principal forming operation.
There is a different PNP for each ancillary operation which is
the mass of aluminum removed from the process following each
process cycle for that specific operation. For example, the PNP
for solution heat treatment would be the mass of aluminum removed
from the contact cooling water quench that follows solution heat
treatment. In the case of press heat treatment the PNP is the
mass of aluminum removed from the contact cooling water quench
that immediately follows extrusion.
DESCRIPTION OF SUBCATEGORIES
Subcategory Terminology and Usac
Each subcategory is broken into "core" and "ancillary" opera-
tions. The core is composed of those operations that always
occur in conjunction with the forming operation, are dry opera-
tions, or are a basic part of the manufacturing process. The
core limitation is based on the mass of aluminum passed through
the principal manufacturing unit. The core limitation does not
vary within a given subcategory and applies to all the plants in
that subcategory.
148
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Operations not included in the core are classified as ancillary
operations. These are operations involving discharged wastewater
streams of significant pollutant concentrations and flows that
may or may not be present at any one facility. The ancillary
operation limitations are based on the mass of aluminum processed
through the given ancillary operations. In other words, the mass
of aluminum cast by the direct chill method is the normalizing
parameter for casting, and the mass of aluminum cleaned or etched
is the normalizing parameter for cleaning or etching. To deter-
mine the effluent limitation for the facility as a whole, the
permit writer must consider the core limitation as well as the
appropriate ancillary limitation.
The ancillary operation of cleaning or etching includes all
surface treatment operations, including chemical or electrochemi-
cal anodizing and conversion coating when they are performed at
the same location where the aluminum is formed. A cleaning or
etching operation is defined by the cleaning or etching baths
which are followed by a rinse. Multiple baths would be consid-
ered multiple cleaning or etching operations only when each bath
is followed by a rinse and a separate limitation would apply to
each bath-rinse combination. Multiple rinses following a single
bath will be regulated by a single limitation.
In the following discussion, the aluminum forming subcategories
are presented on an individual basis. The core and ancillary
operations included in each subcategory are briefly described,
and the appropriate production normalizing parameters are
identified.
Some plants will be included under more than one subcategory.
The frequency of plants with more than one subcategory is tabu-
lated below. In these cases, the subcategories should be used as
building blocks to establish permit limitations. It should be
noted that in most cases the ancillary operations will be
included with only one subcategory (i.e., the core operation with
which it is most closely associated). As an example, consider a
rolling plant which has both rolling with neat oils and rolling
with emulsions. This plant has direct chill casting as one of
the ancillary operations. Since the casting precedes rolling
with emulsions and the rolling with emulsions operation is
performed on the product of the casting operation, casting will
be considered an ancillary operation only to the Rolling with
Emulsions Subcategory.
The lists presented in the following discussions provide informa-
tion specific to the subcategory being addressed. The frequency
of occurrence of ancillary streams considers each ancillary oper-
ation individually and apart from any other ancillary operations
that may be present at the same plant. Thus, the sum of the
149
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frequencies of the ancillary operations cannot be related to the
number of plants in that subcategory. The same methods have been
applied to the frequency of subcategory overlap. Since there are
some plants that will be in more than one subcategory, the sum of
plants in each subcategory will be larger than the number of
plants in the category.
INCIDENCE OF OVERLAP WITH MORE THAN ONE OTHER SUBCATEGORY
Total Plants in
One or More
Percent of
Total Plants in
Subcategory
Rolling wi
Rolling wi
Extrusion
Forging
Drawing wi
Drawing wi
th
th
th
th
Neat Oils
Emulsions
Neat Oils
Emulsions
Subcategory
34
28
22
9
25
5
the Subcategory
68
86
13
57
38
38
or Soaps
Rolling with Neat OJ.ls Subcateqory
This subcategory is applicable to all wastewater discharges
resulting from or associated with aluminum rolling operations in
which neat oils are used as a lubricant. The unit operations and
associated waste streams covered by this subcategory and the
appropriate production normalizing parameters are listed below.
150
-------
ROLLING WITH NEAT OILS SUBCATEGORY
Unit Operation
Waste Stream
Production Normalizing
Parameter
CORE:
Rolling with neat oils
Roll grinding
Stationary casting
Homogenizing
Annealing
Artificial aging
Degreasing
Sawing
Miscellaneous non-
descript wastewater
sources
Spent lubricant
Spent emulsion
None
None
Atmosphere
scrubber
1iquor
None
Spent solvent
Spent lubricant
Various
ANCILLARY:
Continuous
casting
sheet
Rolling solution
treatment
Cleaning or etching
heat
Spent lubricant
Contact cooling
water
Bath
Rinse
Scrubber liquor
Mass of aluminum
rolled with neat oil
Mass of aluminum
rolled with neat oil
Mass of aluminum
rolled with neat oil
Mass of aluminum
rolled with neat oil
Mass of aluminum
rolled with neat oil
Mass of aluminum
rolled with neat oil
Mass of aluminum
rolled with neat oil
Mass of aluminum
rolled with neat oil
Mass of aluminum
rolled with neat oil
Mass of aluminum sheet
cast by continuous
methods
Mass of aluminum
quenched
Mass of aluminum
cleaned or etched
Mass of aluminum
cleaned or etched
Mass of aluminum
cleaned or etched
The following list summarizes data pertaining to the number of
plants in this subcategory and the waste streams which are
present at those plants:
151
-------
Frequency
Associated Waste Streams
No. of Plants
Percent of
Total Plants
in the
Subcategory
CORE:
Rolling with neat oils spent lubricant
Roll grinding spent emulsion
Annealing atmosphere scrubber liquor
Sawing spent lubricant
Miscellanous nondescript wastewater
ANCILLARY:
Continuous sheet casting
Spent lubricant
Rolling solution heat treatment
Contact cooling water
Cleaning or etching
Bath
Rinse
Scrubber liquor
50
*
1
*
*
1 1
6
9
9
0
100
*
2
*
*
22
12
18
18
0
*An accurate count could not be determined from available data,
assumed to be present at all plants.
As this table shows, 50 of the plants surveyed in this study are
included in the Rolling with Neat Oils Subcategory. For the
majority of these plants, the core regulations can be applied
without alteration because no ancillary streams are present.
However, continuous sheet casting is practiced at 11 plants (22
percent), and cleaning or etching of the rolled product is prac-
ticed at nine plants (18 percent). The presence of heat
treatment was reported at only six plants (12 percent).
Over half of the plants (33 of 50) associated with this Subcate-
gory were also associated with one or more additional subcate-
gories. The most common case, overlap with the Rolling with
Emulsions Subcategory, was reported at 19 of the 50 plants (38
percent). Frequently, rolling of aluminum with emulsions is
followed by rolling to desired gauge using neat oils. It is
important to realize that at these plants, operations such as
casting were considered to be associated with the emulsion roll-
ing rather than neat oil rolling for the purpose of subcategori-
zation. In this way, duplication of streams is avoided. Seven
of the plants (14 percent) were included in both the Rolling with
Neat Oils and Drawing with Neat Oils subcategories. In these
152
-------
cases, the aluminum was usually first rolled and then drawn to
form the desired product. If the drawn product was then etched
or heat treated, these operations were associated with drawing
with neat oils rather than rolling with neat oils. In only four
cases (8 percent) was overlap with more than one other subcate-
gory found to exist.
As discussed in Section III (p. 110), the annealing operation
does not use process water. One of the plants surveyed anneals
aluminum which is rolled with neat oils and derives the inert gas
atmosphere used in its annealing process from furnace off-gases.
Because of the sulfur content of furnace fuels, the off-gases
require cleaning with wet scrubbers to remove contaminants.
Other plants import cleaned gases or burn natural gas to provide
an inert atmosphere. Since the Agency believes that this scrub-
ber is necessary to the operation of the annealing furnace in
this process situation, an allowance has been included as part of
the core of the Rolling with Neat Oils Subcategory. For the
Rolling with Neat Oils Subcategory, two core allowances will be
established, because most plants do not have an annealing
scrubber liquor flow. Separate allowances will be established
for core waste streams without an annealing furnace scrubber and
for core waste streams with an annealing furnace scrubber for
only the rolling with neat oils Subcategory since no annealing
furnace scrubbers are known to be in operation in conjunction
with any other forming operation.
Roll ing with Emulsions Subcategory
This subcategory is applicable to all wastewater discharges
resulting from or associated with aluminum rolling operations in
which oil-in-water emulsions are used as lubricants. The unit
operations and associated waste streams covered by this sub-
category and the appropriate production normalizing parameters
are listed below.
153
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ROLLING WITH EMULSIONS SUBCATEGORY
Unit Operation
Waste Stream
Production Normalizing
Parameter
CORE:
Rolling with emulsions Spent emulsion
Roll grinding
Stationary casting
Homogenizing
Artificial aging
Degreasing
Anneal ing
Sawing
Miscellaneous non-
descript wastewater
sources
ANCILLARY:
Direct chill casting
Rolling solution heat
treatment
Cleaning or etching
Spent emulsion
None
None
None
None
None
Spent lubricant
Various
Contact cooling
water
Contact cooling
water
Bath
Rinse
Scrubber liquor
Mass of
with
Mass of
with
Mass of
with
Mass of
with
Mass of
with
Mass of
with
Mass of
with
Mass of
with
Mass of
with
aluminum
emulsions
aluminum
emulsions
aluminum
emulsions
aluminum
emulsions
aluminum
emulsions
aluminum
emulsions
aluminum
emulsions
aluminum
emulsions
aluminum
emulsions
rolled
rol led
rolled
rolled
rolled
rolled
rolled
rolled
rolled
Mass of aluminum cast
by direct chill
method
Mass of aluminum
quenched
Mass of aluminum
cleaned or etched
Mass of aluminum
cleaned or etched
Mass of aluminum
cleaned or etched
The following list summarizes data pertaining to the number of
plants in this subcategory and the waste streams which are pres-
ent at those plants.
154
-------
Frequency
Associated Waste Streams
No. of Plants
Percent of
Total Plants
in the
Subcategory
CORE:
Rolling with emulsions spent emulsion
Roll grinding spent emulsion
Sawing spent lubricant
Miscellaneous nondescript wastewater
ANCILLARY:
29
*
*
*
100
*
*
*
Direct chill casting
Contact cooling water
tiling solution heat treatment
Contact cooling water
.ing
Contact cooling w
Cleaning or Etching
Bath
Rinse
Scrubber liquor
20
8
7
7
2
69
28
24
24
7
*An accurate count could not be determined from available data,
assumed to be present at all plants.
Of the plants surveyed in this study, 29 were classified as
belonging to the Rolling with Emulsions Subcategory. The core
streams in this subcategory include rolling emulsions that are
expected to be present at every plant. As shown in the preceding
list, the regulation of plants in this subcategory will usually
require consideration of waste streams associated with ancillary
operations. Direct chill casting is associated with the rolling
operations at 20 of the plants surveyed. Solution heat treatment
is practiced at eight plants. Seven plants will also require
regulation of cleaning or etching baths and rinses as an ancil-
lary stream, and two plants will receive an allocation for a
cleaning or etching scrubber liquor discharge.
In all but one case (97 percent), plants in the
Emulsions Subcategory were also included in one
subcategories. The most common case, overlap with
with Neat Oils Subcategory, was reported at 19 of
(66 percent). Frequently, rolling of aluminum with
followed by rolling with neat oils to the desired
important to realize that at these plants, operations such as
direct chill casting were considered to be associated with the
emulsion rolling rather than neat oil rolling for the purpose of
subcategorization. In this way, duplication of streams is
Rolling with
or more other
the Rolling
the 29 plants
emulsions is
gauge. It is
155
-------
avoided. Two of the plants (7 percent) were included in both the
Rolling with Emulsions and Drawing with Neat Oils subcategories.
Two of the plants (7 percent) were included in both the Rolling
with Emulsions and Extrusion subcategories. In five cases (17
percent), overlap with more than one other subcategory was found
to exist.
Extrusion Subcategory
This subcategory is applicable to all wastewater discharges
resulting from or associated with aluminum extrusion operations.
The unit operations and associated waste streams covered by this
subcategory and the appropriate production normalizing parameters
are listed below.
EXTRUSION SUBCATEGORY
Unit Operation
Waste Stream
Production Normalizing
Parameter
CORE:
Extrusion
Die cleaning
Stationary casting
Anneal ing
Homogenizing
Artificial aging
Degreasing
Sawing
Miscellaneous non-
descript wastewater
sources
ANCILLARY:
Direct chill casting
Extrusion press or
Dummy block
cool ing
Bath and rinse
Scrubber liquor
None
None
None
None
Spent solvent
Spent lubricant
Various
Mass of aluminum
extruded
Mass of aluminum
extruded
Mass of aluminum
extruded
Mass of aluminum
extruded
Mass of aluminum
extruded
Mass of aluminum
extruded
Mass of aluminum
extruded
Mass of aluminum
extruded
Mass of aluminum
extruded
Mass of aluminum
extruded
Contact cooling
water
Contact cooling
Mass of aluminum cast
by direct chill
method
Mass of aluminum
156
-------
solution heat
treatment
Cleaning or etching
Degassing
Extrusion press
water
Bath
Rinse
Scrubber liquor
Scrubber liquor
Hydraulic fluid
leakage
quenched
Mass of aluminum
cleaned or etched
Mass of aluminum
cleaned or etched
Mass of aluminum
cleaned or etched
Mass of aluminum
degassed
Mass of aluminum
extruded
The following list summarizes
plants in this subcategory and
present at those plants:
Associated Waste Streams
data pertaining to the number of
the waste streams which are
Frequency
Percent of
Total Plants
in the
Subcategory
No. of Plants
CORE:
Extrusion
Die cleaning bath and rinse
Die cleaning scrubber liquor
Sawing spent lubricant
Miscellaneous nondescript wastewater
ANCILLARY:
1 63
*
*
*
*
100
*
*
*
*
Direct chill casting
Contact cooling water
Extrusion press and solution
Contact cooling water
Cleaning or etching
Bath
Rinse
Scrubber liquor
Degassing
Scrubber liquor
Extrusion press leakage
heat treatment
44
52
85
85
3
1
5
27
32
52
52
2
1
3
*An accurate count could not be determined from available data,
assumed to be present at all plants.
157
-------
The Extrusion Subcategory includes more plants, 163, than any
other subcategory, or approximately half of the plants surveyed.
Three of these plants are known to have closed since proposal.
Although an accurate count was not possible from the available
data, extrusion die cleaning is expected to be present at every
extrusion plant, and this operation serves as the principal
component of the core for this subcategory.
More than half of the plants in this subcategory can be regulated
on the basis of the core allocation alone, but the other facil-
ities will require the consideration of ancillary streams. As
shown in the preceding list, the most common ancillary operation
is cleaning or etching (associated with extrusion at 85 of these
plants), followed by heat treatment (32 percent) and direct chill
casting (27 percent).
in the Extrusion Subcategory (88
any other subcategories, some
most common example, nine of the
also associated with the Drawing
Although most of the plants
percent) are not associated with
overlap does occur. In the
extrusion plants (6 percent) are
with Neat Oils Subcategory.
Forging Subcategory
This subcategory is applicable to all wastewater discharges
resulting from or associated with aluminum forging operations.
The unit operations and associated waste streams covered by this
subcategory and the appropriate production normalizing parameters
are listed below.
Unit Operation
FORGING SUBCATEGORY
Waste Stream
Production Normalizing
Parameter
CORE:
Forging
Artificial aging
Annealing
Degreasing
Sawing
Miscellaneous non-
descript wastewater
sources
None
None
None
Spent solvent
Spent lubricant
Various
Mass of aluminum
forged
Mass of aluminum
forged
Mass of aluminum
forged
Mass of aluminum
forged
Mass of aluminum
forged
Mass of aluminum
forged
158
-------
ANCILLARY:
Forging air pollution
control
Forging solution heat
treatment
Cleaning or etching
Scrubber liquor
Contact cooling
water
Bath
Rinse
Scrubber liquor
Mass of aluminum
forged
Mass of aluminum
quenched
Mass of aluminum
cleaned or etched
Mass of aluminum
cleaned or etched
Mass of aluminum
cleaned or etched
The following list summarizes data pertaining to the number of
plants in this subcategory and the waste streams which are
present at these plants:
Frequency
Associated Waste Streams
No. of Plants
Percent of
Total Plants
in the
Subcategory
CORE:
Sawing spent lubricant
Miscellaneous nondescript wastewater
16
*
TOO
*
ANCILLARY:
Forging air pollution
Scrubber liquor
Forging solution heat t
Contact cooling water
Cleaning or etching
Bath
Rinse
Scrubber liquor
control
treatment
4
1 1
13
13
2
25
69
81
81
13
*An accurate count could not be determined from available data,
assumed to be present at all plants.
Of the 16 plants identified with the Forging Subcategory, only
one could be regulated by the core streams alone. The most
common ancillary streams, cleaning or etching baths and rinses,
are each associated with 81 percent of the forging plants. Fre-
quently, more than one ancillary stream is associated with a
159
-------
given plant. Six of the 16 forging plants
at least three such streams.
38 percent) involve
Most of the plants in the Forging Subcategory (81 percent) do not
have operations associated with any other subcategory. Overlap
only occurs with the Extrusion and Drawing subcategories.
Drawing with Neat Oils Subcategory
This subcategory is applicable to all wastewater discharges
resulting from or associated with aluminum drawing operations in
which neat oils are used as a lubricant. The unit operations and
associated waste streams covered by this subcategory and the
appropriate production normalizing parameters are listed below.
DRAWING WITH NEAT OILS SUBCATEGORY
Unit Operation
Waste Stream
Production Normalizing
Parameter
CORE:
Drawing with neat oils
Stationary casting
Homogenizing
Anneal ing
Artificial aging
Degreasing
Sawing
Swaging
Miscellaneous non-
descript wastewater
sources
ANCILLARY:
Continuous rod casting
Spent lubricant
None
None
None
None
Spent solvent
Spent lubricant
None
Various
Contact cooling
water
Spent lubricant
Mass of
with
Mass of
with
Mass of
wi th
Mass of
with
Mass of
with
Mass of
with
Mass of
with
Mass of
with
Mass of
with
aluminum
neat oils
aluminum
neat oils
aluminum
neat oils
aluminum
neat oils
aluminum
neat oils
aluminum
neat oils
aluminum
neat oils
aluminum
neat oils
aluminum
neat oils
drawn
drawn
drawn
drawn
drawn
drawn
drawn
drawn
drawn
Mass of aluminum rod
cast, by continuous
methods
Mass of aluminum rod
cast by continuous
methods
160
-------
Drawing solution heat
treatment
Cleaning or etching
Contact cooling
water
Bath
Rinse
Scrubber liquor
Mass of aluminum
quenched
Mass of aluminum
cleaned or etched
Mass of aluminum
cleaned or etched
Mass of aluminum
cleaned or etched
The following list summarizes
plants in this subcategory and
present at those plants:
Associated Waste Streams
data pertaining to the number of
the waste streams which are
Frequency
Percent of
Total Plants
in the
Subcategory
No. of Plants
CORE:
Drawing with neat oils spent lubricant
Sawing spent lubricant
Miscellaneous nondescript
ANCILLARY:
wastewater
66
*
*
100
*
*
Continous rod casting
Contact cooling water
Spent lubricant
Drawing solution heat treatment
Contact cooling water
Cleaning or etching
Bath
Rinse
Scrubber liquor
2
2
8
13
13
0
3
3
12
20
20
0
*An accurate count could not be determined from available data,
assumed to be present at all plants.
The Drawing with Neat Oils Subcategory is the second largest
aluminum forming subcategory and contains 66 of the 277 plants
surveyed in this study. The majority of the plants in the
Drawing with Neat Oils Subcategory can be regulated on the basis
of the core alone. Heat treatment contact cooling water and
cleaning or etching baths and rinses are the most common ancil-
lary streams in this subcategory.
161
-------
Frequent overlap with other subcategories was noted. The most
common case was with the Extrusion Subcategory; nine of the neat
oil drawing plants (14 percent) were found to have extrusion
processes as well. In all, 36 percent of the plants in the
Drawing with Neat Oils Subcategory were also associated with one
or more other alumminum forming subcategories.
Drawing with Emulsions or Soaps Subcategory
This Subcategory is applicable to all wastewater discharges
resulting from or associated with the aluminum drawing operations
which use oil-in-water emulsion or soap solution lubricants. The
unit operations and associated waste streams covered by this sub-
category and the appropriate production normalizing parameters
are listed below.
DRAWING WITH EMULSIONS OR SOAPS SUBCATEGORY
Unit Operation
Waste Stream
Production Normalizing
Parameter
CORE:
Drawing with emulsions Spent emulsion
or soaps
Stationary casting
Artificial aging
Homogenizing
Anneal ing
Degreasing
Sawing
Swaging
Miscellaneous non-
descript wastewater
sources
None
None
None
None
Spent solvent
Spent lubricant
None
Various
Mass of aluminum drawn
with emulsions or
soaps
Mass of aluminum drawn
with emulsions or
soaps
Mass of aluminum drawn
with emulsions or
soaps
Mass of aluminum drawn
with emulsions or
soaps
Mass of aluminum drawn
with emulsions or
soaps
Mass of aluminum drawn
with emulsions or
soaps
Mass of aluminum drawn
with emulsions or
soaps
Mass of aluminum drawn
with emulsions or
soaps
Mass of aluminum drawn
with emulsions or
soaps
162
-------
ANCILLARY:
Continuous rod casting
Drawing solution heat
treatment
Cleaning or etching
Contact cooling
water
Spent lubricant
Contact cooling
water
Bath
Rinse
Scrubber liquor
Mass of aluminum rod
cast by continuous
methods
Mass of aluminum rod
cast by continuous
methods
Mass of aluminum
quenched
Mass of aluminum
cleaned or etched
Mass of aluminum
cleaned or etched
Mass of aluminum
cleaned or etched
The following list summarizes data pertaining to the number of
plants in this subcategory and the waste streams which are
present at these plants:
Frequency
Percent of
Total Plants
in the
Subcategory
Associated Waste Streams
No. of Plants
CORE:
Drawing with emulsions or soaps spent
lubricants
Sawing spent lubricants
Miscellaneous nondescript wastewater
ANCILLARY:
Continuous rod casting
Contact cooling water
Spent lubricant
Drawing solution heat treatment
Contact cooling water
Cleaning or etching
Bath
Rinse
Scrubber liquor
13
*
*
100
*
*
1
1
0
8
8
31
8
8
0
*An accurate count could not be determined from available data,
assumed to be present at all plants.
163
-------
The Drawing with Emulsions or Soaps Subcategory is the smallest
of the aluminum forming subcategories, with only 13 plants. The
principal core stream in this subcategory, spent emulsions from
drawing with emulsions or soaps, is present at all 13 plants.
For the majority of plants, the core streams accurately describe
all wastewater associated with the subcategory. At four of the
plants (31 percent), solution heat treatment is applied to the
drawn product. Continuous rod casting and cleaning or etching
were each reported less frequently. Consideration of the
appropriate ancillary streams is required for these plants.
Most of the plants (69 percent) are not associated with any other
subcategories. Overlap with other subcategories was observed at
four of the 13 plants surveyed (31 percent).
164
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SECTION V
WATER USE AND WASTEWATER CHARACTERISTICS
This section presents the analytical data that characterize the
raw wastewater and indicate the effectiveness of various waste-
water treatment processes and the fiow data that serve as the
basis for developing regulatory flow allowances in the aluminum
forming category. The data were obtained from four sources: data
collection portfolios (dcp's); sampling and analysis programs;
308 letters sent to industry to obtain additional information on
comments submitted during the comment period; and longterm or
historical data.
SOURCES OF DATA
Data Collection Portfolios
Data collection portfolios (dcp's) are questionnaires which were
developed by the Agency to obtain extensive data from plants in
the aluminum forming category. These dcp's, which were sent to
all known aluminum forming facilities, requested information
about plant age, production, number of employees, water usage,
manufacturing processes, raw material and process chemical usage,
wastewater treatment technologies, the known or believed presence
or absence of toxic pollutants in the plant's raw and treated
process wastewaters, and other pertinent factors.
The dcp responses supplied the quantity of aluminum produced
during 1977, as well as the average production rate (Ib/hr),
maximum production rate, and the rate at full capacity for each
operation. As discussed in Section IV, the average production
rate is considered the most applicable parameter for relating to
water use and raw waste characteristics, and has been used as the
normalizing basis for calculations.
Data supplied by dcp responses were evaluated, and two flow-to-
production ratios were calculated for each stream. The two
ratios, water use and wastewater discharge flow, are differenti-
ated by the flow value used in calculation. Water use is defined
as the volume of water or other fluid (e.g., emulsions, lubri-
cants) required for a given process per mass of aluminum product
and is therefore based on the sum of recycle and make-up flows to
a given process. Wastewater flow discharged after in-process
treatment or recycle (if these are present) is used in calculat-
ing the production normalized flow for that waste stream. The
production normalized wastewater flow is defined as the volume of
wastewater discharged from a given process to further treatment,
disposal, or discharge per mass of aluminum produced. Differ-
165
-------
ences between the water use and wastewater flows associated with
a given stream result from recycle, evaporation, and carryover on
the product. The production values used in calculation corre-
spond to the production normalizing parameter, PNP, assigned to
each stream, as outlined in Section IV.
The production normalized flows were compiled and statistically
analyzed by stream type. Where appropriate, an attempt was made
to identify factors that could account for variations; in water
use. The production normalized flow information is summarized in
this section. A similar analysis of factors affecting the waste-
water values is presented in Sections IX, X, XI, and XII where
representative BPT, BAT, NSPS, and pretreatment discharge flow
allowances are selected for use in calculating the effluent
limitations and standards.
The BPT discharge flows were also used to estimate flows at
aluminum forming plants that supplied EPA with only production
data. The estimated flow was then used to determine the cost of
wastewater treatment at these facilities (see Section VIII).
The methods used in evaluation of wastewater data varied as
dictated by the intended use of the results. For example, in
Section VI the wastewater data from effluent samples are examined
to select pollutants for consideration in regulating the
category.
The mass loading data (kg of pollutant per kkg of production)
from sampled plants were averaged to determine mass loadings
typical of the different wastewater streams.
Sampling and Analysis Program
The sampling and analysis program discussed in this section was
undertaken primarily to implement portions of the Settlement
Agreement and to identify pollutants of concern in the industry,
with emphasis on toxic pollutants. Samples were collected at 25
aluminum forming facilities and subsequently analyzed.
This section summarizes the purpose of the sampling trips and
identifies the sites sampled and parameters analyzed. It also
presents an overview of sample collection, preservation, and
transportation techniques. Finally, it describes the pollutanL
parameters quantified, the methods of analyses and laboratories
used, the detectable concentration of each pollutan^., and the
general approach used to ensure the reliability of the analytical
data produced.
Prior to each sampling visit, all available data, such as layout
and diagrams of the selected plant's production processes and
166
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wastewater treatment facilities, were reviewed. Often an engi-
neering visit to the plant to be sampled was made prior to the
actual sampling visit to finalize the sampling approach. Among
the types of information obtained on engineering visits were
identification and observations of production processes, types of
wastewater generated, use of wastewater treatment technologies,
and in-process technologies. These observations were recorded in
plant visit reports. Representative sample points were then
selected to provide coverage of discrete raw wastewater sources,
total raw wastewater entering a wastewater treatment system, and
final effluents. Finally, before conducting a visit, a detailed
sampling plan showing the selected sample points and all perti-
nent sample data to be obtained was generated and reviewed.
Site Selection. Twenty plants were sampled prior to proposal.
The reason that the Agency selected these 20 plants was to
adequately represent the full range of manufacturing operations
found in this industry as well as the performance of existing
wastewater treatment systems. As such, the plants selected for
sampling were typically plants with multiple forming operations
and associated surface and heat treatment operations. The flow
rates and pollutant concentrations in the wastewaters discharged
from the manufacturing operations at these plants are believed to
be representative of the flow rates and pollutant concentrations
which would be found in wastewaters generated by similar
operations at any plant in the aluminum forming category. In
addition, the 20 sampled plants have a variety of treatment
systems in place. Plants with no treatment as well as plants
using the technologies considered as the basis for regulation
were included.
Five plants were sampled after proposal to obtain data necessary
for the Agency to adequately address several issues that arose
during the comment period. These five plants were identified as
having operations directly related to specific comment issues and
were therefore selected for sampling efforts. Metals and conven-
tional pollutants data have been incorporated into the data base
presented in this section. Organics data for extrusion press
hydraulic fluid are also presented in this section. The remain-
ing organic pollutant analyses were received from the laboratory
too late to be included in the data base. Samples were also
collected from before and after modules of wastewater treatment
systems. These additional performance data were collected to
compare to the treatment effectiveness concentrations derived
using the combined metals data base (see Section VII - Lime and
Settle Performance - Combined Metals Data Base, p. ).
Field Sampling. After selection of the plants to be sampled,
each plant was contacted by telephone, and a letter of notifica-
tion was sent to each plant as to when a visit would be expected.
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These inquiries led to acquisition of facility information neces-
sary for efficient on-site sampling. The information resulted in
selection of the sources of wastewater to be sampled at each
plant. The sample points included, but were not limited to,
untreated and treated discharges, process wastewater, and par-
tially treated wastewater.
Sites visited for this sampling program are listed below by
subcategory and letter designation:
1. Rolling with Neat Oils - Plants B, C, D, E, N, P,
U, T, CC, and EE.
2. Rolling with Emulsions - Plants B, C, D, E, H, P,
T, U, CC, and EE.
3. Extrusion - Plants F, G, K, L, N, R, V, W, AA, BB, and
DD.
4. Forging - Plants A, J, Q, R, and W.
5. Drawing with Neat Oils - Plants E, H, R, and V.
6. Drawing with Emulsions or Soaps - Plants S and W.
Sample Collection, Preservation, and Transportation. Collection,
preservation, and transportation of samples were accomplished in
accordance with procedures outlined in Appendix III of "Sampling
and Analysis Procedures for Screening of Industrial Effluents for
Priority Pollutants" (published by the Environmental Monitoring
and Support Laboratory, Cincinnati, Ohio, March 1977, revised,
April 1977} and in "Sampling Screening Procedure for the
Measurement of Priority Pollutants" (published by the EPA
Effluent Guidelines Division, Washington, D.C., October 1976).
The procedures are summarized in the paragraphs that follow.
Whenever practical, all samples collected at each sampling point
were taken from mid-channel at mid-depth in a turbulent, well-
mixed portion of the waste stream. Periodically, the temperature
and pH of each waste stream sampled were measured on-site.
Each large composite (Type 1) sample was collected in a new 11.4-
liter (3-gallon), narrow-mouth glass jug that had been washed
with detergent and water, rinsed with tap water, rinsed with
distilled water, rinsed with methylene chloride, and air dried at
room temperature in a dust-free environment.
Before collection of Type 1 samples, new Tygon tubing was cut to
minimum lengths and installed on the inlet and outlet (suction
and discharge) fittings of the automatic sampler. Two liters
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(2.1 quarts) of blank water, known to be free of organic com-
pounds and brought to the sampling site from the analytical
laboratory, were pumped through the sampler and its attached
tubing into the glass jug; the water was then distributed to
cover the interior of the jug and subsequently discarded.
A blank was produced by pumping an additional 3 liters (3.2
quarts) of blank water through the sampler, distributed inside
the glass jug, and poured into a 3.8-liter (1-gallon) sample
bottle that had been cleaned in the same manner as the glass jug.
The blank sample was sealed with a Teflon -lined cap, labeled,
and packed in ice in a plastic foam-insulated chest. This sample
subsequently was analyzed to determine any contamination contrib-
uted by the automatic sampler.
During collection of each Type 1 sample, the glass jug was packed
in ice in a separate plastic foam-insulated container. After the
complete composite sample had been collected, it was mixed to
provide a homogeneous mixture, and two 0.95-liter (1-quart)
aliquots were removed for metals analysis and placed in new
labeled plastic 0.95-liter bottles which had been rinsed with
distilled water. One of these 0.95-liter aliquots was sealed
with a Teflon -lined cap; placed in an iced, insulated chest to
maintain it at 4°C (39°F); and shipped by air for inductively
coupled argon plasma emission spectrophotometry (ICAP) metal
analysis. Initially, the second sample was stabilized by the
addition of 5 ml (0.2 ounce) of concentrated nitric acid, capped
and iced in the same manner as the first, and shipped by air to
the contractor's facility for atomic-absorption metal analysis.
Because of subsequent EPA notification that the acid pH of the
stabilized sample fell outside the limits permissible under
Department of Transportation regulations for air shipment,
stabilization of the second sample in the field was discontinued.
Instead, this sample was acid-stabilized at the analytical
laboratory.
After removal of the two 0.95-liter (1-quart) metals aliquots
from the composite sample, the balance of the sample in the 11.4-
liter (3-gallon) glass jug was subdivided for analysis of
nonvolatile organics, conventional, and nonconventional param-
eters. If a portion of this 7.7-liter (2-gallon) sample was
requested by an industry representative for independent analysis,
a 0.95-liter (1-quart) aliquot was placed in a sample container
supplied by the representative.
Sample Types 2 (cyanide) and 3 (total phenol) were stored in new
bottles which had been iced and labeled, 1-liter (33.8-ounce)
clear plastic bottles for Type 2, and 0.47-liter (16 ounce) amber
glass for Type 3. The bottles had been cleaned by rinsing with
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distilled water, and the samples were preserved as described
below.
To each Type 2 (cyanide) sample, sodium hydroxide was added as
necessary to elevate the pH to 12 or more (as measured using pH
paper). Where the presence of chlorine was suspected, the sample
was tested for chlorine (which would decompose most of the cya-
nide) by using potassium iodide/starch paper. If the paper
turned blue, ascorbic acid crystals were slowly added and dis-
solved until a drop of the sample produced no change in the color
of the test paper. An additional 0.6 gram (6.021 ounce) of
ascorbic acid was added, and the sample bottle was sealed (by a
Teflon -lined cap), labeled, iced, and shipped for analysis.
To each Type 3 (total phenol) sample, phosphoric acid was added
as necessary to reduce the pH to 4 or less (as measured using pH
paper). Then, 0.5 gram (0.018 ounce) of copper sulfate was added
to kill bacteria, and the sample bottle was sealed (by a Teflon
-lined cap), labeled, iced, and shipped for analysis.
Each Type 4 (volatile organics) sample was stored in a new 125-ml
(4.2-ounce) glass bottle that had been rinsed with tap water and
distilled water, heated to 105°C (221°F) for one hour, and
cooled. This method was also used to prepare the septum and lid
for each bottle. Each bottle, when used, was filled to overflow-
ing, sealed with a Teflon -faced silicone septum (Teflon side
down) and a crimped aluminum cap, labeled, and iced. Hermetic
sealing was verified by inverting and tapping the sealed con-
tainer to confirm the absence of air bubbles. (If bubbles were
found, the bottle was opened, a few additional drops of sample
were added, and a new seal was installed.) Samples were main-
tained hermetically sealed and iced until analyzed.
Wastewater samples were collected in two stages: screening and
verification. Ideally, the screening phase involves collection
of samples from every waste stream in the category. Pollutants
that were not detected during screening were not considered fur-
ther in the study. Because of the tight schedule of this study,
there was not time to analyze all of the samples obtained during
screening before verification sampling began. Therefore, verifi-
cation samples were analyzed for almost all of the toxic pollu-
tants, as well as selected conventional and. nonconventional
pollutants.
Sample Analysis. Samples were sent by air to one of six
laboratories: Cyrus Wm. Rice Division of NUS Corporation of
Pittsburgh, Pennsylvania; ARO, Inc. of Tullahoma, Tennessee;
Systems Science and Software (SSS) of San Diego, California;
Spectrix of Houston, Texas; Radian Corporation of Austin, Texas;
and Versar, Inc. of Springfield, Virginia. Screening samples
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went to Rice; there the samples were split for metals analysis.
An aliquot of each metal sample received by Rice was sent to
EPA's Chicago laboratory for ICAP analysis; Rice retained an
aliquot for atomic absorption spectrophotometry (AA). Twenty-two
metals were analyzed by ICAP, and five metals were analyzed by
AA, as follows:
Metals Analyzed by ICAP
Calcium Copper
Magnesium Iron
Sodium Manganese
Silver Molybdenum
Aluminum Nickel
Boron Lead
Barium Tin
Beryllium Titanium
Cadmium Vanadium
Cobalt Yttrium
Chromium Zinc
Metals Analyzed by AA
Antimony
Arsenic
Selenium
Thallium
Mercury
Many of the metals analyzed by ICAP are not classified as toxic
pollutants and are not reported in this document as such. They
are considered only because they consume lime and increase sludge
production in wastewater treatment facilities.
Verification samples went to Radian or ARO when metal analysis
was performed by AA. Since metals analysis of screening samples
was complete before verification metals analysis began, Radian
analyzed the samples only for metals shown to be significant in
the aluminum forming category or those expected to consume large
amounts of lime.
Some verification samples were sent to System, Science and Soft-
ware (SSS), Spectrix, Radian, or Rice, where analysis for the
organic toxic pollutants was done.
Due to their very similar physical and chemical properties, it is
extremely difficult to separate the seven polychlorinated
biphenyls (pollutants 106 to 112) for analytical identification
and quantification. For that reason, the concentrations of the
polychlorinated biphenyls are reported by the analytical labora-
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tory in two groups: one group consists of PCB-1242, PCB-1254,
and PCB-1221; the other group consists of PCB-1232, PCB-1248,
PCB-1260, and PCB-1016. For convenience, the first group will be
referred to as PCB-1254 and the second as PCB-1248.
Because the analytical standard for TCDD was judged to be too
hazardous to be made generally available, samples were never
analyzed for this pollutant. There is no reason to expect the
TCDD would be present in aluminum forming wastewater.
Past studies by EPA and others have identified many nontoxic
pollutant parameters useful in characterizing industrial waste-
waters and in evaluating treatment process removal efficiencies.
Some of these pollutants may also be selected as reliable indi-
cators of the presence of specific toxic pollutants. For these
reasons, a number of nontoxic pollutants were also studied for
the aluminum forming cate-gory. These additional pollutants may
be divided into two general groups:
Conventional Non conventional
total suspended solids (TSS) aluminum
oil and grease chemical oxygen demand (COD)
pH phenols (total)
total organic carbon (TOO
total dissolved solids (TDS)
In addition, samples were analyzed for calcium, magnesium, alka-
linity, and sulfate in order to provide the data necessary to
evaluate the cost of lime and settle treatment.
The analytical quantification levels used in evaluation of the
sampling data reflect the accuracy of the analytical methods
employed. Below these concentrations, the identification of the
individual compounds is possible, but quantification is diffi-
cult. Pesticides and PCB's can be analytically quantified at
concentrations above 0.005 mg/1, and other organic toxic levels
above 0.010 mg/1 levels associated with toxic: metals are as
follows: 0.100 mg/1 for antimony; 0.010 mg/1 for arsenic; 1 x
for cadmium; 0.005 mg/1 for chromium; 0.009 mg/1 for copper;
0.010 mg/1 for cyanide; 0.02 mg/1 for lead; 0.0001 mg/1 for
mercury; 0.005 mg/1 for nickel; 0.010 mg/1 for selenium; 0.020
mg/1 for silver; 0.100 mg/1 for thallium; and 0.050 mg/1 for
zinc.
These detection limits are not always the same as those published
in the proposed development document, some of which were in
error; nor are they always the same as some of the detection
limits published elsewhere for these same pollutants by the same
analytical methods. The detection limits used were reported
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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.
Quality Control. Quality control measures used in performing all
analyses conducted for this program complied with the guidelines
given in "Handbook for Analytical Quality Control in Water and
Wastewater Laboratories" (published by EPA Environmental
Monitoring and Support Laboratory, Cincinnati, Ohio, 1976). As
part of the daily quality control program, blanks (including
sealed samples of blank water carried to each sampling site and
returned unopened, as well as samples of blank water used in the
field), standards, and spiked samples were routinely analyzed
with actual samples. As part of the overall program, all
analytical instruments (such as balances, spectrophotometers, and
recorders) were routinely maintained and calibrated.
The atomic-absorption spectrometer used for metal analysis was
checked to see that it was operating correctly and performing
within expected limits. Appropriate standards were included
after not more than 10 samples. Also, approximately 15 percent
of the analyses were spiked with distilled water to assure
recovery of the metal of interest. Reagent blanks were analyzed
for each metal, and sample values were corrected if necessary.
Historical Data
A useful source of long-term or historical data available for
aluminum forming plants are the Discharge Monitoring Reports
(DMR's) completed as a part of the National Pollutant Discharge
Elimination System (NPDES). DMR's were obtained through the EPA
regional offices and state regulatory agencies for the year 1982,
and up to the second quarter of 1983 in some cases. The DMR's
present a summary of the analytical results from a series of
samples taken during a given month for the pollutants designated
in the plant's permit. In general, minimum, maximum, and average
values, in mg/1 or Ibs/day, are presented for such pollutants as
total suspended solids, aluminum, oil and grease, pH, chromium,
and zinc. The samples were collected from the plant outfall(s),
which represents the discharge(s) from the plant. For facilities
with wastewater treatment, the DMR's provide a measure of the
performance of the treatment system. In theory, these data could
then serve as a basis for characterizing treated wastewater from
aluminum forming plants; however, there is no influent to treat-
ment information and too little information on the performance of
the plant at the time the samples were collected to use these
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data in evaluating the performance of various levels of treat-
ment. They do serve as a set of data that was used to compare to
the treatment effectiveness concentrations presented in Section
VII (p. ).
PRESENTATION OF WASTEWATER CHARACTERISTICS
To simplify the presentation of the sampling data, tables were
developed that present ranges of concentrations with the number
of samples in which each pollutant was found within these ranges.
For each waste stream a frequency of occurrence table is pre-
sented for all 129 toxic pollutants. For those pollutants
detected above analytically quantifiable concentrations in any
sample of that wastewater stream, the actual analytical data are
presented in a second table. Where no data are listed for a
specific day of sampling, it indicates that the wastewater
samples for the stream were not collected.
The statistical analysis of data includes some samples measured
at levels considered not quantifiable. The base neutrals, acid
fraction, and volatile organics are considered not quantifiable
at concentrations equal to or less than 0.010 mg/1. Below this
level, organic analytical results are not quantitatively accu-
rate; however, the analyses are useful to indicate the presence
of a particular pollutant. Nonquantifiable results are desig-
nated in the tables with an asterisk (double asterisk for
pesticides).
When calculating averages from the organic sample data, non-
quantifiable results (* or **) were handled as zeros. Since an
"*" or "**" denotes a small but unquantified amount, it is used
as a zero in calculation of averages to minimize overstatement of
the amount present. Organics data reported as not detected (ND)
are not averaged, since ND signifies that the pollutant was not
present in the sample. For example, three samples reported as
ND, *, 0.021 mg/1 would average as 0.010 mg/1.
In the following discussion, water use and field sampling data
are presented for each core operation by subcategory. Discus-
sions of the water use and discharge rates and field sampling
data for the ancillary operations follow thereafter. Appropriate
tubing or background blank and source water concentrations are
presented with the summaries of the sampling data. Figures V-l
through V-25 show the location of wastewater sampling sites at
each facility. The method by which each sample was collected is
indicated by number, as follows:
1 one-time grab
2 24-hour manual composite
3 24-hour automatic composite
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4 48-hour manual composite
5 48-hour automatic composite
6 72-hour manual composite
7 72-hour automatic composite
8 8-hour manual composite
9 8-hour automatic composite
CORE OPERATIONS UNIQUE TO MAJOR FORMING PROCESSES
Rolling
Roll ing with Neat Oils Spent Lubricant. As described in Section
III, the cold rolling of aluminum products typically requires the
use of mineral oil or kerosene-based lubricants. The oils are
usually recycled with in-line filtration and periodically
disposed of by sale to an oil reclaimer or by incineration.
Because discharge of this stream is not practiced, limited flow
data were available for analysis. Of the 50 plants surveyed that
use neat oil rolling lubricants, water (oil) use could be
calculated for only four. These data are presented and
summarized in Table V-l. None of the plants provided sufficient
flow data to calculate the degree of recycle practiced or the
discharge flow of this stream.
Toxic pollutant frequency occurence data are presented in Table
V-2. Wastewater sampling data for neat oil lubricants are
presented in Table V-3.
Rolling with Emulsions Spent Emulsion. Of the plants surveyed,
29 rolling operations were identified that use oil-in-water
emulsions as coolants and lubricants. Rolling emulsions are
typically recycled using in-line filtration treatment. Some
plants discharge a bleed stream, but periodic discharge of the
recycled emulsion is more commonly practiced.
Water use, wastewater factors, and percent recyle corresponding
to this stream are summarized in Table V-4.
Toxic pollutant frequency occurrence data are presented in Table
V-5. Table V-6 summarizes the field sampling data for toxic and
selected conventional and nonconventional pollutants. This
stream is characterized by high levels of COD (79.8 to 1,520,000
mg/1), TOC (38.0 to 560,000 mg/1), and phenolic compounds as
measured by total phenolics-4AAP (0.210 to 49.0 mg/1). Several
toxic organic pollutants were detected in the spent emulsions at
significant concentrations. These included several of the poly-
nuclear aromatic hydrocarbons (PAH) and polychlorinated biphenyls
(PCBs).
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Roll Grinding Spent Emulsion. The steel rolls used in rolling
operations require periodic machining to remove aluminum buildup
and surface imperfections. This process is referred to as roll
grinding. Oil-in-water emulsions are often used as coolants and
lubricants during roll grinding operations. Data on roll
grinding spent lubricants from the dcp's and additional data
collected after proposal have been included in the data base for
this waste stream. Although the available data for this stream
are not as extensive as for other aluminum forming processes,
they did provide a basis for the analysis of water use and
wastewater rates typically associated with roll grinding. This
information is summarized in Table V-7, along with the degree of
recycle or disposal mode practiced at the plants.
One roll grinding operation was sampled prior to1 proposal.
Unfortunately, the sampled facility did not use an emulsified
lubricant. Additional data gathered since proposal, however,
include three samples of roll grinding spent emulsions. Toxic
pollutant frequency occurrence data for the nonemulsified stream
(stream code U-7) and for the three spent emulsions (stream codes
CC-2, EE-11, and EE-12) are presented in Table V-8. The field
sampling data are summarized in Table V-9. This waste stream is
characterized by high levels of oil and grease (11 to 780 mg/1),
suspended solids (9.0 to 120 mg/1), total dissolved solids (340
to 2,200 mg/1), and COD (230 to 850 mg/1).
Extrusion
Extrusion Die Cleaning Bath. As discussed in Section III (p.
101), the steel dies used in extrusion require frequent dres sing
to ensure the necessary dimensional precision and surface quality
of the product. The aluminum that has adhered to the die orifice
is typically removed by soaking the die in a caustic solution,
although a few plants indicated that mechanical brush ing could
be used to clean very simple dies. Water use and wastewater
values corresponding to the die cleaning caustic bath were
calculated for 37 extrusion plants for which information was
available. This information is presented and statistically
summarized in Table V-10.
Although recycle of the caustic solution, as such, is never prac
ticed, periodic discharge of these stagnant baths is common. For
this reason, water use (make-up rate) and wastewater (discharge
rates) are normally identical. Variations in the water use in
caustic die cleaning baths may result from the following:
Intricacy and size of the die orifice. Aluminum alloy being
extruded. Concentration of caustic used. Individual plant
practices.
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The available data are not sufficient, however, to analyze
quantitatively the effect of these factors.
Wastewater samples were collected from three extrusion die clean
ing baths during the sampling program. Wastewater data for
extrusion die cleaning baths are summarized in Tables V-l1 and V-
12. The wastewater characteristics of this stream are similar to
discharges from cleaning or etching baths.
Extrusion Die Cleaning Rinse. After caustic treatment, the
extrusion dies are rinsed with water. At some plants, the dies
are simply hosed off; at others, a rinse tank is used for this
purpose. Most of the plants contacted indicated that rinsing was
required to avoid damage to the die and the material being
extruded. Water use and wastewater factors could be calculated
for only nine of the 30 plants. This information is presented
and summarized in Table V-l3. Water use does not appear to be
affected by differences in rinsing method (i.e., hose or rinse
tank). Other factors, such as the intricacy of the dies, concen
tration of caustic used, aluminum alloy being extruded, and
individual plant practices, could account for minor variations in
water use. The degree of influence of these factors cannot be
determined from the available data.
Toxic pollutant frequency occurrence data are presented in Table
V-14. Table V-15 summarizes the field sampling data for toxic
and selected conventional and nonconventional pollutants detected
above the analytically quantifiable levels. This waste stream is
characterized by high concentrations of aluminum (9.0 to 430
mg/1), dissolved solids (3,200 to 7,200 mg/1), and low concentra
tions of suspended solids (28 to 120 mg/1) and oil and grease
(<3.0 to 17 mg/1). Only five of the toxic organic pollutants
were detected during sampling.
Extrusion Die Cleaning Scrubber Liquor. Of the plants surveyed,
two indicated the use of wet scrubbers associated with their die
cleaning operations. Wet scrubbers may be required to treat
fumes from the caustic die cleaning operation in order to control
air pollution emissions and ensure a safe working environment.
Water use and wastewater factors are calculated in Table V-l6.
Toxic pollutant frequency occurrence data are presented in Table
V-17. Table V-18 summarizes the field sampling data for toxic
and selected conventional and nonconventional pollutants detected
above the analytically quantifiable levels. This waste stream is
characterized by moderate levels of oil and grease (58 mg/1) and
dissolved solids (330 mg/1). The toxic metals, when detected,
were present at levels well below their treatability levels.
Extrusion Press Scrubber Liquor. Of the 163 extrusion plants
surveyed, two plants reported the use of wet scrubbers at the
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extrusion presses to remove caustic fumes. These fumes occur as
a result of cleaning aluminum from extrusion presses between
operations.
One of these plants reported sufficient data for the calculation
of wastewater values. The scrubber at this plant runs continu
ously without recycle and has water use and wastewater values of
2,071 1/kkg. The other plant, while not supplying enough infor
mation to allow calculation of these values, reported that their
scrubber is only run intermittently. These data appear in Table
V-19. This waste stream was sampled at only one plant. Toxic
pollutant frequency occurrence data are presented in Table V-20.
The field sampling data are summarized in Table V-21. As can be
seen in the table, this stream is characterized by low levels of
suspended solids (5 mg/1) and elevated levels of dissolved solids
(360 mg/1). All of the toxic metals were detected well below
their treatability levels.
Extrusion Dummy Block Contact Cooling Water. As described in
Section III (p. ), a dummy block is placed between the ram and
ingot during the direct extrusion process. After the extrusion
is complete, the ingot butt and dummy block are released from the
press. Typically, the dummy blocks are allowed to air cool; how
ever, of the 163 extrusion plants, three indicated that water was
used for this purpose. As can be seen in Table V-22, none of
these plants recycle the cooling water. Data were available to
calculate water use and wastewater discharge rates for two of the
three plants.
Toxic pollutant frequency occurrence data are presented in Table
V-23. Data from wastewater sampling of dummy block cooling water
are presented in Table V-24. This waste stream is characterized
by elevated concentrations of oil and grease (74 mg/1) and dis
solved solids (50 mg/1). Only one toxic organic pollutant
(chloroform) was detected (0.08 mg/1). None of the toxic metals
were detected.
Forging
There are no core waste streams that are unique to the forging
operation.
Drawing
Drawing with Neat Oils Spent Lubricant. Of the 277 plants
surveyed, 66 draw aluminum products using neat oil lubricants.
Two plants avoid discharge of this stream by 100 percent recycle
of the drawing oil. Most of the plants dispose of the spent oil
by incineration or contractor hauling and did not provide the
flow data required to calculate water (oil) use and wastewater
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discharge (oil) values. Table V-25 shows the water use and
wastewater values for the plants that supplied sufficient
information for the calculation of these values.
No wastewater samples of spent drawing neat oils were collected.
Drawing with Emulsions o_£ Soaps Spent Emulsion. Of the plants
surveyed, nine draw aluminum products using oil-in-water
emulsions, and four indicated that soap solutions were used as
drawing lubricants. Water use and wastewater factors calculated
for this stream are presented and summarized in Table V-26. As
can be seen, several plants recycle the emulsions or soap
solutions, then discharge them periodically after their
lubricating properties are exhausted. Review of the data shows
that there is considerable variability in the wastewater
discharge rates. This variation may be somewhat related to
difference in the dimension of wire being drawn. Wastewater
discharge factors were calculated for seven of the 13 plants.
Toxic pollutant frequency occurrence data are presented in Table
V-27. Table V-28 summarizes the field sampling data for the
toxic and selected conventional and nonconventional pollutants
detected above analytically quantifiable levels. This waste
stream is characterized by extremely high levels of oil and
grease (51,540 mg/1) and the presence of certain toxic organic
pollutants.
Swaging. Swaging is frequently associated with drawing
operations and has been included in the Drawing with Neat Oils
Subcategory. Swaging is used as an initial step in drawing with
tube or wire. By repeated blows of one or more pairs of opposing
dies, a solid point is formed. This can then be inserted through
the die and gripped for drawing. In a few cases, swaging is used
in tube forming without a subsequent drawing operation. Some
lubricants, such as waxes and kerosene, may be used to prevent
adhesion of metal or oxide on the dies. Discharge of swaging
lubricants was not reported by any of the plants surveyed in this
study.
CORE OPERATIONS NOT UNIQUE TO SPECIFIC MAJOR FORMING PROCESSES
Sawing Spent Lubricant. Although sawing is associated with
nearly all aluminum forming operations, only 12 of the plants
surveyed reported the use of saw oil emulsions. Because plants
frequently failed to mention minor streams that are not dis
charged, the actual number of plants using saw lubricants may be
much higher. The lubricants are frequently recycled and, in most
instances, discharge from the system is limited to carryover and
disposal by contractor hauling. Only three plants reported
direct or indirect discharge of saw oils.
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Water use and wastewater factors were calculated for plants pro
viding flow and production data corresponding to the stream.
These factors are shown and summarized in Table V-29.
Field samples of sawing spent lubricant from three plants were
collected. The wastewater characteristics of this waste stream
are presented in Tables V-30 and V-31.
Degreasinq Spent Solvents. Although 34 solvent degreasing
operations have been identified from dcp responses, no discharge
is typically associated with this process. Vapor degreasing, the
predominant method of solvent cleaning in the aluminum forming
industry, is described in Section III (p. 113). A number of
toxic organic pollutants, including trichloroethylene, 1,1,1-
trichloroethane, and perchloroethylene, are commonly used
solvents for vapor degreasing. The solvents are frequently
reclaimed by distillation, either on-site or by an outside
recovery service.
Toxic pollutant frequency occurrence data are presented in Table
V-32. Field sampling data for cleaning solvent streams are sum
marized in Table V-33. Besides the presence of volatile organic
pollutants mentioned above, this waste stream is characterized by
high levels of oil and grease (2,180 mg/1) , COD (330 rng/1), and
TOC (143 mg/1).
Annealing Atmosphere Scrubber Liquor. As described in Section
III (p. ), annealing is used to soften work-hardened and
solution-heat-treated alloys, to relieve stress, and to stabilize
the properties and dimensions of the aluminum product. In some
cases, it is necessary to control the atmosphere within the
annealing furnace. At elevated temperatures, the presence of
water vapors can disrupt the oxide film on the surface of the
product, especially if the atmosphere is also contaminated with
ammonia or sulfur compounds. Inert gas atmospheres can be used
within the furnace to avoid possible detrimental effects, such as
blistering, discoloration, and a decrease in tensile properties.
At most plants, natural gas is burned to generate an inert atmo
sphere. At one of the aluminum forming plants surveyed, flue
gases from the burning of fuel to heat the annealing furnace are
used as the furnace atmosphere. Due to the sulfur content of
furnace fuels, however, the off-gases require treatment by wet
scrubbers before they can be used as an inert atmosphere for heat
treatment. The scrubber in use at this plant was reported to
require a relatively large flow of water which is extensively
recycled (more than 99 percent). The water use and wastewater
values calculated for this stream are shown in Table V-34.
Toxic pollutant frequency occurrence data are presented in Table
V-35. Table V-36 summarizes the field sampling data for those
180
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pollutants detected above analytically quantifiable levels. This
waste stream is characterized by high levels of sulfates if the
furnace fuel has a high sulfur content.
ANCILLARY OPERATIONS
Heat Treatment
Solution and Press Heat Treatment Contact Cooling Water. Heat
treatment of aluminum products frequently involves the use of a
water quench in order to achieve desired metallic properties. At
the 277 aluminum forming plants surveyed, 88 solution heat
treatment processes were identified that involve water quenching.
The field samples from heat treatment quenching processes have
been identified and compiled according to the aluminum forming
operation that it follows (i.e., rolling, forging, drawing, and
extrusion). Additional differentiation was made between press
and solution heat treatment of extrusions. The wastewater
streams and the tables which list the water use, percent recycle,
wastewater values, frequency of occurrence of toxic pollutants,
and sampling data for toxic and conventional and nonconventional
pollutants are listed below:
Wastewater Stream
Water Use,
Percent
Recycle,
Wastewater
Values
Toxic
Pollutant
Frequency
of
Occurrence
Field
Sampling
Data
Rolling Solution Heat Table V-37
Treatment Contact Cooling
Water
Extrusion Press Heat Table V-40
Treatment Contact Cooling
Water
Extrusion Solution Heat Table V-43
Treatment Contact Cooling
Water
Forging Solution Heat Table V-46
Treatment Contact Cooling
Water
Drawing Solution Heat Table V-49
Treatment Contact Cooling
Water
Table V-38 Table V-39
Table V-41 Table V-42
Table V-44 Table V-45
Table V-47 Table V-48
Table V-50 Table V-51
The water use factors calculated for this stream were analyzed to
determine if a relationship exists between water use requirements
and the type of products being quenched (extrusions, forgings,
etc.) or the method of heat treatment used (e.g., press versus
181
-------
solution heat treatment of extrusions). It was determined that
neither of these factors account for the variations in water use.
Heat treatment water requirements are independent of the major
forming process which precedes the heat treatment operation. The
water requirements are a function of several variables, including
the mass and surface area of the aluminum, the time allowed for
cooling, and the temperature gradient.
Since the water use requirements are independent of the major
forming process which precedes the operation, it. is assumed that
the pollutant loadings in the discharged wastewater are also
independent and will be similar for the various heat treatment
operations. For regulatory purposes the wastewater discharge
values for all the heat treatment operations will be combined
into a single value for all solution and press heat treatment
operations.
Cleaning or_ Etching Bath. As described in Section III (p. 112 ),
a variety of chemical solutions are used for cleaning purposes or
to provide the desired finish for formed aluminum products.
These treatments and their associated rinses are usually combined
in a single line of successive tanks. Wastewater discharged from
these lines is typically commingled prior to treatment or
discharge.
The acid, alkaline, and detergent solutions used in cleaning or
etching lines are usually maintained as stagnant baths into which
the products are immersed. Chemicals are added as required to
make up for losses due to evaporation, carryover, and splash-out.
In this survey, most of the plants with cleaning or etching lines
did not indicate discharge of these chemical dips. A few plants
reported periodic discharge of cleaning or etching compounds,
usually following treatment. Other plants indicated that the
chemical dip is hauled periodically by an outside contractor or
disposed of on-site. Water use and wastewater discharge rates
for this stream are presented in Table V-52.
Table V-53 presents the frequency of occurrence of toxic pollu
tants for this wastewater stream type. Table V-54 summarizes the
field sampling data for those pollutants detected above analyti
cally quantifiable levels. This waste stream is characterized by
high levels of several of the toxic metals, specifically copper;
chromium and lead; oil and grease (<1 to 1,900 mg/1); suspended
solids (1 to 1,100 mg/1); aluminum (0.300 to 70,000 mg/1); dis
solved solids (586 to 284,000 mg/1); and TOC (1 to 6,260 mg/1).
Cleaning or_ Etching Rinse. Rinsing is usually required following
successive chemical treatments within cleaning or etching lines.
The most common methods are spray rinsing or immersion in a
continuous-flow rinse tank. The number of rinses within a given
182
-------
line varied from plant to plant, depending on the kind of surface
treatment applied.
Water use and wastewater values calculated for the cleaning or
etch lines at aluminum forming plants are shown in Table V-55.
As can be seen, cleaning or etching lines with multiple rinses
tend to have higher water use and wastewater discharge values
than those with single rinses. Direct correlations between these
factors cannot be established on the basis of these data. A more
detailed discussion of factors which could account for variations
in wastewater discharge of this stream is presented in Section
IX. The percent of recycled rinse water could not be calculated
because of the difficulty in defining the amount of water used.
This was caused by countercurrent and stagnant rinses, carryover,
and other practices peculiar to the cleaning or etching lines in
the aluminum forming category.
Toxic pollutant frequency occurrence data are presented in Table
V-56. Table V-57 summarizes the field sampling data for those
pollutants detected above analytically quantifiable levels. This
waste stream, like cleaning or etching baths, is characterized by
elevated concentrations of the toxic metals, copper, chromium,
and lead. In addition, nickel and zinc were present at high
levels in many samples. Oil and grease and suspended solids were
also present at high levels, but lower relative to the baths, as
would be expected.
Cleaning or_ Etching Scrubber Liquor. Of the 40 plants with
cleaning and etching lines, seven indicated that wet scrubbers
are associated with these operations. Fumes from caustic or acid
baths may require treatment to control air pollution emissions
and ensure a safe working environment. Sufficient flow data were
available to calculate water use from one of the seven plants,
and wastewater values were available from four of the seven
plants. This information is summarized and presented in Table V-
58.
Toxic pollutant frequency occurrence data are presented in Table
V-59. Table V-60 summarizes the field sampling data for those
pollutants detected above the analytically quantifiable levels.
This waste stream is characterized by low levels of contamina
tion, as exhibited by suspended solids at 12 mg/1.
Forging Scrubber Liquor. Of the 16 forging plants surveyed,
three indicated that wet scrubbers were used to control
particulates and smoke generated from the partial combustion of
oil-based lubricants in the forging process. Water use and
wastewater discharge rates are summarized in Table V-61.
183
-------
Toxic pollutant frequency occurrence data are presented in Table
V-62. Table V-63 summarizes the field sampling data for the
toxic and selected conventional and nonconventional pollutants
detected above the analytically quantifiable levels. This waste
stream is characterized by the presence of eight toxic organic
pollutants, five of which were polynuclear aromatics. The five
were present at concentrations ranging from 0.018 to 0.075 mg/1.
High levels of oil and grease (162 mg/1), COD (349 mg/1), and
dissolved solids (388 mg/1) are also characteristic of this waste
stream.
Casting
Direct Chill Casting Contact Cooling Water. Of the plants
surveyed, 61 aluminum forming, 25 primary aluminum plants, and
five plants in the secondary aluminum subcategory indicated that
they cast aluminum or aluminum alloys using the direct chill
method. Because the ingot or billet produced by direct chill
casting is used as stock for subsequent rolling or extrusion,
this wastewater stream is considered to be an ancillary stream
for the Rolling with Emulsions and Extrusion Subcategories.
Contact cooling water is used in the direct chill casting method
to spray the ingot or billet as it drops from the mold and then
to quench it as it is immersed in a cooling tank at the bottom of
the casting pit. As described in Section III (p. ), the cool
ing water may be contaminated by lubricants applied to the mold
before and during the casting process. Some plants discharge
this cooling water stream without recycle, but it is commonly
recirculated through a cooling tower. Even with recycle, peri
odic discharge or the discharge of a continuous bleed stream is
required to prevent the accumulation of dissolved solids. Of the
48 aluminum forming plants for which information was available,
30 recycle the contact cooling water stream used in direct chill
casting. The average recycle rate at these plants was 96 per
cent, but the reported values ranged between 50 and IOC percent.
The calculated water use, percent recycle and wastewater values
corresponding to direct chill casting cooling water streams at
aluminum forming plants are presented in Table V-64. The calcu
lated water use, percent, recycle, and wastewater values for
primary aluminum and secondary aluminum plants with direct chill
casting operations are presented in Table V-65.
Toxic pollutant frequency occurrence data are presented in Table
V-66. The field sampling data for those pollutants detected
above analytically quantifiable levels are summarized in Table V-
67. This waste stream is characterized by the presence of
certain toxic organic pollutants at levels ranging from 0.500
mg/1 to below the level of detection. It is also characterized
184
-------
by elevated levels of oil and grease (5 to 214 mg/1) and
suspended solids (<1 to 220 mg/1).
Continuous Rod Casting Contact Cool ing Water. Three of the
aluminum forming plants surveyed in this study use continuous
casting methods to manufacture aluminum rod for subsequent draw
ing. Four plants from the primary aluminum subcategory of the
nonferrous metals forming category also have continuous rod
casting operations. This process, also referred to as Properzi
or wheel casting, is described in Section III (p. ). Although
the cooling water associated with continuous rod casting is, for
the most part, noncontact, some contact with the freshly cast
aluminum bar as it leaves the ring mold is difficult to avoid.
For this reason, the cooling water used in continuous rod casting
operations is classified as an ancillary stream associated with
the Drawing with Neat Oils and Drawing with Emulsions or Soaps
Subcategories.
Water use and wastewater factors corresponding to this stream
could be calculated for only one of the aluminum forming con
tinuous rod casting plants. At this facility no recycle of the
cooling water was practiced. Water use and wastewater rates
could not be calculated for the other aluminum forming plant
known to recycle and periodically discharge this stream. The
other plant indicated that contact cooling water was not used.
This information is presented in Table V-68. Water discharge of
this waste stream was reported from three primary aluminum
plants. All plants reported recycle of this waste stream;
however, only two reported enough information to calculate a
discharge flow. This information is presented in Table V-69.
No field samples of this cooling water stream were collected.
Because of the similarities in raw materials used, water usage in
the processing steps, and product characteristics, it is assumed
that the wastewater characteristics of this stream are similar to
those of the direct chill casting contact cooling water waste
stream. These data are presented in Tables V-66 and V-67.
Continuous Rod Casting Spent Lubricant. As discussed in Section
III (p. 107), in continuous casting operations, oil-in-water
emulsions are used as lubricants. Both of the rod casting plants
providing information practiced total recycle of this stream,
although one aluminum forming plant indicated that periodic
disposal was required. Sufficient flow and production data were
not available to calculate water use or wastewater flows for this
stream. Some recycle information is presented in Table V-60.
No continuous rod casting lubricant field samples were col
lected. Because of the similarities in raw materials used,
lubricant usage in the processing steps, and the nature of the
185
-------
lubricants used in the continuous rod casting operation, it is
assumed that the wastewater characteristics of this waste stream
are similar to those of the rolling with emulsions spent emulsion
waste stream. These data are presented in Tables V-5 and V-6.
Continuous Sheet Casting Spent Lubricant. Of the 277 plants
surveyed in the aluminum forming study, 11 cast aluminum sheet
products using continuous techniques such as the Hunter or
Hazelett methods. No plants in the primary aluminum industry
reported casting aluminum sheet products using continuous
methods. While continuous sheet or strip casting uses only
noncontact cooling water, a few plants indicated that lubricants
were required for the associated rolling line. Oil-in-water
emulsions, graphite solutions, and aqueous solutions of magnesia
can be used for this purpose. Of the plants surveyed, six
reported the use of lubricants in their continuous sheet casting
operations. The lubricants were always recycled and two of the
plants indicated that periodic disposal of this stream was
required. Water use and wastewater rates of this stream are
shown for these two plants and for a third plant which did not
indicate the discharge mode in Table V-71. Two other plants
reported periodic disposal of the lubricant, but provided no flow
data. Six additional facilities with continuous sheet casting
did not indicate the use of a rolling lubricant.
No wastewater samples were collected from continuous sheet cast
ing operations. Because of the similarities in the raw materials
used, lubricant usage in the processing steps, and the nature of
the type of lubricant used in this operation, it is assumed that
the wastewater characteristics of this waste stream are similar
to those of the rolling with emulsions spent emulsion waste
stream. These data are presented in Tables V-5 and V-6.
Stationary Casting. In stationary casting, molten aluminum is
poured into specific shapes for rolling and further processing.
It was observed that in 14 plants, this is done without the
discharge of any contact cooling water. Frequently, the aluminum
is allowed to air cool and solidify. Often, the stationary molds
are internally cooled with noncontact cooling water. In some
plants, a small amount of water or mist is applied to the top of
the stationary cast aluminum to promote more rapid solidification
and allow earlier handling. In most cases, contact cooling water
is either collected and recycled or it evaporates.
Degassing Scrubber Liquor. The purpose, variations, and
limitations of metal treatment technologies are described in
Section III (p. 105). While the wastewater sampling program was
in progress, two of the plants visited had wet air pollution
control devices cleaning the degassing fumes. Since that time,
the plant that was sampled replaced the wet scrubbers with dry
186
-------
devices. Only one of the 80 plants with casting operations
surveyed in this study continues to use wet air pollution
controls in association with their metal treatment operations
prior to casting. Sufficient data were not available from this
plant, however, to calculate the water use or wastewater flow of
this stream. There have been four plants that have gone to the
alternative degassing air pollution control methods since the
draft document was written. Four plants in the primary aluminum
subcategory reported using wet air pollution controls in their
metal treatment operations. Three of these plants provided
information on water use and wastewater flows. This information
is presented in Table V-72.
Toxic pollutant frequency occurrence data are presented in Table
V-73. Table V-74 summarizes the field sampling data for those
pollutants detected above analytically quantifiable levels. This
wastewater is characterized by slightly elevated levels of
suspended solids (<38 mg/1).
Extrusion Press Hydraulic Fluid Leakage
The extrusion of hard alloy aluminum frequently requires the use
of an extrusion press hydraulic fluid, which is typically an oil-
in-water emulsion. Table V-75 presents the wastewater discharge
data on five extrusion press leakage streams. Discharges of this
stream range from 258 1/kkg to 2,554 1/kkg, with two plants prac
ticing recycle.
Wastewater samples of extrusion press leakage were collected at
one plant during the post proposal sampling effort. Toxic pollu
tant frequency of occurence data are presented in Table V-76 and
sampling data are presented in Table V-77. This waste stream is
characterized by elevated levels of oil and grease (490 to 7,300
mg/1).
Additional Wastewater Samples
Table V-78 presents the field sampling data for all raw waste
samples not previously presented. These samples represent com
bined wastewater streams, miscellaneous waste streams, or streams
not considered in the scope of this regulation. Table V-79
presents wastewater discharge flow data for four plants on
miscellaneous nondescript wastewater flows.
TREATED WASTEWATER SAMPLES
Tables V-80 through V-95 present the field sampling data for the
treated wastewater from 16 of the 25 sampled plants. Treated
wastewater data for some of these plants were incorporated into
the larger data base which was used to determine the treatment
187
-------
effectiveness for different control systems. The treatability
limits selected for the aluminum forming control options are
presented in Section VII (Control and Treatment Technology)
(Table VII-20, p. 807).
Most of the treated wastewater streams analyzed were collected
after some form of oil separation (Streams D-15, E-8, and U-3)
and emulsion breaking process (Streams B-7, C-9, E-9, P-7, U-9,
AA-7, and EE-6) (see Figures V-l through V-25). As expected,
these streams showed lower concentrations of oil and grease (<100
mg/1) than found in the influent raw waste streams. In addition,
one stream (Stream B-8) was sampled after an ultrafiltration
process which removes a large percentage of the oil and grease
from the raw waste. Also, samples collected after settling
ponds, lagoons, or clarifiers (Streams D-4, E-ll, J-6, K-5, Q-4,
AA-7, BB-12, DD-16, and EE-8) showed reduced levels of suspended
solids. Lime and settle system effluents (Streams D-14, K-5, and
EE-8) had toxic metal concentrations below the detection limits
for most of the toxic metals.
188
-------
Table V-1
ROLLING WITH NEAT OILS SPENT LUBRICANTS
Plant
1
2
3
4
W;_,ter
1/kkg
10.1 7
4.586
4.753
3. 144
Use
gal/ton
2.440
1 . 100
1 . 140
0.7540
Percent
Recycle
Wastewater
1/kkg gal/ton
3.144
0. 1 7
5.666
4.670
4 of
0.7540
2.440
1.359
1 . 120
50 plants
*
*
*
*Data not available.
Statistical Summary
Minimum
Maximum
Mean
Median
Sample:
Note: Table does not include 46 plants which provided insuffi
cient information to calculate water use and wastewater
values.
189
-------
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Table V-4
ROLLING WITH EMULSIONS SPENT EMULSION
Plant
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
Water Use
I/kkg gal/ton
60.46
*
*
*
*
*
*
*
*
*
30,600
54,870
*
41 ,110
*
76,340
*
*
*
*
*
*
14.50
*
*
*
*
*
*
*
*
*
7,340
*
13,160
*
9,860
*
18, 310
*
*
*
Percent
Recycle
* (P)
* (P)
* (P)
99 (B)
* (P)
* (P)
* (P)
* (P)
* (P)
* (P)
* (P)
* (P)
* (P)
* (P)
* (P)
100 (P)
* (P)
* (P)
97 (B)
* (P)
*
85 (B)
*
100 (P)
100 (P)
* (P)
*
Wastewater
1/kkg gal/ton
0. 3344
0.391 9
0.5879
0.6046
0.6404
0.6671
1.376
2.039
3.919
4.837
5.045
6.921
7.255
12.63
15.05
23.35
28.13
50.87
89.39
181.4
197.8
228.6
304.4
344.4
352.2
0.0802
0.0940
0. 1410
0.1450
0.1536
0. 1600
0.3300
0.4890
0.9400
1. 160
1.210
1 .660
1 .740
3.030
3.610
5.600
6.746
12.20
21 .44
43.50
47.43
54.82
73.00
82. 60
84.48
* (P)
* (P)
*
*
*
*
*
*
*
*
*
*
*Data not available.
P Periodic discharge.
B Bleed discharge.
Statistical Summary
Minimum
Maximum
Mean
Median
Sample:
60.46
76,340
40, 600
41, 110
5 of 29
14. 50
18,310
9,737
9,860
plants
0.3344
352.2
74. 51
7.255
0.0802
84.48
17.87
1.740
25 of 29 plants
Note: Three plants discharge from both hot and cold rolling
operations which appear separately in this table.
196
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209
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Table V-7
ROLL GRINDING SPENT LUBRICANT
Water Use
Plant
1
2
3
4
5
6
7
8
9
1/kkg
*
*
*
*
*
*
*
0.0576
*
gal/ton
*
*
*
*
*
*
*
0.0138
*
Percent
Recycle
100
100
*
P
*
*
P
P
*
Wastewater
1/kkg
0
0
0.15
0.6779
0.93
7.659
18.00
*
*
gal/ton
0
0
0.036
0.1626
0.22
1.837
4.317
*
*
*Sufficient data not available to calculate these values.
P Total recycle with periodic discharge.
Statistical Summary
Minimum
Maximum
Mean
Median
Sample:
Nonzero Mean
Sample:
0 0
18.00 4.317
3.917 0.939
0.6779 0.1626
7 of 9 plants
5.5 1.3
5 of 9 plants
210
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219
-------
Table V-10
EXTRUSION DIE CLEANING BATH
Plant
1
2
3
4
5
6
7
8
9
10
1 1
12
13
14
15
16
1 7
Water Use
l/kk% gal/ton
Percent
Recycle
Wastewater
1/kkg gal/ton
*
51 .87
0.2506
2.472
*
2.811
4.009
5.833
12.52
13.90
13.99
*
39.68
53.45
9.957
*
1 2.44
*
0.0601
0.5929
*
0.6742
0.9615
399
003
333
1 ,
3.
3.
3.356
*
9.517
1 2.82
2.388
**
**
**
**
**
**
**
**
**
**
ifif
**
**
**
**
**
0
0
0
0.2506
0.69
2,
2.
2,
3.
5,
060
66
811
341
833
12.52
13.90
13.99
16.6
39.68
53.45
0
0
0
0.0601
0.17
0.4941
0. 64
0.6742
0.8013
399
003
3.333
3.356
4.0
9.517
12.82
1 ,
3,
*Data not available.
**Not applicable.
Statistical Summary
Minimum
Maximum
Mean
Median
Sample:
Nonzero
Mean
Sample:
Nonzero
0.2506
53.45
17.56
1 1 .24
12 of
17.56
37
0.0601
12.82
4.212
2.696
plants
4.212
12 of 37 plants
17.56 4.212
Mean (Proposal)
Sample: 12 of 37 plants
0
53.45
10.49
3.076
0
12.82
2.52
0. 738
16 of 37 plants
12.9 3. 1
13 of 37 plants
14.79 3.546
10 of 37 plants
Note: Table does not include 23 plants which provided insuffi-
cient information to calculate water use and wastewater
values.
220
-------
Table V-11
EXTRUSION DIE CLEANING RINSE
Plant
1
2
3
4
5
6
7
8
9
10
Water Use
1/kkg gal/ton
0.7025
4.
5.
009
833
8.285
9.957
11.78
*
53.45
155.6
0.
0.
1 .
1 .
2.
2.
12.
1685
9615
399
987
388
826
*
82
37.33
*Data not available.
Statistical Summary
Minimum
Maximum
Mean
Median
Sample:
Nonzero
Mean
Sample:
Note:
0.7025
155.6
31.21
9.121
8 of 30
31 .21
0.1685
37.33
7.485
2. 188
plants
7.485
8 of 30 plants
Percent
Recycle
100
0
*
0
0
0
0
*
0
*
Wastewater
1/kkg gal/ton
0
0.7025
3.341
5.833
8.285
9.957
11.78
18.65
53.45
118.6
0
118.6
23.06
9.121
0
0.1685
0.8013
399
987
388
826
4.473
12.82
28.44
1 .
1 .
2,
2.
0
28.44
5.530
2.188
10 of 30 plants
25.62 6.145
9 of 30 plants
Table does not include 20 plants which provided insuffi-
cient information to calculate water use and wastewater
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234
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Table V-16
EXTRUSION DIE CLEANING SCRUBBER LIQUOR
Plant
1
2
Water Use
1/kkg gal/ton
258.8 62.08
292.2 70.08
Percent
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0
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292.2 70.08
Statistical Summary
Mean 275.5 66.08 275.5 66.08
Sample: 2 of 2 plants 2 of 2 plants
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Table V-19
EXTRUSION PRESS SCRUBBER LIQUOR
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Table V-22
EXTRUSION DUMMY BLOCK CONTACT COOLING WATER
Plant
1
2
3
Water Use
1/kkg gal/ton
2,072
2,172
*
497.0
521.0
*
Percent
Recycle
0
0
0
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1/kkg gal/ton
2,072 497.0
2,172 521.0
* *
*Data not available.
Statistical Summary
Mean 2,122 509.0
Sample: 2 of 3 plants
2,122 509.0
2 of 3 plants
247
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Table V-25
DRAWING WITH NEAT OILS SPENT LUBRICANT
Plant
1
2
3
4
5
Water Use
1/kkg gal/ton
*
*
*
*
5.879
*
*
*
1 .410
Percent
Recycle
100
100
*
*
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Statistical Summary
Minimum
Maximum
Mean
Median
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Sample:
Wastewater
1/kkg gal/ton
0
0
5.420
8.147
0
0
1 . 300
1.954
0 0
8.147 1.954
3.392 0.8135
2.710 0.6500
4 of 66 plants
6.784 1.627
2 of 66 plants
Note: Table does not include 61 plants which provided insuffi-
cient information to calculate water use and wastewater
values.
253
-------
Table V-26
DRAWING WITH EMULSIONS OR SOAPS SPENT EMULSION
Water Use
Plant 1/kkg gal/ton
1
2
3
4
5
6
7
8
9
10
1 1
12
13
*
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1 ,072,000
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discharge.
Statistical Summary
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Table V-29
SAWING SPENT LUBRICANT
Plant
1
2
3
4
5
6
7
8
9
10
1 1
12
Water Use
1/kkg gal/ton
0.5212
*
*
*
1.438
*
*
*
*
*
*
*
0.1250
*
*
*
0.3450
*
*
*
*
*
*
Percent
Recycle
0
0
*
*
*
*
*
*
*
Wastewater
1/kkg gal/ton
0
0,
0.
1,
1.
6,
19.
4586
6671
167
438
379
14
*
*
*
0
0.
0.
0.
0.
1,
*Sufficient data not available to calculate these values.
Statistical Summary
Minimum
Maximum
Mean
Median
Sample:
Nonzero Mean
Sample:
01 1 0
1600
2800
3450
530
4.590
*
*
*
0
19. 14
4. 119
1. 167
7 of
4.807
6 of
12
12
0
4.590
0.9880
0.2800
plants
1 . 153
plants
260
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Table V-37
ROLLING SOLUTION HEAT TREATMENT CONTACT COOLING WATER
Plant
1
2
3
4
5
6
7
8
9
10
Statistical Summary
Water Use
1/kkg gal/ton
*
41.59
67.54
*
2, 110
2,585
*
*
52,950
145,100
*
9.974
16.20
*
506.0
620.0
*
*
12,700
34,800
Minimum
Maximum
Mean
Median
Sample:
Nonzero
Mean
Sample:
Note:
41.59
9.974
145,100 34,800
33,810 8,109
2,347 563.0
6 of 9 plants
33,810
8, 109
6 of 9 plants
Percent
Recycle
100
100
0
*
0
0
0
0
*
*
Wastewater
1/kkg gal/ton
0
0
20.01
,478
,110
2,585
*
*
*
*
1,
2,
0
0
4.800
354.4
506.0
620.0
*
*
*
*
0 0
2,585 620.0
1,032 247.5
748.8 179.6
6 of 9 plants
1,548 371.3
4 of 9 plants
This table includes data from one plant which discharges
from two rolling heat treatment operations.
280
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Table V-40
EXTRUSION PRESS HEAT TREATMENT CONTACT COOLING WATER
1
1,
1,
26,
2,
2,
2,
3,
5,
10,
16,
21,
25,
28,
Water
/kkg
*
*
924
76.30
80.05
833.9
113.0
116.7
433.6
554.5
*
*
768
600
522
668
831
185
*
670
760
700
890
850
690
*
*
*
*
*
Use
gal/ton
*
*
461 .
18.
19.
200.
27.
28.
104.
133.
*
*
424.
6,380
605.
640.
679.
764.
*
1 ,360
2,580
4,076
5,250
6,200
6,880
*
*
*
*
*
5
30
20
0
10
00
0
0
0
0
0
0
0
Percent
Recycle
100
100
100
0
0
0
0
0
0
0
*
0
0
92
0
0
0
0
0
*
0
0
0
0
0
*
0
*
*
n
Wastewater
1/kkg gal/ton
1,
1,
1,
2,
2,
2,
2,
3,
3,
5,
10,
16,
21,
25,
28,
0
0
0
65.46
68.80
81 .35
96.73
100.1
433.6
554.5
057
447
768
218
522
668
831
185
536
670
760
700
890
850
690
*
*
*
*
*
0
0
0
15.
16.
19.
23.
24.
104.
133.
253.
347.
424.
532.
605.
640.
679.
764.
848.
1 ,360
2,580
4,076
5,250
6,200
6,880
*
*
*
*
*
70
50
51
20
00
0
0
4
0
0
0
0
0
0
0
0
Plant
2
3
4
5
6
7
8
9
10
1 1
12
13
14
15t
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
*Data not available.
tComblnation of two presses.
Statistical Summary
Minimum 76.30 18.30
Maximum 28,690 6,880
Mean 7,676 1,841
Median 2,596 622.5
Sample: 20 of 29 plants
Nonzero 7,676 1,841
Mean
Sample: 20 of 29 plants
0
28,690
5,299
1,768
25 of
6,021
29
0
6,880
1,271
424.0
plants
1 ,444
22 of 29 plants
Note: This table includes data from one plant which discharges
from two extrusion press heat treatment operations.
288
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Table V-43
EXTRUSION SOLUTION HEAT TREATMENT CONTACT COOLING WATER
Plant
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
*Data not available.
Statistical Summary
Water Use
1/kkg gal/ton
*
161,
9,
*
1,
41,
39,
2,
41,
3,
5,
8,
7,
10,
15,
*
*
*
*
*
*
*
*
*
*
*
4,
800
631
268
420
690
635
690
394
003
547
130
730
680
962
38,
2,
9,
9,
10,
1,
2,
1,
2,
3,
1,
*
800
310
*
304.0
933
520
632.0
000
81 4.0
200
050
710
573
760
*
*
*
*
*
*
*
*
*
*
*
190
Percent
Recycle
I
100
100
91
100
0
99
80
0
87
*
*
*
*
*
*
0
0
0
0
0
0
0
0
0
0
0
0
1
2
3
3
5
6
7
10
15
30
44
9
9
9
t
9
9
9
9
9
9
9
*
*
*
*
*
*
*
*
*
*
Wastewater
/kkg gal/ton
0
0
0
0
181.0
879.7
993
635
056
381
003
421
130
730
680
020
150
1,
1,
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3,
7,
10,
0
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632.
733.
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540
710
573
760
200
590
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0
Minimum
Maximum
Mean
Median
Sample :
Nonzero
Mean
Sample:
1 , 268
1 61 ,800
25, 250
9,089
14 of 27
25,250
14 of 27
304.0
38,800
6,057
2,180
plants
6,057
plants
0 0
44,150 10,590
7,901 1,895
3,056 733.0
17 of 27 plants
10,330 2,478
13 of 27 plants
299
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Table V-46
FORGING SOLUTION HEAT TREATMENT CONTACT COOLING WATER
Water Use
Plant 1/kkg gal/ton
1
2
3
4
5
6
7
8
9
10
11
12
833.9
1,151
2,956
2,502
3,235
4,169
21 , 120
32,230
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200.0
276.0
709.0
600.0
776.0
1 ,000
5,065
7,730
*
*
*
*
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Statistical Summary
Minimum
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Sample:
Nonzero
Mean
Sample:
833.9
32,230
8,524
3,096
200.0
7,730
2,045
742.5
8 of 12 plants
8,524 2,045
8 of 12 plants
Percent
Recycle
0
0
*
0
0
0
0
0
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0
*
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1/kkg
0
1,109
2,148
2,502
3,235
3,752
21, 120
32,230
32,320
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gal/ton
0
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515.2
600.0
776.0
900
5,065
7,730
7,752
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0 0
32,320 7,752
10,940 2,623
3,235 776.0
9 of 12 plants
12,300 2,951
8 of 1 2 plants
307
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Table V-49
DRAWING SOLUTION HEAT TREATMENT CONTACT COOLING WATER
Plant
1
2
3
4
5
6
7
8
9
10
11
*Data not available.
Statis t ical Summary
Water Use
1/kkg
13,430
119.2
496.2
921 .4
3,002
*
*
*
*
*
*
gal/ton
3,220
28.60
119.0
221.0
720.0
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*
*
*
*
Percent
Recycle
95
0
0
0
0
*
*
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*
*
*
Wastewater
1/kkg
0
119.2
328.1
921.4
3, 002
27,850
*
*
*
*
*
gal/ton
0
28.60
78.70
221 .0
720.0
6,680
*
*
*
*
*
Minimum
Maximum
Mean
Median
Sample:
Nonzero
Mean
119.
13,430
3,593
921.
5 of
3,593
2
4
1 1
28.6
3,220
861.7
221.0
plants
861.7
Sample:
5 of 11 plants
0 0
27,850 6,680
5,370 1,288
624.8 149.9
6 of 11 plants
6,446 1,546
5 of 11 plants
317
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Table V-52
CLEANING OR ETCHING BATH
Plant
1
2
3
4
5
6
7
8
9
10
1 1
12
13
14
15
16
1 7
18
19
20
21
22
23
24
Water Use
1/kkg gal/ton
Recycle
Wastewater
1/kkg gal/ton
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*Data not available
**Not applicable.
Statistical Summary
Minimum
Maximum
Mean
Median
Sample:
Nonzero Mean
Sample:
Nonzero Mean
(Proposal)
Sample:
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
**
**
**
**
**
**
**
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**
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**
**
**
**
**
**
**
**
**
**
**
**
**
0
0
0
0
0
0
0
0
0.9
1.430
5.816
8.406
9.498
28.35
38.0
69.0
121 .0
156.0
192.4
280.0
346.4
355.0
446.5
800.5
0
0
0
0
0
0
0
0
0.22
0.3430
1.395
2.01 6
2.278
6.800
9.0
1 7.0
29.0
51.5
46.15
67.0
83.08
85.0
107.1
1 92.0
0
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11 9. 13
8.95
0
1 92
28.33
2.1 5
24 of 24 plants
178.7 42.9
16 of 24 plants
204.4 49.02
9 of 10 plants
326
-------
Table V-52 (Continued)
CLEANING OR ETCHING BATH
Note: This table includes only plants that discharge or haul
away the baths and provided enough data for calculation of
the wastewater value.
Note: This table individually lists data from four plants which
have both cleaning and etch line bath discharges.
327
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Table V-55
CLEANING OR ETCHING RINSE
Water Use
Plant
1
2
3
4
5
6
7
8
9
10
1 1
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
1/kkg
21,180
15,800
*
*
8,339
*
102.1
*
*
400.3
500.3
5,003
9,727
141,600
1,063
3,490
*
1 ,313
2,377
*
1,780
*
2, 224
*
*
*
50,030
5,212
*
*
*
10,670
*
*
16, 120
41 ,690
*
23,520
*
*
*
gal/ton
5,080
3,790
*
*
2,000
*
24.49
*
*
96.00
120.0
1 ,200
2,333
33,970
255.0
837.0
*
315.0
570.0
*
427.0
*
533.3
*
*
*
12,000
1 ,250
*
*
*
2,560
*
*
3,865
1 0,000
*
5,640
*
*
*
Percent
Recycle
*
*
*
*
*
*
0
*
*
0
0
*
94.3
99.6
0
*
*
0
*
*
0
*
*
*
*
*
90.0
0
*
*
*
0
*
*
0
50.0
*
0
*
*
*
Wastewater
I/kkg
1.430
2.635
14.48
61 .00
80.05
98.97
102.1
143.8
178.0
333.6
500.3
500.3
558.3
600.0
938.1
1 , 163
1,227
1 ,313
1,591
1 ,692
1, 780
1 ,853
2, 110
2,330
3,386
3,519
5,003
5,212
5,653
5,683
9,795
10,670
11 , 525
14,480
16, 120
20, 850
23, 350
23,520
36, 390
43,950
63, 920
gal/ton
0.3430
0.6320
3.472
14.63
19.20
23.7
24.49
34.5
42.70
80.00
120.0
120.0
133.3
143.9
225.0
279.0
294
315.0
381.6
406
427.0
445
506.0
558.8
812.6
844
1 ,200
1 ,250
1,356
1 ,363
2,350
2,560
2, 765
3,473
3,865
5,000
5,600
5,640
8, 727
10,540
15,330
349
-------
Table V-55 (Continued)
CLEANING OR ETCHING RINSE
Water Use
Plant 1/kkg gal/ton
42
43
44
75,430
89,350
250,200
18,090
21,430
60,000
*Data not available.
Statistical Summary
Minimum 102.1 24.49
Maximum 250,000 60,000
Mean 32,380 7,766
Median 9,033 2,167
Sample:
24 of 30 plants
Percent Wastewater
Recycle 1/kkg gal/ton
0
0
0
75,430
89,350
125, 100
18,090
21 ,430
30,000
1.430
125,100
13,912
982
1
0.3430
30,000
3,338
476
44 of 44 plants
Note: This table individually lists data from six plants which
have both cleaning and etch line rinse discharges.
350
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Table V-58
CLEANING OR ETCHING SCRUBBER LIQUOR
Plant
1
2
3
4
5
6
7
Water Use
1/kkg gal/ton
Percent
Recycle
*
*
*
47,780
*
*
*
*
*
*
11,460
*
*
*
*
*
*
0
*
*
*
*Data not available.
Statistical Summary
Minimum
Maximum
Mean
Median
Sample:
Wastewater
1/kkg gal/ton
1,
1,
12,
47,
880
985
002
780
*
*
*
451 .
476.
2,880
1 1 ,460
*
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*
0
0
1,
47,
15,
6,
880
780
911
994
4 of
451 .0
11,460
3,817
1 ,678
7 plants
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Table V-61
FORGING SCRUBBER LIQUOR
Plant
1
2
3
4
Water Use
1/kkg gal/ton
*
*
5,937
*
*
1,424
*
Percent
Recycle
P
P
0
*
Wastewater
1/kkg gal/ton
28.85
159.7
4,453
*
*Data not available.
P Periodic discharge.
Statistical Summary
Minimum
Maximum
Mean
Median
Sample:
28.85
4,453
1,547
159.7
3 of
6.920
38.31
1,068
*
6.920
1,068
371.1
38.31
4 plants
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Table V-64
DIRECT CHILL CASTING CONTACT COOLING WATER
(ALUMINUM FORMING PLANTS)
Plant
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
Water
1/kkg
*
*
2,743
*
*
*
*
*
8.339
82,050
105,000
86,430
82,640
908.9
30,670
37,530
31 ,340
392.8
*
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73,800
31 ,440
3,819
14,090
35,320
36,980
177,900
70,880
62,960
72,130
43,360
3,394
*
5,041
*
9,089
9,506
23,060
28,390
35,500
52,540
Use
gal /ton
*
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658.0
*
*
*
*
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2.000
19,680
25,190
20,730
19,820
218.0
7,355
9,000
7,516
94.20
*
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17,700
7,540
916.0
3,380
8,470
8,870
42,670
17,000
1 5,100
17,300
10,400
814.0
*
1,209
*
2,180
2,280
5,530
6,810
8,514
12,600
Percent
Recycle
100
100
50
97
100
100
100
100*
100
99
99
100
99
0
98
97
99
0
*
*
97
98
0
93
94
97
99
96
96
94
92
0
*
0
*
0
0
0
0
0
0
Wastewater
1/kkg
0
0
0
0
0
0
0
0
0
0.2989
0.3252
0.4169
0.4169
120.9
150.1
250.2
313.4
392.8
496.2
514.5
612.9
629.6
779.7
963.1
1,113
1 , 167
1 ,483
1 ,534
1 ,955
2,397
2,753
3,002
4,003
5,041
5,337
9,089
9,506
16,590
28,390
35,500
52,540 1
gal /ton
0
0
0
0
0
0
0
0
0
0.0717
0.0780
0.1000
0.1000
29.00
36.00
60.00
75.16
94.20
119.0
123.4
147.0
151 .0
187.0
231 .0
267.0
280.0
355.6
368.0
469.0
575.0
660.4
720.0
960.0
1,209
1 ,280
2, 180
2,280
3,980
6,810
8,514
2,600
404
-------
Table V-64 (Continued)
DIRECT CHILL CASTING CONTACT COOLING WATER
(ALUMINUM FORMING PLANTS)
Plant
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
Water
1/kkg
58,370
91 ,310
*
*
*
*
*
*
*
*
*
*
*
*
50,030
*
*
*
*
*
Use
gal/ton
14,000
21,900
*
*
*
*
*
*
*
*
*
*
*
*
1 2,000
*
*
*
*
*
Percent
Recycle
0
0
98
96
*
*
0
0
*
0
*
0
*
*
100
*
*
0
90
*
Wastewater
1/kkg
58,370
91 ,310
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
gal/ton
14,000
21 ,900
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*Data not available.
405
-------
Table V-65
DIRECT CHILL CASTING CONTACT COOLING WATER
Primary Aluminum Subcategory
Plant
1
2
3
4
5
6
7
8
9
10
1 1
12
13
14
15
16
1 7
18
19
20
21
22
23
24
25
26
27
28
29
30
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
ter Use
gal/ton
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
*
Percent
Recycle
99+
99
98
98
94
82
48
20
0
0
0
0
0
0
0
0
0
0
0
93
*
*
0
*
*
Wastewater
1/kkg
123
459
1,801
9,549
3,303
2,610
600
19,473
6,964
12,552
15,638
27,188
32,860
34,903
38,406
45,870 1
57,129 1
59,214 1
79,230 1
NA
NA
NA
NA
NA
NA
gal/ton
29.52
110.2
432.2
2,292
792.7
626.4
144.0
4,674
1,671
3,012
3,753
6,525
7,886
8,377
9,217
1 ,009
3,711
4,21 1
9,015
NA
NA
NA
NA
NA
NA
Secondary Aluminum Subcategory
*
*
*
*
*
99
100
100
100
100
0.3002
0
0
0
0
0.0720
0
0
0
0
*Data not available.
406
-------
Table V-65 (Continued)
DIRECT CHILL CASTING CONTACT COOLING WATER
Statistical Summaryt
Minimum 8.339 2,
Maximum 177,900 42,670
Mean 43,900 10,530
Median 35,500 8,514
Sample: 33 of 91 plants
000
0
91 ,310
1 ,329
1,483
67 of
21
91
0
900
318.9
355.6
plants
tThe statistical summary includes direct chill casting data for
aluminum forming, primary aluminum, and secondary aluminum
plants with 90 percent recycle or greater.
407
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Table V-68
CONTINUOUS ROD CASTING CONTACT COOLING WATER
(ALUMINUM FORMING PLANTS)
Water Use Percent
Plant 1/kkg gal/ton Recycle
1 0 0 Dry
2 1,555 375 0
3 * * P
Wastewater
1/kkg gal/ton
0
1 ,555
*
0
375
*
*Sufficient data not available to calculate these values.
P Total recycle with periodic discharge.
Statistical Summary
0
1 ,555
777.5
777.5
Minimum
Maximum
Mean
Median
Sample:
Nonzero
Mean
Sample :
1 ,
2
1,
1
0
555
777.
777.
of 3
555
of 3
0
375
5 187.
5 187.
plants
375
plants
5
5
0
375
187.5
187.5
2 of 3 plants
1,555 375
1 of 3 plants
426
-------
Table V-69
CONTINUOUS ROD CASTING CONTACT COOLING WATER
(PRIMARY ALUMINUM PLANTS)
Production Normalized
Plant Code Percent Recycle Discharge Flow _
2 99 415
3 99+ 11.3
*Data unknown.
427
-------
Table V-70
CONTINUOUS ROD CASTING SPENT LUBRICANT
Plant
1
2
3
Water
1/kkg
*
*
*
Use
gal /ton
*
*
*
Percent
Recycle
100
100 (P)
*
Wastewater
1/kkg
0
*
*
gal /ton
0
*
*
*Sufficient data not available to calculate these values.
P Periodic discharge.
428
-------
Table V-71
CONTINUOUS SHEET CASTING SPENT LUBRICANT
Plant
1
2
3
4
5
Water Use
1/kkg gal/ton
*
5.087
*
1.220
*
*
Percent
Recycle
100
* (P)
* (P)
* (P)
* (P)
Wastewater
1/kkg gal/ton
0
1 .017
2.668
0
0.2440
0.6400
^Sufficient data not available to calculate these values
P Periodic discharge.
Statistical Summary
Mini mum
Maximum
Mean
Median
Sample:
Nonzero
Mean
Sample: 2 of 5 plants
0
2.
1 .
1 .
1 .
668
229
017
3 of
964
0
0.6400
0.2947
0.2440
5 plants
New
Note: An additional seven continuous sheet casting plants did
not mention the use of a lubricant , but one is probably
used. Also, three additional plants did not provide
sufficient data to characterize water use or discharge.
429
-------
Table V-72
DEGASSING SCRUBBER LIQUOR (PRIMARY ALUMINUM PLANTS)
Water Use
Plant
1
2
3
4 (a)
I
2
3
1
/kkg
,842
,125
,854
*
gal/ton
682
750
445
if
Percent
Recycle
0
0
0
*
*Data not available or not applicable,
Statistical Summary
Minimum
'-laximum
'lean
Median
-ample :
1,854 445
3,125 750
2,607 626
2,842 682
3 of 4 plants
Wastewater
1/kkg gal/ton
2,842
3, 125
1,854
1 ,854
3, 125
2,607
2,842
3 of 4
682
750
445
445
750
626
682
plants
(a) Data is reported with potline and potroom scrubbing and
can not be separated.
430
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Table V-75
EXTRUSION PRESS HYDRAULIC FLUID LEAKAGE
Plant
1
2
3
4
5
Water
1/kkg
*
*
*
*
*
Use
^al/ton
*
*
*
*
*
Percent
Recycle
99P
99P
0
0
0
Wastewater
1/kkg
258
337
452
1,429
2,554
gal/ton
61.8
81
108
343
613
* Data not available,
P Periodic discharge,
Statistical Summary
Minimum
Maximum
Mean
Median
Sample
Mean (no recycle)
Sample
Mean (recycle)
Sample
258
2,554
1,006
452
5 of
478
3 of
298
2 of
1
61.8
613
241 .4
108
5 plants
354.7
5 plants
71.4
5 plants
436
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Table V-79
MISCELLANEOUS NONDESCRIPT WASTEWATER
Plant
1
2
3
4
Water
1/kkg
Use
gal/ton
*
*
*
*
*
*
Percent
Recycle
0
0
0
0
Wastewater
1/kkg gal/ton
3.7
60.6
70.8
353.8
*Data not available.
Statistical Summary
Minimum
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