Development Document for Interim Final Effluent Limitations Guidelines and Proposed New Source Performance Standards for the Forming, Finishing and Specialty Steel Vol 2

EPA 440/1-76/048- Group I, Phase II . / - -,- '7''.-t ,.) ------- DEVELOPMENT DOCUMENT for INTERIM FINAL EFFLUENT LIMITATIONS GUIDELINES and PROPOSED NEW SOURCE PERFORMANCE STANDARDS for the FORMING, FINISHING AND SPECIALTY STEEL SEGMENTS Of the IRON AND STEEL MANUFACTURING POINT SOURCE CATEGORY Volume 2 Russell E. Train Administrator Andrew W. Briedenbach, Ph.D. Assistant Administrator for Water and Hazardous Materials Ernst P. Hall Acting Director, Effluent Guidelines Division Edward L. Dulaney, P.E. Project Officer Patricia E. Williams, P.E. Project Officer John G. Williams Assistant Project Officer March, 1976 Effluent Guidelines Division Office of Water and Hazardous Materials U.S. Environmental Protection Agency Washington, D.C. 20460 ------- SECTION VIII COST, ENERGY, AND NON-WATER QUALITY ASPECTS INTRODUCTION This section will discuss the incremental costs incurred in applying the different levels of pollution control technology. The analysis will also describe energy requirements, nonwater quality aspects (including sludge disposal, by-product recovery, etc.), and their techniques, magnitude, and costs for each level of technology. It must be remembered that some of the technology beyond the reference level is already in use. Also many possible combinations or permutations of various treatment methods are possible. Thus, not all plants will be required to add all of the treatment capabilities, or incur all of the incremental costs indicated to bring the reference level facilities into compliance with the effluent limitations. Costs The water pollution control costs for the plants visited during the study are presented in latles 109 through 128. The treatment systems, gross effluent loads, and reduction benefits were described in Section VII. The costs were estimated from data supplied by the plants. The1 results are summarized as follows: ') Process Plant Cost per unit weight of product (1) $/kkg $/ton Product M. Hot Forming A-2 B-2 C-2 D-2 E-2 F-2 G-2 H-2 1-2 J-2 K-2 L-2 M-2 N-2 0. 203 0.286 0.482 0.445 0.644 1.69 0.730 0. 161 1.81 0.809 1. 19 (NA) 0.604 0.925 0.184 0.26 0.437 0.404 0.584 1.53 0.662 0.146 1.64 0.734 1.08 (NA) 0.548 0.839 Hot Rolled Product 455 ------- M. Hot-Forming (primary) N. Hot-Forming (section) O. Hot-Forming (flat) P. Pipe and Tubes Ave E H K R M D Q C H K 0 R 0 Q E F D E-2 GG-2 HH-2 II-2 JJ-2 KK-2 0.284 — 0.203 - - None 0 - 0.417 — 1.894 0.739 - — 0.052 0.491 - None 0.927 (NA) (NA) 0.378 0.397 0.093 0.696 0.258 _ 0.184 — — None - 0.378 . 1.718 0.670 — _ 0.047 0.445 — None 0.841 (NA) (NA) 0.343 0.360 0.084 Steel Rolled Steel Rolled Steel Rolled Pipe and Tubes Ave Q. Pickling-Sulfuric Acid-Batch Cone. 1-2 0-2 P-2 Q-2 R-2 Ave Sulfuric Acid Batch Pickling R Batch Rinse 1-2 1-2 P-2 Q-2 R-2 S-2 0.264 0. 122 0. 115 (NA) (NA) 0.0507 0.679 0.407 1.80 0.353 1.98 0.319 0.373 1.63 0.320 1.80 0.289 0.338 0.875 0.0239 0.0111 0. 104 (NA) (NA) 0.046 0.616 Pickled Product Pickled Product 456 ------- Continuous Ave T-2 R. Pickling- Hydrochloric Acid- Batch Cone. U-2 V-2 Batch Rinse Continuous Cone. Continuous Rinse S. Cold Rolling Ave U-2 V-2 Ave 1-2 W-2 X-2 Y-2 Z-2 AA-2 BB-2 Ave 1-2 W-2 X-2 Y-2 Z-2 AA-2 EB-2 Ave 0.777 0.427 0.0709 1.98 0.0342 (NA) (NA) (-0.662) (NA) 1.28 (NA) 0. 105 0.354 (NA) (NA) (NA) 0.0673 0. 136 0.400 0.798 0. 169 0.645 0.258 0.389 0.194 0.705 0.387 0.0643 0.226 1.80 0.0311 0.916 (NA) (NA) (-0.600) (NA) 1.16 (NA) 0.0953 0.628 0.321 (NA) (NA) (NA) 0.0610 0.123 0.363 0.217 0.724 0. 153 0.585 0.234 0.353 Pickled Product Pickled Product Pickled Product Pickled Product Pickled Product X-2 BB-2 DD-2 EE-2 FF-2 Ave D I P 0.798 0. 169 0.645 0.258 0.389 _ — _ 0.724 0. 153 0.585 0.234 0.353 0.410 _ _ _ Cold Rolled Product 457 ------- T. Hot Coatings- Galvanizing 1-2 MM-2 NN-2 Ave 0.368 0.908 0.498 U. Hot Coatings- Terne Plate W. Combination , (Continuous) (Batch pipe & tube) Combination Acid Pickling (Other batch) X. Kolene Scale Removal Hydride Scale Removal Y. Wire Coating & Pickling Z. Continuous Alkaline Cleaning 0.334 0.824 0.452 0.537 Coated Product OO-2 PP-2 Pickling A D I 0 Pickling U (NA) (NA) 2.547 0.388 0.598 4.043 19.800 (NA) (NA) 2.315 0.353 0.544 3.675 18.00 Coated Product Steel Pickled Steel Pickled C F L L C Q L K L O ie I 0.949 4.663 0.822 0.011 0.031 1.247 0.005 3.896 0.066 1.486 4.239 1.486 0.010 0.028 1.134 0.006 3.542 0.060 Steel Pickled Steel Cleaned Steel Cleaned Wire Processed Steel Cleaned NOTE: (1) NA or (-) means not available from company supplied data. (2) Appearance of a negative cost indicates a profitable operation. FULL RANGE O_F TECHNOLOGY .IN USE OR AVAILABLE TO THE STEEL INDUSTRY 458 ------- CO •Pi I 81 col ml (0 n a co x K O u H EH CO 0 >t4J •p e in c n o id rlP« -P rl 0 CO -t Ct3 C O 0 C C co u id u H 3Vl 0 ex; 04J i o c n c id 0 O-PX. 4-> Vl 0 EH 10 H Id S Hit HH 10 4J C 0 fgj g Sni VI iJ-H 3 tr 0 « g •H -p a 0 +1 % fi-rl 0 EH 0 rH to 10 C E O " •" H rH C-P A a a O -P Vl -rl P. 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M H EH 3 O Q Q 01 VO VO VO VO CO CO 00 c^ o in vr> r~ I-H o co r~ co CN in ro in en 04 in . o CO o CN d co o CN 0 ro o r- rH O O r- o EH 0 o o rH «• > 00 rH r~ en in 04 "t rH rH rH CN cn in EH 01 8 1 I O o o 512 ------- O X w o 5jJ 3 K (N 1 £ 04 1 CO (N 1 Ol Ol PLANT s o • o 1 00 n ro O 0 o 91 00 VO rH 1 00 0 CN O Z « O W W Q EH S « W EH « 1 UN EH CO W O W W EH co « « O CM nl n H EH J3 O S Q Q W rH rH 00 O OJ O CTl CO ** O OJ CN in CO itf CO «? O m royi^rcororHt^- o H ^ • 00 CM O s to ooOrHoco r- 01 O 00 CT1 VD r^ rH Oi O r~ OJCTICO^IVDICV o f rH •>» O rH S Pi J a o a EH i% 3 H co •• M w o 04 > EH O CO J2 EH 3 & W 2 W 9 rf H O H H a H CM CJ EH EH W O O J fe M EH W « q < J K i-l E: 05 EH W «; H 3 WHHP• 00 o OJ I o ------- CO s i X CM X CM 3 CM 1 CM 1 PLANT g § EH ft 8 01 EH ft O O D !H U S3 W (0 r^ CM co co cn rH (N CM rH CM P- CM cn CM r- o rH o r- CM to r^ o «» tO CM H CO CO EH Q § Q H S CO EH ft O O D X U Z CO ! O W Q W « Q 55 Q ft O H ioj EH \|J CO D > ft w P< J cn q 3 8O W p4 H W O fe & O rl ft CJ to to r» ^ r- cn to t^ vo co r-* in tO tO CO VO VD rH co cn ^r en i co rH «* co cn co CM cn n in EH 3 3 H CO •• i-] W O ft U co O H C > EH CD CO S3 EH O 53 CO 2! W «5 n; H O H H 2 H h U CH EH W CJ O 3 t-l Si-1I3KEHW'3 H i=? WHHftcoCQEH S3 EH D ftEHrfWOEHO O H g ODSQCJOEH EH 55 S? "^ cn in 00 H i o CO CO VO cn EH O O 0 rH 514 ------- o CN CO g W 5 J3 W CN 1 x CN i s CN 1 CN 1 D IN H £4 J2j At EH S £-4 gj O « 25 EH EH a < W Q H hi s§s O 2 to O m CN v 1 rH 1 1 1 III co n r~ co in CO 1 I g g co •• 13 w W CO O SS CO S W rt! H O H H 2 H «J W M H EH D Pi EH ft, H g O D S H rtj g Pi a CN CN rH VO CTv H ^ 1 1 CN O O ID ID VO ID ^ B. i i in m rH H r~ o CN CN m ID co co co co m rH g jrf[ H tt u o w B: j 2 EH W rii p< CO Bd EH W O EH p Q O O EH CN O CO rH . 1 rH cn o d rH m o , 0 CN O CO , rH r-l CN m O 1 0 rH CM 1 00 < O 7S CO M EH EH 2 55 H CO •• >-] W O Cu W CO O H ft! > EH CD CO 2 EH (J 2 CO E; W «! rt H O H H 2 H bi O E< EH W O O J itf H EH W »! iJ ft iJ MiJ2SEHW< H 3 WHHCWCOKEH EH D PtEnrtWOEHO H g ODSQUOEn H rf fM 0 00 1 H n o o CO VD n o m CN rH 0 rH VO O o I o H CM 00 OJ O O 0 ^» 00 rH o rH CN H cn T O 1 O o o rH 4> 515 ------- u W a 3 •)( CM 1 W W •rl Ul •rl ^ in vo CM «» coinfcnvoi' o co f^ O CO CO rH CM rH H CO CM Q & 3 W Q O ^ co CH fa c3 en < w in cC EH O tO 3 U rH O 2 X \ o co w «> co vo CM r^ CK co o in CM in CM eo m in vo rH oo m CN rl CO CO VO CO CO in vO CD i-H t- CO CO rH rH O O in in vo in «3" CM o rH rH CO rH CT1 ^o v0 oo r^ CN G\ ro o to rH i"1"* ^ ^i* irt ^r ^•lOC^OVi) ID rH ^D N •» ». h ^* . * ino^r^oorHit^- o oo n co cs if) in •H d o on ro rj« O LO G* f CN • I >1 rH c 0 rl O a) JJ id o •Q 01 in •rl vU 4J 3 •rl 4J ortion a P4 M 3 3 3j * V >, tn * CM i CM J, p> * (N 1 co CO « CN pj, IV, 7 « £ 0 rH en o in rH p— 00 CO CO co co •41 m CO in (N o [••. o o CO o r- o Ol CO rH ^ g S ^1 CO I H 3 H EH H g H f r- o l CO « o 0 CO oocncOrHcovoin co i^Ovocncocovo ^t t'tvOOMCOCO o CM rH ^" Ul VO O O H CO o o r- co o o co in vo co co r^ o en CM I1 CO n CO CO rH CO rH VO w x o w a CO a Z Q EH Q OHOH§«Hl-1g rtOEHDCSEHrlH rfSiwDWcooSSco D CJ O U Q W EH ZEHgUOEHQQWCO ^^K^r.^^goO rHVOCOO'S'rHCM in cOroocMCOr-o co om^rco^rr-rH o n IN H r- r- co rH CO mvDcor~r-r-icn 0\ CO CJ OK 00 i-l d in in CM d m VO Cft rH *j en ,_J •* en rH EH EH O o o rH s^ • >1 C3 o g, 4) •M ------- o u 517 ------- a CO g ui O O 53 O H N EH H W O EH I EH U) 53 O H S3 8 a i ™ vo o r- o oo vo in vo o r~ CM 03 03 or~-rnkO'U' ^J VD r** c>j m vo ^-f (^ o^ rH c) fo ^r or-tNi^oaor^ co m r^ comrHvorocNC- o M VD (N rH in (N CN • in rH o $* 25 W « H 2 O N O Q b, M M H >j K EH O i^ (/) icll rfj H flj EH > 3 > Qt W J W EH Q S o «; PM o S o O U O 2 Ai U O in O rH CN CO ^J O m^Q>QCOrorQCM vo rH co ro I1 n in 00 II rH O rH S (j/ J w o 3 EH ffl E5 H EH EUJ O H 3 EH EH O to 2J EH O 01 a w 3 "! i^ HOHHSSHfe H fl O M a 0) n) o •9 (0 U) •H ,3 4J •a s 3 a j nj Portion 518 ------- ro (M § CO 8B °3 EH O, < w W EH EH I £H CO 13 O gg J EH fa rt; CM O W O « EH J» s 8 i S61 W O Pi O H re " % V St* .. u o ft H EH U « J K iJ E3 B EH U < CqMMO.COKEH !3 P ------- 9 o § to 8 tfl !3 CM P* O Pti to 8 CO H a * a w o RANGE Slagging M 0) O 25 W EH EH 2 H CO CO S W CO EH EH W < g S o 3 ii EH g,.Q § ^g 2 « J W O «! S fq EH EH rd 3 H EH CO •• i~1 W O Pi « M M O H oj EH > IH O W 2 EH O fe yi Z W < rt i-5 HOHHiSHCu «! O EHEHWOO^ O hJ ffi H EH W « J 2 J (2iJS;3EHw5 0 H 2 WHHP ------- 00 EH 00 O CD o is H EH hJ S Vi W O z: H LO EH PH CM < H WO PS H Wr . f \ t-H CJ j < 03 EH • O CM O CD OO CD cn CO o co H LO r-l zt- cn oo rH CM CD 00 J- CO CD rH r- o CNI o o CM j- H CO t~- O • O O J- C~^ CMCOOHOCOLO CO HCDCDCCMOOO en CM zi- rH H oo co =t~ rH OO LO oo : . o CO COCDLOLOCMJ-LO cn cnHCDrHHcoH H f^LOrHJ-J-COCO LO CMCDLOCMCDCOCsl CD J- CD J- CM rH cn CM EH W < P^ S EH W EH H S EH ^ 00 •• PL, O S O W 00 < H M PH > tr< tJ fr <, S 00 < S "S H O PH H O O O us >H J W CD • J S <^l-4EHPHPHPHO EH 0 EH < S oo H J W CD • iJ S EH O EH < S 00 < S CAS H O PH H CJ O O CAS >H J W CD • J S ^F-JEHPHPHPHCJ-^CO H ------- B 8 fj EH 2 H l-l « ng CN rf O ^ § § W E^ S 3 9 £9 64 S6 SCO H Pi 15 •a; s •H ID > 1 p; (U rH us O w g a) -t s z CH r ' H^ EH ,4 P O 0 c. 1 , , , , , 1 , w w § 1 1 1 1 1 § 1 o o S till r** r^* <~( O (N CN1 O & 0 c y W W 3 H H Pi J2 W3 &< ^ S 3 H O OH U O u) >< J W W O • J !3 3 J EHpJPSPiOiSp H < i/l PM W W W iH t-i f D OWPtZHp\ H g oaowafiw 2 « H ------- CM rH W PQ EH CO EH CO O3 O 55 O M H EH < 55 O W O EH Q < 55 W < EH 03 EH M W X D O J H PH P-H H W W EH w 03 52 EH 55 CO H 0 O -J j t t-p^ 55 55 M < 00 CM CD f- rH 1 rH O O rH rH j EH H p i <] O PH 0 EH CO O O oo r- CO rH CD CO O O -Hr rH 1 1 c-- r- C^ rH CD CO C-- CD CM 55 EH o a M M EH H CD W W CM LO 00 ,—\| CO CD CD O 00 -,- CO ^~~1 o J2; ------- 03 CM 3 ------- The full range of technology in use or available to the steel industry today is presented in Tables 66 to 87. In addition to presenting the range of treatment methods available, these tables also describe for each method: 1. Resulting effluent levels for critical constituents 2. Status and reliability 3. Problems and limitations 4. Implementation time 5. Land requirements 6. Environmental impacts other than water 7. Solid waste generation BASIS OF COST ESTIMATES Costs associated with the full range of treatment technology including investment, capital depreciation, operating and maintenance, and energy and power are presented on water effluent cost tables corresponding to the appropriate category technology Tables 129 to 150. Costs were developed as follows: 1. National annual production rate data was collected and tabulated along with the number of plants in each subcategory. From this, an "average" size plant was established. 2. Flow rates were established based on the data accumulated during the survey portion of this study and from knowledge of what flow reductions could be obtained with minor modifications. The flow is here expressed in 1/kkg or gal./ton of product. 3. Then a treatment process model diagram was developed for each subcategory. This model was based on knowledge of the manner in which most plants in a given subcategory handle their wastes, and on the flow rates established by 1 and 2 above. 4. Finally, a quasi-detailed cost estimate was made on the developed flow diagram. Total annual costs in August, 1971 dollars were calculated on total operating costs (including all chemicals, maintenance, labor, energy, and power) and the capital recovery costs. Capital recovery costs were then subdivided into straightline ten-year depreciation and the cost of capital at a 1% annual interest rate for ten years. 525 ------- The capital recovery factor (CRF) is normally used in industry to help allocate the initial investment and the interest to the total operating cost of a facility. The CRF is equal to i plus i divided by a -1, where a is equal to (1 i) to the power n. The CRF is multiplied by the initial investment to obtain the annual capital recovery. That is: (CRF) (P) = ACR. The annual depreciation is found by dividing the initial investment by the depreciation period (n = 10 years). That is: P/10 = annual depreciation. Then the annual cost of capital has been assumed to be the total annual capital recovery minus the annual depreciation. That is: ACR - P/10 = annual cost of capital. Construction costs are dependent upon many different variable conditions, and in order to determine definitive costs the following parameters are established as the basis of cost estimates. In addition, the cost estimates as developed reflect only average costs. a. The treatment facilities are contained within a "battery limit" site location and are erected on a "green field" site. Site clearance costs such as existing plant equipment relocation, etc., are not included in cost estimates. b. Equipment costs are based on specific water flow rates requiring treatment. A change in water flow rates will affect costs. c. The treatment facilities are located in close proximity to the steelmaking process area. Piping and other utility costs for interconnecting utility runs between the treatment facilities battery limits and process equipment areas are not included in cost estimates. d. Sales and use taxes or freight charges are not included in cost estimates. e. Land acquisition costs are not included in cost estimates. f. Expansion of existing supporting utilities such as sewage, river water pumping stations, increased boiler capacity are not included in cost estimates. g. Potable water, fire lines, and sewage lines to service treatment facilities are not included in cost estimates. h. Limited instrumentation has been included for pH control, but no automatic samplers, temperature indicators. 526 ------- flow meters, recorders, etc., are included in cost estimates. i. The site conditions are based on: (1) No hardpan or rock excavation, blasting, etc. (2) No pilings or spread footing foundations for poor soil conditions. (3) No well pointing. (H) No dams, channels, or site drainage required. (5) No cut and fill or grading of site. (6) No seeding or planting of grasses and only minor site grubbing and small shrubs clearance; no tree removal. j. Control buildings are prefabricated buildings, not brick or block type. k. No painting, pipe insulation, and steam or electric heat tracing are included. 1. No special guardrails, buildings, lab test facilities, signs, docks are included. Other factors that affect costs but cannot be evaluated: a. Geographic location in United States. b. Metropolitan or rural areas. c. Labor rates, local union rules, regulations, and restrictions. d. Manpower requirements. e. Type of contract. f. Weather conditions or season. g. Transportation of men, materials, and equipment. h. Building cede requirements. i. Safety requirements. j. General business conditions. The cost estimates do reflect an on-site "battery limit" treatment plant with electrical substation and equipment for powering the facilities, all necessary pumps, treatment plant interconnecting feed pipe lines, chemical treatment facilities, foundations, structural steel, and control house. Access roadways within battery limits area are included in estimates based upon 3.8 cm (1.5 in.) thick bituminous wearing course and 10 cm (4 in.) thick sub-base with sealer, binder, and gravel surfacing. A nine gage chain link fence with three strand barb wire and one truck gate was included for fencing in treatment facilities area. 527 ------- The cost estimates also include a 15% contingency, 10% contractor's overhead and profit, and engineering fees of 15%. The costs as developed above were scaled to the size of facilities appropriate in alloy and stainless steel operations for those categories in which similar wastewater treatments would be utilized. Capital costs were scaled on the basis of the ratios of the wastewater flow rates raised to the 0.6 power. The "six-tenths" rule is an accepted relationship in chemical process cost estimation and its validity was tested and found to be acceptable using steel industry wastewater treatment plant cost data. Operating, maintenance and other similar costs were scaled on the basis of the direct ratios of wastewater flow rates. REFERENCE LEVEL AND INTERMEDIATE TECHNOLOGY, ENERGY, AND NON- WATER IMPACT The reference levels of treatment, the energy reguirements, and non-water quality aspects associated with intermediate levels of treatment are discussed below by subcategories. Basic Oxygen Furnace (Wet Air Pollution Controls) 1. Base Level of Treatment: Agueous discharge from primary scrubber to thickener with water used on a once-through basis. Thickener underflow filtered by rotary vacuum filters and filter cake recycled to sinter plant or landfilled for disposal. Filtrate recycled to thickener. 2. Additional Energy Requirements: To bring the quality of the effluent of the water treatment system utilized in the fume collection of the EOF (wet) steel manufacturing process up to the anticipated standard for 1977, additional energy will be necessary. The additional energy consumed will be 0.63 kwh/kkg (0.58 kwh/ton) of steel made. The annual operating cost for this additional consumption of power will be approximately $6,766.00. 3. Non-Water Quality Aspects a. Air Pollution: The air pollution problem of primary significance in the EOF (wet) method .of steelmaking is particulate emissions. Although the furnace exhaust fumes will be passed through a scrubber or electrostatic precipitator, some particulate matter will be emitted into the atmosphere. This is inherent in the production process and is not derived from the wastewater treatment system. 528 ------- TABLE 129 WATER EFFLUENT TREATMENT COSTS STEEL INDUSTRY Basic Oxygen Furnace (Wet Air Pollution Control Methods) Treatment or Control Technologies Identified under Item III of the Scope of Work: Investment Annual Costs: Capital Depreciation Operation & Maintenance Sludge Disposal Energy & Power Chemical TOTAL Effluent Quality: Raw Effluent Constituents Waste Parameters-units Load Flow, sal/ton 872 Suspended Solids, TOR/! 2,700 Fluoride, me/1 10 pH 6-9 BPCTCA A <— $901,709 18 38,773 90,171 1 24,597 74,443 16,110 70 $244,094 74 B ,643 801 ,864 506 362 ,562 ,095 RESULTING EFFLUENT 872 872 80 10 6-9 40 10 6-9 C 301,318 12,957 30,131 8,219 6,404 978 58,689 LEVELS 50 50 50(1) 6-9 BATEA ' ' D ' 250,280 10,761 25,028 6,827 558 5,679 3,328 52,181 50 25 20 6-9 1 E 247,785 10,655 24,779 6,904 2,417 16 44,771 50 10 5 6-9 (1) Value that can be obtained using BPCTCA treatment technology. 529 ------- b. Solid waste Disposal: There should be no problem in disposing of the solid waste generated by the fume collection system for the EOF (wet) process for the manufacture of steel. It can be internally consumed in the sinter process plant, where available, or otherwise by landfill. Vacuum Degassing 1. Base Level of Treatment: Once-through system. Treatment involves a scale removal classifier. 2. Additional Energy Requirements: Additional power will be necessary when bringing the quality of the effluent from the water treatment system utilized in the barometric condensers for the vacuum degassing process up to the anticipated standard for 1977. The additional energy utilized will be 11.4 kwh/kkg (10.3 kwh per ton) of steel produced. For the typical 472 kkg/day (520 tons/day) vacuum degassing facility, the additional power required will be 224 kw (300 hp). The annual operating cost for this additional power consumption will be approximately $22,500.00. 3. Non-Water Quality Aspects a. Air Pollution: Won-condensable gases are vented to the atmosphere during degassing. This is inherent to the production process, however. b. Solid Waste Disposal: The solid waste that will be generated by the creation of a vacuum for the degassing process should present no problem. It can be landfilled or consumed in the sinter plant. Continuous Casting and Pressure Slab Molding The carbon steel costs were based on a water use of 4200 gallons per ton and a daily production of 1070 tons. The plant survey data here indicate an average production of about 600 tons per day and a water use of 1,000 gallons per ton. Although the flow rates during casting are higher, the proportions should be valid as follows for scaling purposes: Carbon steel: 4200 X 1070 1440 = 3120 gpm Alloy steel: 1000 X 600 1440 = 417 gpm Capital costs were thus scaled on the basis of the ratio of flow rates to the six-tenths power. 530 ------- TABLE 130 WATER EFFLUENT TREATMENT COSTS STEEL INDUSTRY Vacuum Degassing Treatment or Control Technologies Identified under Item III of the Scope of Work: Investment Annual Costs: Capital Depreciation Operation & Maintenance Sludge Disposal Energy & Power Chemical TOTAL Effluent Quality: Raw Effluent Constituents Waste Parameters-units Load Flow, gal/ton 560 Suspended Solids, mg/1 Lead, me/1 Manganese, mg/1 Nitrate, mg/1 (1) Zinc, me/1 (2) PH 200 3 20 80 30 5-10 BPCTCA A B $259,774 423,797 11,170 18,224 25,977 42,379 9,092 14,832 36 22,500 $ 46,275 97,935 RESULTING EFFLUENT 560 25 100 50 2.5 2.0(3) 15 10(3) 80 175(3) 20 15(3) . 6-9 6-9 BATEA C ' D 307,170 60,008 13,208 2,581 30,717 6,000 10,750 2,100 31 29,250 2,250 753 84,709 12,931 LEVELS 25 25 25 10 0.5 0.3 5 3 45 45 5 3 6-9 6-9 (1) If nitrogen gas is used to purge system, nitrate concentrations can be very high. If inert gases are used, nitrates are negligible. (2) Zinc concentration depends on type of scrap used in steelmaking process. (3) Value expected of typical treatment plant utilizing BPCTCA technology. 531 ------- TABLE 131 WATER EFFLUENT TREATMENT COSTS STEEL INDUSTRY Continuous Casting £ Pressure Slab Molding Treatment or Control Technologies Identified under Item III of the Scope of Work: Investment Annual Costs: Capital Depreciation Operation & Maintenance Sludge Disposal Energy & Power Chemical TOTAL Effluent Quality: Raw Effluent Constituents Waste Parameters-units Load Flow, gal/ton. 1000 BPCTCA A $16,653 594,245 715 25.553 Ir665 59r424 9.290 BATEA B ' 29.751 1.279 2r975 465 2.000 98 4.955 1.206 4.380 99.320 5.925 RESULTING EFFLUENT LEVELS 1000 125 125 Oil & Grease. me:/l 15 15 15 10 Suspended Solids, mg/1 125 6-9 100 6-9 50 6-9 10 6-9 532 ------- Operating and maintenance and other costs were scaled on the basis of the ratio of flow rates. 1. Base Level of Treatment: Recycle system utilizing scale pit settling, oil skimming, flat bed filtration and cooling towers. 2. Additional Energy Requirements: Additional power will not be required to meet proposed standards for 1977 since the base level is the BPCTCA treatment model. 3. Non-Water Quality Aspects a. Air Pollution: Non-condensable gases and fumes are generated during continuous casting operations but to a relatively minor extent. b. Solid Waste Disposal: The solid waste generated can be consumed internally in the sinter plant. Hot Forming - Primary Reference Level of Treatment. Once-through system. Scale pit with oil catching baffles for suspended solids and gross oil removal. Additional Energy Requirements. To meet EPA 1977 standards for wastewater discharge to public waters, modifications will be required to the wastewater treatment system. The additional power consumed will be 2.67 kwh/kkg (2.42 kwh/ton) processed. For the typical 3,628 kkg/day (1,000 ton/day) facility, the power required will be 403 kw (540 horsepower). The annual cost to operate this equipment will be $40,500. Non-Water Quality Aspects. 1. Air Pollution: None 2. Solid Waste Disposal: The sludge will be collected and recycled to melting operations. Hot Forming - Section Reference Level of Treatment. Once-through system. Scale pit with oil catching baffles for suspended solids and gross oil removal. Additional Energy Requirements. To meet EPA 1977 standards for wastewater discharge to public waters, modifications will be required to the wastewater treatment system. The 533 ------- eN cn rH s OH O H O Cu BC 00 CQ in XT to- co rH V}- 00 sf co [C ro O ^ CN ro rH O O O m rH CO ^o ro CN 00 f>- oo CTi r^ CN in oo o in VO o CO f~ CN CN 0 0 in r-T CN in ro ro CM co in CO i£> rH i£> O CTI ro CM CN p~ ro rH O "sf cn in o o o < CN \D CN r~- cn r-~ rs ^ CTl rH 0 oo rH m ^ ro rH 00 in rH o o m OJ O) O M CN O —1 w- CN CO cn rH 00 * rH r- ro !/) CN rH rH in CTl CTi CO in ro ». CT^ •p V. ^x CP T3 ro 0) ro •P » in rH O U ^H rd Cr> 4-> C O in in CN CN o r-l 0 rH CTl i •H EH 3 O OH MH 4J »w CP O o in (0 "3" CO rH Q) £> 01 0 J O 1 CTi O MH "H 0 0 C H X! H CJ H 0) 4J a a w rd CO O 0) 0) -E) U > £-1 H W C EH H rH CTl in V 00 II tn 4-) tn O -H O rd 4J rH -rH rd a 3 rd I ° CTl r — cn CTI rH C 0 •H 4-> ns •rH CJ 0) a 0) Q ro CTl CTl « vD 0) CJ C C (1) 4-> C •H rd S C3 C O •H •P rd CO rH rd tn o a tn •H Q cu 1 rH CO •M 0" f rH O rd OH tn * a w £>S\| .,_( CP Q J H d -H W O tn 4J in 0 CJ rH rd O •H S CU 6 ro ^D m w in ro TOTAL CTl ^ ** ro CTl ro s rH 0 O CN 1 O o rH o o rH i 0 m CTl 1 vD (\|_) ^f 4H rd in tn w u 4-1 4-> rd cn C -H U cu d tn xi 3D 4-J 4-> O -H •H 3S >i 4-1 1 4-1 in •H C C rH O O rd u in 4-i 3 H \ Ot 4J CO rH rd iH MH rd 5 t-l W OH O MH H W Cu rH \ CP g «, in T) •H rH 0 cn •d cu Suspend rH •\ Cn e «, 0) in rd 0) 0 c rd rH •H o a c c 0 0 i) t ] X^ \ (T\ vD "^D *0 CM O O O i i EH EH OH < m m 534 ------- Ot 00 in CM, V CO ro o> in CM ^ ro < prf &* S JS Ik. ?J rH II S« \|§ , w . e« a S -P ^ EH I"H \|fj Pi S5 1 1 9E* _j CO M pq 2 "o k) EH 2>4 £v fe W t, «3 U O SB i ^. co rH at 00 in rH 00 00 Q_ * m CO vo in Ol U - CO o in vo n "* * rH CO CO CO in CM at in CM in H in 00 jn H «o o r» CO H at 00 in 00 00 ^ in VO at 00 o r- VO « H L' at. CM at H CO CM VO H rH 'S1 at CO co i-H o ^* in rH CO o in CO in CO vo 00 CM co o CM 00 in 0 at rH co in at • at oo 00 at o % oo at I vo CM rH at OJ aS 4) -P •H 8"S 00 4 00 o oo rH VO p^ r- (C « 00 o 00 rH CO CM at in CO I o U) in o o o in o o o o CM O O rH I O in O ex at vo o in o CM O O o in at I vo at I vo O H SH oH £•* Q) .p i\ H4 o •P at e-5 •• O C £t U 3 JH 0 WO S O Oi j ^ \|^\| Q C *H Treatme Ident Scope 4J c (U Investm •• CO 4J ca o U Annual C 0 •H ^J (0 rH ^H (0 U 43 0> • 3 0 «4 rH (0 >i U Ot -rl (I) (1) C A H U rH 10 CO O Oi to •H Q 3 S ° § EH •• >• •H rH RJ O •P Effluen a 43 C 0) CO 3-P •P-H •H C •p 3 CO C 1 o U CO ^ •p a> C -M 0) ai f"H (15 !« ii «M (0 i-H •H O cc 00 •P-M ^N, "X^ •^t" l/> ^- oo oo o • • H U d SH 535 ------- TABLE 133 WATER EFFLUENT TREATMENT COSTS STEEL INDUSTRY HOT FORMING - SECTION Treatment of Control Technoloqies Identified under Item III of the Scope of Work: A Investment $216,510 Annual Costs: Capital 9,310 Depreciation 21,651 Operation & Maintenance 7, 578 Sludge Disposal Energy & Power Oil Disposal Chemical Costs TOTAL Effluent Quality: Effluent Constituents Parameters - Units Flow, gal./ton 6,029 BPCTCA BATEA B C D E \| I F G $13,529 $662,880 $383,940 $650,855 $1,420,275 $441^18 582 1,353 473 ,28,503 16,509 27,987 66,289 38,394 65,085 _23,200 13,438 22,780 5,400 61,072 18,97 142,027 44.11 49,710 15,44 900 8,894 22,500 9,375 7,500 22,500 22.50 $38,539 $12,202 $140,492 $83.116 $123,_352 $275,309 $101,02 6,029 Resulting Effluent Levels 2,626 2,626 2,626 2,626 Suspended Solids, mg/1 100-200 100-150 100-200 50-75 Oil and Grease, mg/1 50-100 20-50 20-70 20-40 pj 6-9 6-9 6^9 Gr3__ 10 10 10 10 6-9 6-9 BPT - $1.Ob3/ton BAT - $l.ll/ton Different from XI in Level C. Total flow is pumped either to RFL or CL. 536 ------- m to fr «* o 01 rH 01 fa in to en r- oo 01 to OI 00 OI to rH 0 01 to OI t- in to in oi ^T n to r>. ^ M rH O 01 to O n OI * to o 0 en n rt 00 en ^ n f-i rH < CO t H In EH rH U >t O 0) (X fltf H CU PQ EH CO -M CO W D 1 0 >» a o ^ w i 'o M O ^ EH £t\| CX CO 1 W EH W co H m rH H O CO to P. to Qk r* f^ r' rH \O f» o to O rH to ,C9 OI to m °i CM H O ^ to r> o en rH » m rH cn to OI o CM rH O CO 00 to f r> rH (^ ^ to ^ O M to OI to f. o CO CO rH 01 r» n n OI 'fl1 « to rH n rH in 0) ' & rH r. C CM CO CO in CM o n 01 » to en ^ 01 01 to V OI CO H in - o CM CM CO CO O OI in * to f^ CO f* n ^r o\ iH O O iH OO O m «» CT> rH O O rHJ OO en o OI in oi E"* 21 W D 1 EH i^ •3 CO § to 01 'O ^ OI en 01 « to en OI o « to 0 o OI 1 0 rH O in I o o rH 0 o OI 1 o o rH O r» 1 o OI c in i 0 01 o o rH 1 O in en l to cn I to en l to OH •s" 4J •3H £ «. CTJ " O GM (J 3 M tg o"1 -rl«H •MD U gHW EH ent M 0 O 41 a 9 o 0) § 5 g 5 S Capita p •rl -H O -P O id M H «) Oi O De id w o a 01 0) tr •a t-H (A m o a m O w •H a m 4> 0 M 3 -P +»Tt " -H C 4J o) rl §' <0 CJ to O -P ------- additional power consumed will be 8.14 kwh/kkq (7.38 kwh/ton) processed. For the typical 1,179.1 kkq/day (1,300 ton/day) facility, the power required will be 400 kw (537 horsepower). The annual cost to operate this equipment will be $40,275. Non-Water Quality Aspects. 1. Air Pollution: None 2. Solid Waste Disposal: The sludge will be collected and recycled to melting operations. Hot Forming - Flat - Plate Reference Level of Treatment. Once-through system. Scale pit with oil catching baffles for suspended solids and gross oil removal. Additional Energy Requirements. To meet EPA 1977 standards for wastewater discharge to public waters, modifications will be required to the wastewater treatment system. The additional power consumed will be 13.22 kwh/kkg (11.99 kwh/ton) processed. For the typical 1,814 kkg/day (2,000 ton/day) facility, the power required will be 999 kw (6340 horsepower). The annual cost to operate this equipment will be $100,500. Non-Water Quality Aspects. 1. Air Pollution: None 2. Solid Waste Disposal: The sludge will be collected and recycled to melting operations. Hot Forming - Flat - Hot Strip and Sheet Reference Level of Treatment. Once-through system. Scale pit with oil catching baffles for suspended solids and gross oil removal. Additional Energy Requirements. To meet EPA 1977 standards for wastewater discharge to public waters, modifications will be required to the wastewater treatment system. The additional power consumed will be 16.36 kwh/kkg (14.84 kwh/ton) processed. For the typical 3,447 kkg/day (3,800 ton/day) facility, the power required will be 2,349 kw (3,150 horsepower). The annual cost to operate this equipment will be $236,250. Non-Water Quality Aspects. 538 ------- •H CO CO m ^j* CN 0 ID 0 'rH vD ^J1 ro r- ro O O o in ^ji cn CN cn • C H CO 0 O CO 0 <3- c^ o rH 1C ro ^f M1 in CM ro in 0 CTi co o o in r- ^0 r^ CTl ro O CM in CO- 0 Cn O CM D r^ iH O 0 0 in r^ 00 CN VD Q} ry CO CM in O o 0 CD cn CM Cn t^ rH in ro in en ID rH CM •sr en ro O co ro H O in r~ ro r^ •^< o en (N ^r rH CO en ro •CO- 1 — 1 rd 4-> •H ft rd U C O •H 4-1 rd •H D 0) ^1 ft (U Q Maintenance 13 c o •H 4-1 rH 0) o rH rd co 0 ft co •H Q Q) 'CJ ^ rH CO U 0 o< ta »>i cn iH 0) C rH rd CO O ft CO •rH Q rH •rH O CO -p co O U rH rd U •H c-* U m rH O ^ co o 0 CM \| 0 o rH o O •H 1 O in I VD O CO 4J (1) C d) 3 0 rH CO iii t i MH v W 3 cn C m r- i o m O ^ 1 0 CN cn I ID •H MH 4J -H \^ ^1 cn rd rH in o ro CO 0 - 4-1 •H ro 4-1 ft rH 3 CO 0) cd o co rH s T^1 m rH i o 0 rH in f-^. i o CM cn 1 iD -H- § fy] P\| 1 U iH 0) Q) rJI in rH O ^ co O in rH 1 o o 0 in i 0 CM cn i ID 4J a 0) u X 0) H H H 0} rd U) i> ^1 4-1 •H rH . rd 3 cx _p c 0) 3 rH MH M-l W CO 4J C OJ 3 4-1 •H -P CO C O u •M c 0) 3 rH MH MH U) -P •H C D 1 CO ^4 0) 4-1 0) 0 flj ^\| rd C 0 4J \^ « rH rd tn S, } 0 rH frj rH N^ cn B ^ CO •H rH O 10 Tl 0) C Q) ft co 3 to rH \ cn g . 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W 4J U) O rH U id 4J rH -H . >d ft 3 id G U i< P^ CM r^- ^ VO CM C 0 •H 4J •H O ft rH o ^d & in * a U) ^i H cn Q }H Q) rH C -rH W O in 4-> w O U rH id o •H 5 ro p^. m .. c^ ^ W g EH . ^1 -P •H i — \| •H cn £ o u 4J C CD 3 rH MH H cn 4J •H c D 1 cn ^ 0) 4-> o nJ rl ft o o in ^ m O 0 CN \| O o •H o o •H \| 0 in cn I VO o frj O c o 4J N^ • rH n) tp 0. u O rH tu •H \ CP B ^ cn rrj •H •H 0 •o Q) T) C QJ ft W 3 W i-i \ tn g , OJ cn id 0) ^ o -d c id iH -H O K Q. j^ ft <4H 0 C o ^L cn H iH •CO- 1 EH ft CQ O 3 TJ O £•( P. UH o c 0 ^^ O H • H I f-i rtj CQ 540 ------- EH n 8 H i B § H i 3 >i }* 0) ^* 55 cj t* (u * 1™ $ M H KQ fe >> O §** H ' H 0 EH m 10 ft. &* 2 r? ^ "^ ® H H M ^ ^ R p jjj. m to O OJ EH 0S ^5 M S3 0g ^ in ^ o O • o •» o CM «gi h W VO rH r— "> 3- O M H HO o H 9l OO VO Q •* ^* in ^ ^* 91 O - m 9k vo 0 91 « m rH rH rH CM * O CM CM n rH rH r- ^ UJ o f> CO H/ N n r^ 91 rH in in rH CM 91 p« "T rH rH VO O a\ in v ^ in « 00 rH O 00 rH t "1 CM IO if r- tt CM rH O 91 in rH rH to OO 0 p^ m in 9) vo r» in rH * r- rH CO m * 91 9. 91 9l ^" r- o m to to 00 M ^ OO H r» 91 91 O rH m 91 O rH n rH r. 91 in * o H O l/> co to to • at S W (O CO PH • 25 O> g W O (^ 5 s i u S 91 r* 00 « CM fH 0 o i-H O H • in r- in in f» rH J^ O iH O in rH 1 O o rH O o H O H O CM in r- i o o in 0 'CM 91 \| VO 91 1 VO 91 to en I vo 91 1 VO 91 VO O H VO CM VO rH CM 00 CM VO O f» 1& * •* • O do o in O CM CM D>HH 0 0 O H CH J5 H 4) 0 U rHH I 0 4^ MM e 4J G) -H rH §TJ » (3 (0 C X S W 91 91 -H r» ««• CO * 1- CM C1) rH O O CM 1 O o rH o o rH O in 91 I VO a « n 9 -P M rl C « 4J w c CJ9M C O£ -H C I O O •• O «> Q. O rH rH O -P M B S n -H 10 O OJ -P -P C -H •H VH -P to 10 o a +><«O C OrH-H-H C-rl C 0. iJrH-HMM'O oo oi d a a w 3 1300 vgiaaicurH 4) M W > CUQOCO -K c «3 0i ia o cj m \ W 9 M rH 4 rH O <3 -P u n CO CQ H 541 ------- in eo oo en vo oo m r- oo in o o CM en vo l_ M en CM CM vo in in CD en o CM erv CM 01 vo in CM vo in CM i -i t~ in vo CM o 00 en I vo CO CO o esi O W K m && r- Rl to £ 0) P< en a n K -P CO H >fl I CO IH i o IU ex co CM in r- o n CM in r- en CM oo U CM VO CM vo vo o 00 en l vo in O •p c V fl 01 o c IH 0 01 O •H n) 3 I H m •H a M V U rH 10 0 •H (U U O cu 01 •H O •• S- 4J •H rH (d 3 4J C cu 3 rH •to- ll II EH H a, < 03 CO 542 ------- 1. Air Pollution: None 2. Solid Waste Disposal: The sludge will be collected and recycled to melting operations. Pipe and Tubes - Integrated Reference Level of Treatment. Once-through - contact and noncontact wastewaters. Scale pit with oil skimmer for removal of heavy solids and oil. Additional Energy Requirements. To meet the EPA 1977 standards for discharge of wastewater into public waters, modifications will be required to the wastewater treatment system. The additional power consumed will be 11.83 kwh/kkg (10.74 kwh/ton) processed. For the typical 363 kkg/day (400 ton/day) facility, the power required will be 179 kw (240 horsepower)• The annual cost to operate this equipment will be $18,000. Non-Water Quality Aspects. 1. Air Pollution: None 2. Solid Waste Disposal: The sludge will be clamshelled and landfilled, or recycled to melting operations. Pipe and Tubes - Isolated Reference Level of Treatment. Once-through - contact and noncontact wastewaters. Scale pit with oil skimmer for removal of heavy solids and oil. Additional Energy Requirements. To meet the EPA 1977 standards for discharge of wastewater into public waters, modifications will be required to the wastewater treatment system. The additional power consumed will be 7.87 kwh/kkg (7.14 kwh/ton) processed. For the typical 363 kkg/day (400 ton/day) facility, the power required will be 119 kw (160 horsepower). The annual cost to operate this equipment will be $12,000. Non-Water Quality Aspects. 1. Air Pollution: None 2. Solid Waste Disposal: The sludge will be clamshelled and landfilled, or recycled to melting operations. Pickling - Batch Sulfuric Acid - Concentrates and Rinses 543 ------- TABLE 135-1-INTEGRATED WATER EFFLUENT TREATMENT COSTS STEEL INDUSTRY PIPE AND TUBES Treatment of Control Technologies Identified under Item III of the Scope of Work: A Investment $182,658 Annual Costs: Capital 7,854 Depreciation 18,266 Operation & Maintenance 6,393 Sludge Disposal 1,217 Energy & Power Oil Disposal Chemical Costs TOTAL $33,730 BPCTCA 1 B $10,765 462 1,077 377 C D $272,330 $102,330 11,710 4,400 27,233 10,233 9,531 3,581 E 1 $178,210 7,665 17,821 6,235 1,875 11,250 3,750 3,000 1,587 $3,505 $61,599 $21,964 $34,720 BATEA 16,666 2,98( 38,760 6,93( 13,566 2,42! 11,250 1,871 $80,242 $14,21 Effluent Quality: Effluent Constituents Parameters - Units Flow, gal./ton Suspended Solids, mg/1 Oil and Grease, mg/1 PH BPT - $0.976/ton BAT - $0.757/ton 4,209 50-100 6-9 4,209 100-200 100-150 20-50 6-9 Other - 0.114/ton Resulting Effluent Levels 4,209 1,002 1,002 50-75 20-40 6-9 50-100 20-50 6-9 10 10 6-9 Seamless Only A-B-C - 4,209 g/t D - R - 3,207 g/t (pumping all inclusive of 1,002 to filter) E - Filter - 1,002 g/t F - CT - 1,002 g/t G - R - 1,002 g/t 544 1,002 10 10 6-9 ------- TABLE 135-2 - ISOLATED WATER EFFLUENT TREATMENT COSTS STEEL INDUSTRY PIPE AND TUBES Treatment of Control Technologies Identified under Item III of the Scope of Work: Investment Annual Costs: Capital Depreciation Operation & Maintenance Sludge Disposal Energy & Power Oil Disposal TOTAL A $182,658 7,854 18,266 6,393 1.217 I B $10,765 462 1,077 377 BPCTCA C $43,640 1,876 4,364 1,527 BATEA 5 I I EI $102,330 $69,305 4,400 10,233 3,581 3,750 2,980 6,930 2,425 1,875 $33,730 $3,505 $7,767 $21,964 $14,210 Effluent Quality: Effluent Constituents Parameters - Units Flow, gal. /ton _ Suspended Solids, mg/1 Oil and Grease, mg/1 BPT - $0.266/ton BAT - $0.114/ton C - Ponds - 4,209 g/t D - R 3,207 g/t E - R 1,002 g/t 4,209 100-200 50-100 6-9 Resulting Effluent Levels 4,209 4,209 1,002 100-150 20-50 6-9 50-75 20-40 6-9 50 15 6-9 545 ------- Reference Level of Treatment. Contract hauling of spent pickle liquor off-site for disposal or treatment. Additional Energy Requirements. To meet EPA 1 for was tester discharge to public waters, will be reguired to the wastewater treatment additional power consumed will be 36.16 kwh/ton) processed. For the typical 227 ton/day) facility, the power required will horsepower). The annual cost to operate this be $3U,420. 977 standards modif ications system. The kwh/kkg (32.83 kkg/day (250 be 312 kw (U59 equipment will Non-Water Quality Aspects. 1. Air Pollution: None 2. Solid Waste Disposal: and landfilled. The sludge will be clamshelled Water uses and flow rates are siirilar between the carbon steel and stainless and alloy steel operations. Costs were thus assumed to be equivalent. Pickling - Batch Sulfuric Acid - Rinse Reference Level of Treatment. rates. No additional treatment. Minimize rinse water flow Additional Energy Requirements. To meet EPA 1977 standards for wastewater discharge to public waters, modifications will be required to the wastewater treatment system. The additional power consumed will be 1.98 kwh/kkg (1.80 kwh/ton) processed. For the typical 227 kkg/day (250 ton/day) facility, 18.7 kw (25 horsepower) . The annual cost to operate this equipment will be $1,875. Non-Water Quality Aspects. 1. Air Pollution: None 2. Solid Waste Disposal: The sludge will be clamshelled and landfilled. Pickling - Continuous Sulfuric Acid - Concentrates and Rinses - Neutralization Reference Level of Treatment. Minimize rinse water flow rates. No additional treatment. Additional Energy Requirements. To meet EPA 1977 standards for wastewater discharge to public waters, modifications 546 ------- TABLE 136 WATER EFFLUENT TREATMENT COSTS STEEL INDUSTRY PICKLING - H^S04 - BATCH - CONG. & RINSES Treatment of Control Technologies BPCTCA Identified under Item III of the BATEA Scope of Work: A \| B I C Investment $36,224 $636,300 Annual Costs: Capital 1,558 27,361 Depreciation 3,622 63,630 Operation & Maintenance 1,268 22,271 Crystal Disposal 7,800 Energy & Power 1,500 34,420 SPL Disposal 81,250 TOTAL $89,198 $155,482 LESS CREDIT: Acid Recovery 8,549 Contract Hauling 81,250 $65,683 Effluent Quality: Effluent Constituents Parameters - Units Resulting Effluent Levels Cone. 25 Flow, gal./ton, Rinse 200 0 Cone. 300-600 Suspended Solids, mg/1. Rinse 200-300 Cone. 2-5% Dissolved Iron, mg/1. Rinse 6000-7000 Cone. <1 pH, Rinse 2-5 Cone. - Disposed by continuous hauling - no discharge to stream. A: Cont. hauling SPL; disc, rinse untreated. B: Cascade rinse and use as PL makeup; recover H2S04 and FeSO4'7H20 in evaporative recovery system. 547 ------- TABLE 137 WATER EFFLUENT TREATMENT COSTS STEEL INDUSTRY PICKLING - H2S04 - CONTINUOUS - CONC. & RINSES - NEUTRALIZATION Treatment of Control Technologies Identified under Item III of the BPCTCA BATEA Scope of Work: Investment Annual Costs: Capital Depreciation Operation & Maintenance Sludge Disposal Energy & Power SPL Disposal Chemical Costs TOTAL LESS CREDIT for Contract Hauling Costs NET ANNUAL COST Ac AR 1 B 1 1 C 1 $212,975 $455,828 $629,906 $136,200 9,157 19,600 27,085 5,857 21,298 45,583 62,991 13,620 7,454 15,954 22,047 4,767 224.640 7.500 15,000 7,875 2,700 468,000 (Replacement Cost) 5.055 158.770 19,320 $513,409 $101.192 $503,408 $46,264 468,000 $35,408 Effluent Quality: Effluent Constituents Parameters - Units Flow, gal./ton Suspended Solids, mg/1 Dissolved Iron, mg/1 PH 25 Resulting Effluent Levels 225 250 50 300-600 2-8% <1 250-500 5-25 4-7 50 25 1.0 0.2 6-9 6-9 A: Concentrates disposed by hauling - no discharge to stream; rinses treated via lime neut. No settling. B: Neutralize cone, and rinses together; aerate; one-day lagoon. C: Countercurrent rinse to reduce flows; rest stays same; lagoon holds five days. 548 ------- TABLE 137-1 WATER EFFLUENT TREATMENT COSTS STEEL INDUSTRY PICKLING - H2SO4 - CONTINUOUS - CONC. & RINSES - ACID RECOVERY Treatment of Control Technologies BPCTCA Identified under Item III of the BATEA Scope of Work: A IB\| Investment $212,975 $1,870,975 Annual Costs: Capital 9,157 80,451 Depreciation 21,298 187,098 Operation & Maintenance 7,454 65,484 Crystal Disposal 44,928 Energy & Power 7,500 122,700 SPL Disposal 468,000 - Replacement Parts 19,320 TOTAL $513,409 $519,981 LESS CREDITS: Acid Recovery 49,242 Contract Hauling 468,000 NET ANNUAL COST $2,739 Effluent Quality: Effluent Constituents Parameters - Units Resulting Effluent Levels Flow, gal. Suspended mg/1, Dissolved mg/1, Cone. pH, Rinse /ton. Solids Iron, Cone. Rinse , Cone . Rinse Cone. Rinse 25 225 300-600 250-500 2-8% 1800-3600 <1 2-5 0 0 - - : A: Concentrates disposed by hauling - no discharge to stream; rinses discharged untreated. B: Cascade rinsing to minimize flow; recover 113804 and FeSO4-7H2O in evap. recovery system. 549 ------- will be required to the wastewater treatment system. The additional power consumed will be 1.72 kwh/kkg (1.56 kwh/ton) processed. For the typical 1,088 kkg/day (1,200 ton/day) facility, the power required will be 78 kw (105 horsepower). The annual cost to operate this equipment will be $7,875. Non-Water Quality Aspects. 1. Air Pollution: None 2. Solid Waste Disposal: Sludges will be clamshelled and land filled. Pickling - Continuous Sulfuric Acid - Concentrates and Rinses - Acid Beeovery Reference Level of Treatment. Minimize rinse water flow rates. No additional treatment. Additional Energy Requirements. To meet EPA 1977 standards for wastewater discharge to public waters, modifications will be required to the wastewater treatment system. The additional power consumed will be 26.91 kwh/kkg (24.4 kwh/ton) processed. For the typical 1,088 kkg/day (1,200 ton/day) facility, the power required will be 1,220 kw (1,636 horsepower). The annual cost to operate this equipment will be $122,700. Non-Water Quality Aspects. 1. Air Pollution: None 2. Solid Waste Disposal: The sludge will be clamshelled and landfilled, Pickling - Hydrochloric Acid - Concentrated - Alternate ^ Reference Level of Treatment. Deep well disposal, or contract hauling of spent pickle liquor off-site for disposal or treatment. Additional Energy Requirements. To meet EPA 1977 standards for wastewater discharge to public waters, modifications will be required to the wastewater treatment system. The additional power consumed will be 0.66 kwh/kkg (0.60 kwh/ton) processed. For the typical 2,721 kkg/day (3,000 ton/day) facility, the power required will be 75 kw (100 horsepower). The annual cost to operate this equipment will be $7,500. Non-Water Quality Aspects. 550 ------- 1. Air Pollution: None 2. Solid Waste Disposal: The sludge will be clamshelled and landfilled. Pickling - Hydrochloric Acid - Rinse - Alternate J Reference Level of Treatment. Equalization and neutralization of free acidity before direct discharge to receiving stream. Additional Energy Requirements. To meet EPA 1977 standards for wastewater discharge to public waters, modifications will be required to the wastewater treatment system. The additional power consumed will be 1.31 kwh/kkg (1.19 kwh/ton) processed. For the typical 2,721 kkg/day (3,000 ton/day) facility, the power required will be 149 kw (200 horsepower). The annual cost to operate this equipment will be $15,000. Non-Water Quality Aspects. 1. Air Pollution: None 2. Solid Waste Disposal: The sludge will be clamshelled and landfilled. Pickling - Hydrochloric Acid - Concentrates and Rinses Alternate II Reference Level of Treatment. Deep well disposal,, or contract hauling of spent pickle liquor off-site for disposal or treatment; neutralization of free acidity before direct discharge to receiving stream. Additional Energy Requirements. To meet EPA 1977 standards for wastewater discharge to public waters, modifications will be required to the wastewater treatment system. The additional power consumed will be 1.64 kwh/kkg (1.49 kwh/ton) processed. For the typical 2.721 kkg/day (3,000 ton/day) facility, the power required will be 164 kw (250 horsepower). The annual cost to operate this equipment will be $18,750. Non-Water Quality Aspects. 1. Air Pollution: None 2. solid Waste Disposal: The sludge will be clamshelled and landfilled. Cold Rolling - Recirculation 551 ------- TABLE 138 WATER EFFLUENT TREATMENT COSTS STEEL INDUSTRY PICKLING - HYDROCHLORIC ACID - RINSES - ALTERNATE I Treatment or Control Technologies Identified under Item III of the BPCTCA BATEA Scope of Work: A I~B Investment $ 373,391 $ 583.136 $ 235,900 Annual Costs: Capital 16,056 25,075 10,144 Depreciation 37,339 58,314 23,590 Operation & Maintenance 13,069 20,410 8,257 Sludge Disposal 6,521 Energy & Power 5,625 15.000 2,720 Chemical Costs 18,270 19,418 Replacement Parts 33,480 TOTAL $ 90,359 $ 144,738 $ 78,191 Effluent Quality: Effluent Constituents Parameters - units Resulting Effluent Levels Flow, gal./ton 200 (:L) 200(1) 50(1) Suspended Solids, mg/1 200-400 50 25 Oil and Grease, mg/1 20-30 10(2) 10(2) ---Dissolved Iron, mg/1 100-240 i. Q i. Q pH 5-6 6-9 6-9 (1) If the plant has a wet fume hood scrubber system over the pickle tanks, an additional load of 50 gals./ton applies and is added to the flow shown. (2) This load allowed only when these wastes are treated in combination with cold rolling mill wastes. 552 ------- TABLE 139 WATER EFFLUENT TREATMENT COSTS STEEL INDUSTRY * PICKLING - HYDROCHLORIC ACID - CONCENTRATES - ALTERNATE I Treatment or Control Technologies Identified under Item III of the Scope of Work: Investment Annual Costs: Capital Depreciation Operation & Maintenance Sludge Disposal Energy & Power Disposal Costs Chemical Costs Less Credit for Recovered Acid and Iron Salts TOTAL ,e BPCTCA A \| B \| $ 402,093 $9,057,448 17,290 389,470 40,209 905,745 14,073 317,011 BATEA 1 C 1 $ 64,464 2,771 6,445 2,256 3,750 7,500 1,500 1,044,000 11,045 (-2,624,530) $1,119,322 $(-993,.759) $ 12,972 Effluent Quality: Effluent Constituents Parameters - units Flow, gal./ton Suspended Solids, mg/1 Oil and Grease, mg/1 Dissolved Iron, mg/1 PH 200-400 8-12% Resulting Effluent Levels 20 200 30 50 25 10* 10* 1.0 1.0 6-9 6-9 This load allowed only when these wastes are treated in combination with cold rolling mill wastes. 553 ------- TABLE 140 WATER EFFLUENT TREATMENT COSTS STEEL INDUSTRY PICKLING - HYDROCHLORIC ACID - CONCENTRATES & RINSES - ALTERNATE II Treatment or Control Technologies Identified under Item III of the Scope of Work: Investment Annual Costs: Capital Depreciation Operation & Maintenance Sludge Disposal Costs: Acid Energy & Power Replacement Costs Chemical Costs Less Credit for Recovered Acid and Iron Salts TOTAL e BPCTCA A S 752, 32, 75, 26, 1,044, 15, 353 351 235 332 000 000 1 B 5 874 37 87 30 152 18 1 ,607 ,460 ,611 ,000 ,750 18, 270 396 ,918 BATEA $ 235,900 10,144 23,590 8,257 2,720 33,480 $1,211,188 $ 723,346 $ 78,191 Effluent Quality: Effluent Constituents Parameters - units Flow, gal./ton Suspended Solids, mg/1 Oil and Grease, mg/1 Dissolved Iron, mg/1 PH Resulting Effluent Levels 220 (1) 230 (1) 80 (1) 200-400 8-12% 50 25 15 (2) 10 (2) 1.0 1.0 6-9 6-9 (1) If the plant has a wet fume hood scrubber system over the pickle tanks, an additional load of 50 gals./ton applies and is added to the flow shown. (2) This load allowed only when these wastes are treated in combination with cold rolling mill wastes. 554 ------- TABLE 141 WATER EFFLUENT TREATMENT COSTS STEEL INDUSTRY COLD ROLLING - RECIRCULATION Treatment or Control Technologies Identified under Item III of the Scope of Work: Investment Annual Costs: Capital Depreciation Operation & Maintenance Sludge Disposal Energy & Power Chemical Costs TOTAL BPCTCA BATEA A $ 186,877 8,035 18,688 6,541 1,958 525 $ 35,747 1 B S 267, 11, 26, 9, 1. 9, 2, $ 61, 1 588 501 759 365 392 750 590 357 Effluent Quality: Effluent Constituents Parameters - units Flow, gal./ton Suspended Solids, rog/1 Oil and Grease, mg/1 Dissolved Iron, mg/1 PH 25 200 600 6-9 Resulting Effluent Levels 25 25 10 6-9 This load allowed only when these wastes are treated in combination with pickling rinses. 555 ------- Reference Level of Treatment. Recirculation of rolling solutions on all rolling stands. Oil skimmer in recycle sump. Blending of rolling solution blowdown and miscellaneous (tramp oils) wastewaters. Treatment of mixture with oil separator/settler. Additional Energy Requirements. To meet EPA 1977 standards tot wastewater discharge to public waters, modifications will be reguired to the wastewater treatment system. The additional power consumed will be 0.86 kwh/kkg (0.78 kwh/ton) processed. For the typical 2,721 kkg/day (3,000 ton/day) facility, the power required will be 97 kw (130 horsepower). The annual cost to operate this equipment will be $9,750. Non-Water Quality Aspects. 1. Air Pollution: None 2. Solid Waste Disposal: The sludge will be clamshelled and landfilled. Cold Rolling - Combination Reference Level of Treatment. Recirculation of rolling solutions on as many stands as possible, with remaining stands oncethrough. Oil skimmer in recycle sump. Blending of rolling solution blowdown and miscellaneous (tramp oils) wastewaters. Treatment of mixture with oil separator/settler. Additional Energy Requirements. To meet EPA 1977 standards for wastewater discharge to public waters, modifications will be required to the wastewater treatment system. The additional power consumed will be 10.53 kwh/kkg (9.55 kwh/ton) processed. For the typical 1,360.5 kkg/day (1,500 ton/day) facility, the power reguired will be 597 kw (800 horsepower). The annual cost to operate this equipment will be $60,000. Non-Water Quality Aspects. 1. Air Pollution: None 2. Solid Waste Disposal: The sludge will be clamshelled and landfilled. Cold Rolling - Direct Application Reference Level of Treatment. All stands use rolling solutions once-through. Oil skimmer in recycle sump. Blending of rolling solution blowdown and miscellaneous 556 ------- TAfcLE 142 WATER EFFLUENT TREATMENT COSTS STEEL INDUSTRY COLD ROLLING - COMBINATION Treatment or Control Technologies Identified under Item III of the Scope of Work: BPCTCA BATEA Investment Annual Costs: Capital Depreciation Operation £ Maintenance Sludge Disposal Energy & Power Chemical Costs TOTAL $ 242,245 $1,055,013 10,416 24,225 8,479 15,670 3.000 45^366 105,501 36,925 11,143 60.000 20,732 61,790 $ 279,667 Effluent Quality: Effluent Constituents Parameters - units Flow, gal./ton Suspended Solids, ing/1 Oil and Grease, mg/1 Dissolved Iron, mg/1 PH Resulting Effluent Levels 400 400 120 25 360 10 1* 6-9 6-9 This load allowed only when these wastes are treated in combination with pickling rinses. 557 ------- TABLE 143 WATER EFFLUENT TREATMENT COSTS STEEL INDUSTRY COLD ROLLING - DIRECT APPLICATION Treatment or Control Technologies Identified under Item III of the Scope of Work: BPCTCA BATEA Investment Annual Costs: Capital Depreciation Operation & Maintenance Sludge Disposal Energy & Power Chemical Costs TOTAL $ 269,856 $1.083.235 11,603 26,986 9,445 19,500 3,750 46.579 108.323 37.913 13,920 60,000 25,792 $ 71,284 $ 292,527 Effluent Quality: Effluent Constituents Parameters - units Flow, gal./ton Suspended Solids, mg/1 Oil and Grease, mg/1 Dissolved Iron, mg/1 PH 1000 80 Resulting Effluent Levels 1000 25 200 6-9 10 6-9 This load allowed only when these wastes are treated in combination with pickling rinses. 558 ------- (tramp oils) wastewaters. Treatment of mixture with oil separator/settler. Additional Energy Requirements. To meet EPA 1977 standards for wastewater discharge to public waters, modifications will be required to the wastewater treatment system. The additional power consumed will be 15.79 kwh/kkg (14.32 kwh/ton) processed. For the typical 907 kkg/day (1,000 ton/day) facility, the power required will be 597 kw (800 horsepower). The annual cost to operate this equipment will be $60,000. Non-Water Quality Aspects. 1. Air Pollution: None 2. Solid Waste Disposal: The sludge will be clamshelled and landfilled. Hot Coatings - Galvanizing Reference Level of Treatment. No treatment of effluent. Tight control of dragout in process. Additional Energy Requirements. To meet EPA 1977 standards for wastewater discharge to public waters, modifications will be required to the wastewater treatment system. The additional power consumed in galvanizing operations will be 3.67 kwh/kkg (3.33 kwh/ton) processed. For the typical 635 kkg/day (700 ton/day) facility, the power required will be 97 kw (130 horsepower). The annual cost to operate this equipment will be $9,750. Non-Water Quality Aspects. 1. Air Pollution: None' 2. Solid Waste Disposal: The sludge will be clamshelled and landfilled. Hot Coatings - Terne Reference Level of Treatment. No treatment of effluent. Tight control of dragout in process. Additional Energy Requirements. To meet EPA 1977 standards for wastewater discharge to public waters, modifications will be required to the wastewater treatment system. The additional power consumed will be 3.36 kwh/kkg (3.05 kwh/ton) processed. For the typical 635 kkg/day (700 ton/day) facility, the power required will be 89 kw (120 559 ------- TABLE 144 WATER EFFLUENT TREATMENT COSTS STEEL INDUSTRY HOT COATINGS - GALVANIZING Treatment or Control Technologies Identified under Item III of the Scope of Work: A BPCTCA BATEA Investment $ 0 Annual Costs: Capital 0 Depreciation 0 Operation & Maintenance 0 Sludge- Disposal 0 Energy & Power 0 Oil Disposal 0 Chemical Costs 0 TOTAL $ 0 Effluent Quality: Effluent Constituents Parameters - units Flow, gal./ton (With No Scrubber) 600 (With Fume Scrubber) 1200 Suspended Solids, mg/1 120-200 Oil and Grease, mg/1 25-75 Chromium, Total, mg/1 12-16 Chromium, Cr+6, mg/1 10-12 Zinc, mg/1 75-140 $ 585.333 $ 225.995 $ 193,336 25,169 58,533 20,436 7,500 9,718 8,314 22,599 7.909 2,250 2,548 16,092 $ 111,688 $ 61,116 $ ' 38,421 193,333 6.767 257 3,750 Resulting Effluent Levels 600 1200 50-100 15-30 5-10 4-6 PJL 2-6 15-75 3-5 600 1200 50 15 0.02 100 250 25 10 0.1 0.02 6-9 6-9 560 ------- TABLE 143 WATER EFFLUENT TREATMENT COSTS STEEL INDUSTRY HOT COATINGS - TERNE Treatment or Control Technologies Identified under Item III of the Scope of Work: BPCTCA BATEA D Investment Annual Costs: Capital Depreciation Operation & Maintenance Sludge Disposal Energy & Power Oil Disposal Chemical Costs TOTAL Effluent Quality: Effluent Constituents Parameters - units Flow, gal./ton (With No Scrubber) (With Fume Scrubber) Suspended Solids, mg/1 Oil and Grease, mg/1 Lead, mg/1 $ 585.333 $ 208,538 $ 193,336 25,169 58,533 20,486 7,500 8,967 20,854 7,299 1,500 2,548 12,124 8,314 19,333 6,767 257 3,750 $ 111,688 $ 53,292 $' 38,421 Resulting Effluent Levels Tin, mg/1 PH r) 600 1200 120-200 600 1200 50-100 600 1200 50 25-75 1.2-2.0 10-30 2-6 15-30 0.75-1.5 5-15 3-5 15 0.5 100 250 25 10 0.25 6-9 6-9 561 ------- TABLE 146-1 WATER EFFLUENT TREATMENT COSTS STEEL INDUSTRY MISCELLANEOUS RUNOFFS - COAL STORAGE PILES Treatment of Control Technologies Identified under Item III of the Scope of Work: BPCTCA BATEA Investment Annual Costs: Capital Depreciation Operation & Maintenance Sludge Disposal Energy & Power Oil Disposal Chemical Costs TOTAL I A I 0 I B $343,540 14,772 34,354 12,024 3,000 1,220 $65,370 C I $256,790 11,042 25,679 8,987 507 5,250 2,000 $53,465 Effluent Quality: Effluent Constituents Parameters - Units Flow, gal./day* Suspended Solids, mg/1 Oil and Grease, mg/1 PH Resulting Effluent Levels 1,600,000 320,000 320,000 20-2000 20-200 5-100 5-10 5-100 6-9 25 10 6-9 Based on 2.5 inches of rainfall in a 24-hour period on a coal storage pile serving a 5000 ton/day iron-making blast furnace shop. 562 ------- TABLE 146-2 WATER EFFLUENT TREATMENT COSTS STEEL INDUSTRY MISCELLANEOUS RUNOFFS - STONE STORAGE PILES Treatment of Control Technologies Identified under Item III of the Scope of Work: BPCTCA BATEA Investment Annual Costs: Capital Depreciation Operation & Maintenance Sludge Disposal Energy & Power Oil Disposal Chemical Costs TOTAL A 0 I B $201,687 8,672 20,169 7,059 2,475 1,080 $39,455 $162,000 6,966 16,200 5,670 134 4,275 1,770 $35,015 Effluent Quality: Effluent Constituents Parameters - Units Flow, gal./day Suspended Solids, mg/1 Oil and Grease, mg/1 PH Resulting Effluent Levels 560,000 112,000 112,000 20-2000 20-200 5-100 5-10 5-100 6-9 25 10 6-9 Based on 2.5 inches of rainfall in a 24-hour period on a stone storage pile serving a 5000 ton/day iron-making blast furnace shop. 563 ------- TABLE 146-3 WATER EFFLUENT TREATMENT COSTS STEEL INDUSTRY MISCELLANEOUS RUNOFFS - ORE STORAGE PILES Treatment of Control Technologies Identified under Item III of the Scope of Work: BPCTCA BATEA Investment Annual Costs: Capital Depreciation Operation & Maintenance Sludge Disposal Energy & Power Oil Disposal Chemical Costs TOTAL A I 0 I B $258,225 11,103 25,823 9,038 2,775 1,200 $49,939 C I $204,640 8,800 20,464 7,162 353 4,725 1,985 $43,489 Effluent Quality: Effluent Constituents Parameters - Units Flow, gal./day Suspended Solids, mg/1 Oil and Grease, mg/1 PH Resulting Effluent Levels 226,500 45,300 45,300 20-2000 5-100 5-10 20-200 5-100 6-9 25 10 6-9 Based on 2.5 inches of rainfall in a 24-hour period on an ore storage pile serving a 5000 ton/day iron-making blast furnace shop. 564 ------- TABLE 146-4 WATER EFFLUENT TREATMENT COSTS STEEL INDUSTRY MISCELLANEOUS RUNOFFS - CASTING AND SLAGGING Treatment of Control Technologies Identified under Item III of the Scope of Wor : REFERENCE LEVEL, BPCTCA & BATEA I A I Investment $51,716 Annual Costs: Capital 2,223 Depreciation 5,172 Operation & Maintenance 1,810 Sludge Disposal - Energy & Power - Oil Disposal - Chemical Costs TOTAL $9,205 Effluent Quality: Effluent Constituents Parameters - Units Resulting Effluent Levels ' Flow, gal./day* Q Suspended Solids, mg/1 0 Oil and Grease, mg/1 0 PH - Costs shown are based on excavation of slag pits suitable for handling all slag generated by a 5000 ton/day iron- making blast furnace shop. 565 ------- horsepower). The annual coust to operate this equipment will be $9,000. Non-Water Quality Aspects. 1. Air Pollution: None 2. Solid Waste Disposal: The sludge will and landifilled. be clamshelled Specialty Steel Pickling Cleaning and Coating Operations For these categories costs were based upon a plant designed to treat the combined wastewaters from a mill with a 750 gpm flow. Costs were then scaled to the size appropriate for each subcategory on the basis of the following: Production Flow Ratio of Capital Cost (tons/day) (gpm) Flows Factor Combination Acid Pickling: Continuous 1384 750 1.00 Batch and Pipe Tube 21 15 0.02 Other Batch 144 30 0.04 Kolene Scale Removal 29 15 0.020 Hydride Scale Removal 60 75 0.10 Continuous Alkaline Cleaning 144 45 0.06 Wire Coating and Pickling 547 500 0.67 1.00 0.096 0.145 0.096 0.251 0.185 0.784 Combination Acid Pickling, Scale Removal, Continuous Alkaline Cleaning, and Wire Pickling and Coating Reference Level of Treatment; Once-through use with treatment by neutralization and solids separated via clarifier and vacuum filter. Polymer added to improve settling and dewatering. Additional Energy Requirements: Additional power will not be required to meet proposed standards for 1977, since the reference level is the BPCTCA treatment model. Non-Water Quality Aspects ; 1. Air Pollution: No air pollution problems are foreseen. 2. Solid Waste Disposal: The neutralization can be landfilled. sludge produced ADVANCED TECHNOLOGY, ENERGY, AND NON-WATER IMPACT by 566 ------- TABLE 147-1 WATER EFFLUENT TREATMENT COSTS STEEL INDUSTRY Combination Acid Pickling - Continuous Treatment or Control Technologies BPCTCA Identified under Item III of the BATEA Scope of Work: 'A' Investment $1,465,210 Annual Costs: Capital 63,004 Depreciation 146,521 Operation & Maintenance 135,084 Sludge Disposal 22,133 Energy & Power 7,000 Chemical 146,753 TOTAL $520,495 Effluent Quality: Raw Effluent Constituents Waste Parameters-units Load RESULTING EFFLUENT LEVELS Flow, gal/ton 1,000 1,000 Suspended Solids, mg/1 _250 25 Oil S Grease, mg/1 5 10 Piss. Chromium, mg/1 25 0 . 5 Piss. Nickel, mg/1 15 0. 25 Piss. Iron, mg/1 100 1 Fluoride, mg/1 100 15 pH 4 6-9 567 ------- TABLE 147-2 WATER EFFLUENT TREATMENT COSTS - STEEL INDUSTRY Combination Acid Pickling - Batch Pipe £ Tube Treatment or Control Technologies BPCTCA Identified under Item III of the BATEA Scope of Work: i Investment Annual Costs: Capital Depreciation Operation & Maintenance Sludge Disposal Energy & Power Chemical TOTAL Effluent Quality: Raw Effluent Constituents Waste Parameters-units Load 1 A $140.118 6,025 14,012 1,627 266 84 1,768 $23,782 RESULTING EFFLUENT LEVELS Flow, pa~l/-\|-on Snsppnded Solids, mg/1 TH s s - nhroirri i mi , mg/ 1 Hiss. Nickel, mg/1 Diss. IronT mg/1 Fluoride, mg/1 PH Oil £ Grease, mg/1 700 5 150 75 1100 500 2 5 700 25 0.5 0. 25 1 15 6-9 10 568 ------- TABLE 147-3 WATER EFFLUENT TREATMENT COSTS STEEL INDUSTRY Combination Acid Pickling - Other Batch Treatment or Control Technologies BPCTCA Identified under Item III of the BATEA Scope of Work: r A—' Investment $212,455 Annual Costs: Capital 9,135 Depreciation 21,246 Operation & Maintenance 3,243 Sludge Disposal 530 Energy & Power 168 Chemical 3,523 TOTAL $37,845 Effluent Quality: Raw Effluent Constituents Waste Parameters-units Load RESULTING EFFLUENT LEVELS Flow, gal/ton Suspended Solids, ms/l Diss. Chromium, me/1 Diss. Nickel, mg/1 Diss. Iron, mg/1 Fluoride, mg/1 Oil g Grease, mg/1 DH 200 100 25 20 150 250 I 2 200 25 0.5 0.25 1 15 10 6-9 569 ------- TABLE 148-1 WATER EFFLUENT TREATMENT COSTS STEEL INDUSTRY Scale Removal -Kolene A $140,QUO 6,025 114,012 Treatment or Control Technologies Identified under Item III of the BPCTCA Scope of Work: BATEA Investment Annual Costs: Capital Depreciation Operation & Maintenance Sludge Disposal Energy & Power Chemical TOTAL Effluent Quality: 1,627 266 1.768 $23,782 Raw Effluent Constituents Waste Parameters-units Load 500 RESULTING EFFLUENT LEVELS 500 Suspended Solids, mg/1 300 25 Piss. Chromium, mg/1 2.100 0.5 Hex. Chromium, mg/1 1.700 0.05 Diss. Iron, me/l 0.5 13 + 1.0 6-9 570 ------- TABLE 148-2 WATER EFFLUENT TREATMENT COSTS STEEL INDUSTRY Scale Removal - Hydride A $367,768 15,811 36,777 Treatment or Control Technologies Identified under Item III of the BPCTCA Scope of Work: BATEA Investment Annual Costs: Capital Depreciation Operation & Maintenance Sludge Disposal Energy & Power Chemical TOTAL Effluent Quality: 8,084 1,321 419 8,782 71,197 Raw Effluent Constituents Waste Parameters-units Load Flow, gal/ton 1,200 RESULTING EFFLUENT LEVELS 1,200 SusTgended Solids, mg/1 375 25 Cyanide, mg/1 _PH 1.0 12 0.25 6-9 571 ------- TABLE 149 WATER EFFLUENT TREATMENT COSTS STEEL INDUSTRY Wire Pickling and Coating Treatment or Control Technologies Identified under Item III of the BPCTCA Scope of Work: Investment Annual Costs: Capital Depreciation Operation & Maintenance Sludge Disposal Energy & Power Chemical TOTAL Effluent Quality: Raw Effluent Constituents Waste Parameters-units Load BATEA 1,1^8,725 49,395 114,873 57,537 9,402 2,979 62,502 296,688 Flow, gal/ton 1,000 RESULTING EFFLUENT LEVELS 1,000 Suspended Solids, mg/1 450 25 Cyanide, mg/1 30 0.25 Piss. Nickel, mg/1 35 0.25 Piss. Iron, mg/1 25 1.0 Piss. Copper, mg/1 10 0.25 Diss. Chromium, mg/1 15 0.5 Fluoride, mg/1 pH 35 15 6-9 572 ------- TABLE 150 WATER EFFLUENT TREATMENT COSTS STEEL INDUSTRY Continuous Alkaline Cleaning Treatment or Control Technologies BPCTCA Identified under Item III of the _.BATEA_ Scope of Work: r A n Investment $271,061 Annual Costs: Capital 11,656 'Depreciation 27,106 Operation & Maintenance 4,861 Sludge Disposal 795 Energy & Power 252 Chemical 5,281 TOTAL $1+9,957 Effluent Quality: Raw Effluent Constituents Waste Parameters-units Load RESULTING EFFLUENT LEVELS Flow, gal/ton 50 50 Suspended Solids, ing/1 Oil £ Diss . Diss . Diss . PH Grease, mg/1 Iron, mp/1 Cr, mg/1 Nickel, mg/1 560 1 60- 20 10 10 + 25 10 1 0.5 0.25 6-9 573 ------- The energy requirements and non-water quality aspects associated with the advanced treatment technology for each subcategory are discussed below. Basic Oxygen Furnace Operation Wet Systems 1. Additional Power Requirements: Additional equipment will be required to improve the waste water system to the anticipated 1983 standard. The additional energy consumption will be 0.53 kwh/kkg (0.48 kwh/ton) of steel produced. The annual operating cost for the consumption of this extra power will be approximately $5,679.00. 2. Non-Water Quality Aspects a. Air Pollution: The additional waste water equip- ment required will not affect the quality of the exhaust gases released to the atmosphere. The particulate emissions will be the same as they were for 1977. b. Solid Waste Disposal: Same as 1977 Vacuum Degassing 1. Additional Power Requirements: To improve the quality of the waste water treatment system effluent to the anticipated 1983 standard, will require additional equipment. The additional power requirement is 291 kw (390 hp) . This equates to 15.9 kwh/kkg (14.4 kwh/ton) of steel produced. The cost to operate this additional equipment will be $29,250.00. 2. Non-Water Quality Aspects a. Air Pollution: Same as 1977 b. Solid Waste Disposal: Same as 1977 Continuous Casting Operation 1. Additional Power Requirements: Additional equipment will be required to improve the water to meet the anticipated 1983 standard. The additional energy consumption will be 0.53 kwh/ kkg (0.48 kwh/ton) of steel produced. The additional power requirements will be 12.0 kw (166 hp) for the typical 544 kkg/day (600 ton/day) continuous casting facility. The annual operating cost due to the addition of this equipment will be $1,206. 574 ------- 2. Non-Water Quality Aspects a. Air Pollution: Same as 1977 b. Solid Waste Disposal: Same as 1977 Hot Forming - Primary Additional Energy Requirements. To meet EPA 1983 standards for wastewater discharge to public waters, modifications will be required to the wastewater treatment system. The additional power consumed will te 0.74 kwh/kkg (0.67 kwh/ton) processed. For the typical 3,628 kkg/day (4,000 ton/day) facility, the power required will be 112 kw (150 horsepower). The annual cost to operate this equipment will be $11,250. Non-Water Quality Aspects. 1. Air Pollution: None 2. Solid Waste Disposal: The sludge will be collected and recycled to melting operations. Hot Forming - Section Additional Energy Requirements. To meet EPA 1983 standards for wastewater discharge to public waters, modifications will be required to the wastewater treatment system. The additional power consumed will be 9.10 kwh/kkg (8.25 kwh/ton) processed. For the typical 1,179 kkg/day (1,300 ton/day) facility, the power required will be 447 kw (600 horsepower). The annual cost to operate this equipment will be $45,000. Non-Water Quality Aspects. 1. Air Pollution: None 2. Solid Waste Disposal: The sludge will be collected and recycled to melting operations. Hot Forming - Flat - Plate Additional Energy Reguirements. To meet EPA 1983 standards for wasteviater discharge to public waters, modifications will be required to the wastewater treatment system. The additional power consumed will be 8.88 kwh/kkg (8.05 kwh/ton) processed. For the typical 1,814 kkg/day (2,000 ton/day) facility, the power required will be 671 kw (900 horsepower). The annual cost to operate this equipment will be $67,500. 575 ------- Non-Water Quality Aspects. 1. Air Pollution: None 2. Solid Waste Disposal: The sludge will be collected and recycled to melting operations. Hot Forming - Flat - Hot Strip and Sheet Additional Energy Requirements. To meet EPA 1983 standards for wastewater discharge to public waters, modifications will be reguired to the wastewater treatment system. The additional power consumed will be 7.79 kwh/kkg (7.07 kwh/ton) processed. For the typical 3,447 kkg/day (3,800 ton/day) facility, the power required will be 1,119 kw (1,500 horsepower). The annual cost to operate this equipment will be $112,500. Non-Water Quality Aspects. 1. Air Pollution: None 2. Solid Waste Disposal: The sludge will be collected and recycled to melting operations. Pipe and Tubes - Integrated Additional Energy Reguirements. To meet EPA 1983 standards for wastewater discharge to public waters, modifications will be required to the wastewater treatment system. The additional power consumed will be 8.6 kwh/kkg (7.8 kwh/ton) processed. For the typical 363 kkg/day (400 ton/day) facility, the power required will be 130 kw (175 horsepower). The annual cost to operate this equipment will be $13,125. Non-Water Quality Aspects. 1. Air Pollution: None 2. Solid Waste Disposal: The sludge will be clamshelled and landfilled, or recycled to melting operations. Pipe and Tubes - Isolated Additional Energy Requirements. To meet EPA 1983 standards for wastewater discharge to public waters, modifications will be required to the wastewater treatment system. The additional power consumed will be 1.26 kwh/kkg (1.14 kwh/ton) processed. For the typical 363 kkg/day (400 ton/day) facility, the power required will be 19 kw (25 horsepower). The annual cost to operate this equipment will be $1,875. 576 ------- Non-Water Quality Aspects. 1. Air Pollution: None 2. Solid Waste Disposal: The sludge will be clamshelled and landfilled, or recycled to melting operations. Pickling - Batch Sulfuric Acid - Concentrated Additional Energy Requirements. To meet EPA 1983 standards for wastewater discharge to public waters, modifications will be required to the wastewater treatment system. The additional power consumed will be 33.33 kwh/kkg (30.23 kwh/ton) processed. For the typical 227 kkg/day (250 ton/day) facility, the power required will be 315 kw (422 horsepower). The annual cost to operate this equipment will be $31,666. Non-Water Quality Aspects. 1. Air Pollution: None 2. solid Waste Disposal: The sludge will be clamshelled and landfilled. Pickling - Batch Sulfuric Acid - Rinse Additional Energy Requirements. To meet EPA 1983 standards for wastewater discharge to public waters, modifications will be required to the wastewater treatment system. The additional power consumed will te 2.90 kwh/kkg (2.63 kwh/ton) processed. For the typical 227 kkg/day (250 ton/day) facility, the power required will be 27.4 kw (36.7 horsepower). The annual cost to operate this equipment will be $2,754. Non-Water Quality Aspects. 1. Air Pollution: None 2. solid Waste Disposal: The sludge will be clamshelled and landfilled. Pickling - Continuous Sulfuric Acid - Concentrates and Rinses - Neutralization Additional Energy Requirements. To meet EPA 1983 standards for wastewater discharge to public waters, modifications will be required to the wastewater treatment system. The additional power consumed will be 0.60 kwh/kkg (0.54 kwh/ton) processed. For the typical 1,088 kkg/kday (1,200 ton/day) facility, the power required will be 27 kw (36.7 577 ------- horsepower). The annual cost to operate this equipment will be $2,700. Non-Water Quality Aspects. 1. Air Pollution: None 2. Solid Waste Disposal: Sludges will be clamshelled and landfilled. Pickling - Hydrochloric Acid - Concentrated - Alternate I Additional Energy Requirements. To meet EPA 1983 standards for wastewater discharge to public waters, modifications will be required to the wastewater treatment system. The additional power consumed will be 0.13 kwh/kkg (0.12 kwh/ton) processed. For the typical 2,721 kkg/day (3,000 ton/day) facility, the power required will be 14.9 kw (20 horsepower). The annual cost to operate this equipment will be $1,500. Non-Water Quality Aspects. 1. Air pollution: None 2. Solid Waste Disposal: The sludge will be clamshelled and landfilled. Pickling - Hydrochloric Acid - Rinse - Alternate I Additional Energy Requirements. To meet EPA 1983 standards for wastewater discharge to public waters, modifications will be required to the wastewater treatment system. The additional power consumed will be 0.24 kwh/kkg (0.22 kwh/ton) processed. For the typical 2,721 kkg/day (3,000 ton/day) facility, the power required will be 27 kw (36 horsepower). The annual cost to operate this equipment will be $2,720. Non-Water Quality Aspects. 1. Air Pollution: None 2. Solid Waste Disposal: The sludge will be clamshelled and landfilled. Pickling - Hydrochloric Acid - Concentrates and Rinses Alternate II Additional Energy Requirements. To meet EPA 1983 standards for wastewater discharge to public waters, modifications will be required to the wastewater treatment system. The additional power consumed will be 0.24 kwh/kkg (0.22 578 ------- kwh/ton) processed. For the typical 2,721 kkg/day (3,000 ton/day) facility, the power required will be 27 kw (36 horsepower). The annual cost to operate this equipment will be $2,720. Npn-Water Quality Aspects. 1. Air Pollution: None 2. Solid Waste Disposal: The sludge will be clamshelled and landfilled. Hot Coatings - Galvanizing and Terne Plating Additional Energy Requirements. To meet EPA 1983 standards for wastewater discharge to public waters, modifications will be required to the wastewater treatment system. The additional power consumed will be 1.UO kwh/kkg (1.27 kwh/ton) processed. For the typical 635 kkg/day (700 ton/day) facility, the power required will be 37 kw (50 horsepower). The annual cost to operate this equipment will be $3,750. Non-Water Quality Aspects. 1. Air Pollution: None 2. Solid Waste Disposal: The sludge will be clamshelled and landfilled. Specialty Steel Co mbi ft at ion Acid Pickling, Scale Removal, Continuous Alkaline Cleaning, and Wire Pickling and Coating Additional Energy Reguirements; Additional power will not be required to meet standards for 1983, since the base level is the BATEA treatment model. Non-Water Quality Aspects; 1. Air Pollution: No air pollution problems are foreseen. 2. Solid Waste Disposal: The sludge produced by neutralization can be landfilled. 579 ------- SECTION IX EFFLUENT QUALITY ATTAINABLE THROUGH THE APPLICATION OF THE BEST PRACTICABLE CONTROL TECHNOLOGY CURRENTLY AVAILABLE EFFLUENT LIMITATIONS GUIDELINES The effluent limitations which must be achieved by July 1, 1977 are to specify the effluent quality attainable through the application of the Best Practicable Control Technology Currently Available. Best Practicable control Technology Currently Available is generally based upon the average of the best existing performance by plants of various sizes, ages, and unit processes within the industrial subcategory. This average is not based upon a broad range of plants within the steel industry, but based upon performance levels achieved by plants purported by the industry or by regulatory agencies to be equipped with the best treatment facilities. Experience demonstrated that in some instances these facilities were exemplary only in the control of a portion of the waste parameters present. In those industrial categories where present control and treatment practices are uniformly inadequate, a higher level of control than any currently in place may be required if the technology to achieve such higher level can be practicably applied by July 1, 1977. Considerations must also be given to: 1. The size and age of equipment and facilities involved 2. The processes employed 3. Non-water quality environmental impact (including energy requirements) 4. The engineering aspects of the application of various types of control techniques 5. Process changes 6. The total cost of application of technology in relation to the effluent reduction benefits to be achieved from such application Also, Best Practicable Control Technology Currently Available emphasizes treatment facilities at the end of a manufacturing process, but includes the control technologies 581 ------- within the process itself when the latter are considered to be normal practice within an industry. A further consideration is the degree of economic and engineering reliability which must be established for the technology to be "currently available." As a result of demonstration projects, pilot plants and general user there must exist a high degree of confidence in the engineering and economic practicability of the technology at the time of commencement of construction or installation of the control facilities. IDENTIFICATION OF BEST PRACTICABLE CONTROL TECHNOLOGY CURRENTLY AVAILABLE - BPCTCA - BY SUBCATEGORY G. Basic Oxygen Furnace - Wet Air Pollution Control Methods - thickener with polymer addition to the feed and vacuum filtration of the thickener underflow. 550 gal/ton of the thickener overflow is recycled, while 50 gal/ton of this recycle flow is discharged. K. Vacuum Degassing - sedimentation with recycle of solids to sinter; recycle and cooling of 535 gal/ton of process waters over cooling towers and discharge of 25 gal/ton of blowdown. L. Continuous Casting and Pressure Slab Molding sedimentation with continuous dragout and oil skimming, recycle flow over a cooling tower and filtration of the entire recycle flow. Slowdown is 125 gal/ton. M. Hot Forming-Primary - primary scale pit, oil skimmer, followed by recycle of 489 gpt (692 gpt for alloy) back to the flume for flushing. This is followed by a clarifier with a vacuum filter on the underflow, and a deep bed filter on the overflow. At this point 845 gpt (1220 gpt for alloy) is discharged for BPT. N. Hot Forming-Section - primary scale pit (assumed to be part of the operation, rather than a pollution control expense) , followed by an oil skimmer followed by recycle to the flume of 3,405 gpt of scale pit effluent, with the remainder (2626 gpt) going to a clarifier and the overflow from the clarifier filtered prior to discharge. O. Hot Forming-Flat-Plate - primary scale pit, oil skimmer, with 1,500 gpt (3,513 gpt for alloy) of the scale pit effluent recycled to the flume. The remainder (4,000 gpt(9,366 for alloy)) goes through a clarifier, with 582 ------- chemical treatment, with vacuum filtration of the underflow, and the overflow filtered and discharged. Hot Strip and Sheet - primary scale pit, oil skimmer, with recycle of 3,835 gpt of the scale pit effluent to the flume for flushing. The remainder of the scale pit effluent is clarified, with the underflow vacuum filtered. The overflow (4,180 gpt) is pressure filtered and discharged. P. Pipe and Tubes - following the primary scale pit, the integrated plant BPT treatment model consists of an oil skimmer and a clarifier, with 3,207 gpt of the clarifier effluent recycled to the flume. The remaining 1,002 gpt is filtered and discharged. For BATr this flow is cooled via cooling tower and totally recycled, resulting in no discharge. The isolated plant model is identical to the integrated one except that ponds replace the clarifiers, filters, and cooling tower in the integrated plant model. The effluent limitations for BPT and BAT are the same as for the integrated plants. Q. Pickling-Sulfuric Acid-Batch and Continuous Concentrates acid recovery unit or neutralization for those who are neutralizing as of December 1, 1975. Pickling-Sulfuric Acid-Batch and Continuous Rinses - counter-current rinsing, with the rinsewater used to dilute the concentrated acid (after acid recovery) to make up the pickle bath; neutralization for those who are doing so as of December 1, 1975. R. Pickling-Hydrochloric Acid Batch and Continuous - Batch: Concentrates - segregated collection of acid wastes and equalization, segregated collection of caustic wastes, neutralization by waste blending, lime treatment, mixing, aeration, polymer addition, one day settling. Rinses - equalization with acid and caustic wastes, neutralization by chemical addition, mixing aeration, one day settling. Fume Hood Scrubber - equalization, neutralization by chemical addition, mixing, aeration, one day settling. Continuous: Concentrates - neutralization by chemicals, mixing aeration, one day settling. 583 ------- Absorber Vent Scrubber - Acid regeneration, neutralization by chemicals (lime), aeration, one day settling. Rinses - neutralization by chemicals (lime) , mixing, aeration, polymer addition, one day settling. Fume Hood Scrubber - neutralization by chemicals (lime), mixing, aeration, polymer addition, one day settling. S. Cold Rolling-Recirculation - oil skimming, equalization, chemical treatment and flocculation, air flotation, surface skimming, settling lagoon with 2-5 day retention. Cold Rolling-Combination - oil skimming, equalization, chemical treatment and flocculation, air flotation, surface skimming, settling lagoon with 2-5 day retention. Cold Rolling-Direct Application - oil skimming, equalization, chemical treatment and flocculation, air flotation, surface skimming, settling lagoon with 2-5 day retention. T. Hot Coat - Galvanizing - segregated collection, equalization, neutralization by waste blending, mixing, hexavalent chrome reduction, neutralization by chemical addition, polymer addition. U. Hot Coat-Terne - segregated collection, equalization, neutralization by waste blending, mixing settling lagoon (1 day) , oil skimming. V. Mi seellaneous Runoff s-Casti nq and Slagging - water conservation to prevent runoff. W. Combination Acid-Batch and Continous - lime neutralization and clarification with flocculant addition and vacuum filtration of underflow. X. scale Removal - Kolene and Hydride - for kolene waste waters, acidification and reduction with sulfur dioxide of hexavalent chromium; for hydride waste waters, chemical oxidation of cyanides; the specific pretreatment step to be followed by lime neutralization and clarification with flocculant addition and vacuum filtration of the underflow. Y. Wire Pickling and Coating - lime neutralization and clarification with flocculant addition and vacuum filtration of the underflow. Alkaline chlorination for cyanide removal as a pretreatment, if necessary. 584 ------- Z. Continuous Alkaline Cleaning - neutralization and clarification with flocculant addition and vacuum filtration of the underflow. In establishing the subject guidelines, it should be noted that the resulting limitations or standards are applicable to aqueous waste discharge only, exclusive of noncontact cooling waters. In the section of this report which discusses control and treatment technology for the iron and steelmaking industry as a whole, a qualitative reference has been given regarding "the environmental impact other than water" for the subcategories investigated. The effluent guidelines established herein take into account only those aqueous constituents considered to be major pollutants in each of the subcategories investigated. In general, the critical parameters were selected for each subcategory on the basis of those waste constituents known to be generated in the specific manufacturing process, and also known to be present in sufficient quantity to be inimical to the environment. Certain general parameters, such as suspended solids, naturally include the oxides of iron and silica, however, these latter specific constituents were not included as critical parameters, since adequate removal of the general -parameter (suspended solids) in turn provides for adequate removal of the more specific parameters indicated. This does not hold true when certain of the parameters are in the dissolved state; however, in the case of iron oxides generated in the iron and steelmaking processes, they are for the most part insoluble in the relatively neutral effluents in which they are contained. The absence of apparent less important parameters from the guidelines in no way endorses unrestricted discharge of same. The recommended effluent limitations guidelines for BPCTCA resulting from this study are summarized in Tables 151 to 173. These tables also list the control and treatment technology applicable or normally utilized to reach the constituent levels indicated. Figures 128 to 150 present the BPCTCA treatment models. These effluent limitations contained herein are by no means the absolute lowest values attainable (except where no discharge of process wastewater pollutant is recommended) by the indicated technology, but moreover they represent values which can be readily controlled around on a day by day basis. It should be noted that these effluent limitations represent values not to be exceeded by any 30 continuous day average. The maximum daily effluent loads per unit of production 585 ------- H tfi W ™ 1 en n H M a H D e> w o H EH rf ^ H JEJ •• • 1-1 EH 2 (4 D h CM H I i^ g ^J (U m in •a o 4J 0) z o 4J O u c o •H 4J 3 O PU ^i •H i^ 4J fl) V^i- 0) U id C 3 c 0) ^ X u •rl CO id n 53 ~ P ^^ r ( "x. p en co- pa o H U SSlri EH EH ^ I MOW WEn \ ^~- "TJ ^-^ r^ O o i-4 O E o EH EH M s EH rtj M g iB h5 ^^ 1 O U I rH U E fl> U JS •H •— - •P s> •H 4J • . 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U ul a. Q.O: 611 ------- 1 r '- rf1 ff?SS " ^ 5 "* 1 i di a. itt ib D -J O a,2 u 4 £ u Jo S a tt ti I i 612 ------- should not exceed these values by a factor of more than three. In the absence of sufficient performance data from the industry to establish these factors on a statistical basis, the factor of three was chosen in consideration of the operating variations allowed for in selecting the 30 continuous day average limitations. RATIONALE FOR SELECTION OF BPCTCA The following paragraphs summarize the factors that were considered in selecting the categorization, water use rates, level of treatment technology, effluent concentrations attainable by the technology, and hence in the establishment of the effluent limitations for BPCTCA. Size and Age of Facilities and Land Avai labi li ty Considerations As discussed in Section IV, the age and size of steel industry facilities has little direct bearing in the quantity or quality of wastewater generated. Thus, the ELG for a given subcategory of waste source applies equally to all plants regardless of size or age. Land availability for installation of add-on treatment facilities can influence the type of technology utilized to meet the ELG's. This is one of the considerations which can account for a range in the costs that might be incurred. Consideration of Processes Employed All plants in a given subcategory use the same or similar production methods, giving similar discharges. There is no evidence that operation of any current process or subprocess will substantially affect capabilities to implement the best practicable control technology currently available. At such time that new processes appear imminent for broad application, the ELGs should be amended to cover these new sources. No changes in process employed are envisioned as necessary for implementation of this technology for plants in any subcategory. The treatment technologies to achieve BPCTCA are end-of process methods which can be added onto the existing treatment facilities. Consideration of Non-Water Quality Environmental Impact Impact gf Limitations on Air Quality. The increased use of recycle systems has the potential for increasing the loss of volatile substances to the atmosphere. Recycle systems are so effective in reducing wastewater volumes, and hence waste loads, to and from treatment systems, and in reducing the 613 ------- m ID rH 3 CO EH CO w Z M 1 H 3 O W § H EH EH H S M J EH fa fc. M 1 rtj rj 3 to M CO Z S Q 3 w IH p2 53 Z 8 t Q H O u 3 M Q a re i z B u H CO § C •H 4J C 8 0 o 4J 1 E o •H JJ 18 •rl rH id jJ 3 Z .. H H 1 EH 3 •* •§ 4J t Estima CO B o •rl 4J id JJ •H < - 0 B, c o p JJ 3* 3 2\| «» •— fT) ^, S1 H O C U HI EH jj C g id HI EH as O JJ C 0 u -. (S •H X^ rti _ * 3 1 H 01 o i o 2 o -V rH 4 JJ. rH - . 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There are no air pollution problems which have been identified as resulting from the application of the control and treatment technologies described herein. The handling and storage of spent nitric-hydrofluoric pickling solutions must be done with care to avoid fumes of nitrogen oxides. One plant uses floating plastic balls on the surface of open tanks to avoid this problem. Impact of Limitations on Solid Waste Problems. Consideration has also been given to the solid waste aspects of water pollution controls. The processes for treating the wastewaters from this industry produce considerable volumes of sludges. Much of this material is inert iron oxide which can be reused profitably in melting operations. Other sludges not suitable for reuse must be disposed in landfills, since they are mainly chemical precipitates which could be little reduced by incineration. Being precipitates, they are by nature relatively insoluble and nonhazardous substances requiring minimal custodial care. The solid waste problem of most significance is the generation of sludge from neutralization of spent solutions and rinsewaters. The sludge produced from the lime neutralization of sulfuric acid spent pickling solutions is voluminous, equal in volume to the original solution and remains plastic indefinitely. Air oxidation to produce ferric hydroxide rather than ferrous hydroxide reduces the sludge volume and the material is somewhat drier. Oxidation to magnetic iron oxide can reduce the volume of sludge dramatically and produce a dry material. The sludge resulting from the neutralization of spent solutions containing nitric acid contains mostly ferric iron, resulting in lower volumes and drier materials. In order to ensure long-term protection of the environment from harmful constituents, special consideration of disposal sites should be made. All landfill sites should be selected so as to prevent horizontal and vertical migration of these contaminants to ground or surface waters. 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Where appropriate, the location of solid hazardous materials disposal sites should be permanently recorded in the appropriate office of legal jurisdiction. Impact of Limitations on Energy Reguirements. The effect of water pollution control measures on energy requirements has also been determined. The additional energy required in the form of electric power to achieve the effluent limitations for BPCTCA and BATEA amounts to less than 3% of the 51.6 billion kwh of electrical energy used by the steel industry in 1972. Energy requirements in the specialty steel segments for various levels of treatment have been estimated and generally do not exceed 2 percent of the 606 kw-hr per kkg (550 kw-hr per ton) of electric power required in electric furnaces producing stainless steel. The enhancement to water quality management provided by these effluent limitations substantially outweighs the impact on air, solid waste, and energy requirements. Consideration of the Engineering Aspects of the Application of Various Types of Control Techniques The level of technology selected as the basis for BPCTCA limitations is considered to be practicable in that the concepts are proven and are currently in place and in use by the various steel mills as more fully described below. The level of technology selected as the basis for BPCTCA limitations is considered to be practicable in that the concepts are proven and are currently available for implementation and may be readily applied as "add-ons" to existing treatment facilities. Identification of the Best Practicable Control Technology Currently Available - BPCTCA Discussion By Subcategories; The rationale used for developing the BPCTCA effluent limitations guidelines is summarized below for each of the Subcategories. All effluent limitations guidelines are presented on a "gross" basis since for the most part, removals are relatively independent of initial concentrations of contaminants. The ELG^ are in kilograms of pollutant per metric ton of product or in pounds of pollutant per 1,000 pounds of product and in these terms only. The ELG's are not a limitation on flow, type of technology to be utilized, or concentrations to be achieved. These items are listed only to show the basis for the ELG's 642 ------- and may be varied as the discharger desires so long as the ELG loads per unit of production are met. Basic Oxygen Furnace Operation The only direct contact process water used in the EOF plant is the water used for cooling and scrubbing the furnace off- gases. One method used is the wet gas cleaning system which uses a venturi scrubber and a gas quencher. The use of wet air pollution control is rare in the alloy and stainless steel industry. The water use at one plant producing alloy steel in a EOF was 870 gals/ton. The water was used once- through and the only treatment provided was clarification where the EOF waste water was combined with blast furnace gaswasher water. The technology identified as used in the alloy and stainless steel industry was judged to be inadequate. The water use rate lies within the range found in the carbon steel industry (130-1020 gal/ton) and there is no reason to believe that the technology in use there is not directly transferable, since the characteristics of the waste waters and the nature of the processes are similar. The BPCTCA limitations have thus been established on the basis of an effluent suspended solids concentration of 50 mg/1 at an effluent volume of 209 1/kkg (50 gals/ton). The blowdown rate of 5.9 percent is being achieved in at least one carbon steel plant and at least two such plants are achieving lower effluent concentrations of suspended solids. The pH of the scrubber water effluent from the alloy steel EOF averaged 7.4, so that no difficulty with a pH 6-9 limitation is foreseen. Vacuum Degassing Subcategory The direct contact process water used in specialty steel vacuum degassing is the cooling water used for the steam-jet barometric condensers. Although most systems use steam ejectors to draw the vacuum, dry mechanical pumps are also used. The vacuum degassing systems surveyed in the alloy and stainless steel industry used water once-through with little effective treatment, completely recirculated -£he water with no discharge, or use mechanical pumps. It was judged to be unduly restrictive to impose a zero effluent discharge limitation for BPT because all plants may not be able to completely recirculate the water or convert to mechanical pumps. The water use rate determined for the once-through system (3021 1/kkg) lies in the range found in the carbon steel industry plants surveys (813-3750 1/kkg) 643 ------- and there is no reason to believe that the technology in use there is not directly transferable, since the characteristics of the waste waters and the nature of the processes are similar. The BPCTCA limitations have thus been established on the basis of an effluent suspended solids concentration at 50 mg/1 at an effluent volume of 101 1/kkg (25 gals/ton). The blowdown rate of 3.4 percent is being achieved in at least one carbon steel plant and, of course, in the completely recirculated system mentioned above. At least one carbon steel plant is achieving lower effluent suspended solids concentrations and the pH of the once-through alloy steel systems averaged 6.5 (within the specified 6-9 range) . Continuous Casting and Pressure Slab Molding Subcategory Continuous casting and pressure slab molding are processes by which primary steel shapes are cast or molded from molten steel instead of being rolled from ingots. The molds are cooled by indirect water circulation. The continuous casting spray cooling water system is direct contact cooling of the cast product. As the cast product (slab, bloom, or billet) emerges from the mold, the water sprays further solidify and cool the cast product. The principal waste contaminant in this contact cooling water is suspended solids and, additionally, oil from machinery lubrication finds its way into this water effluent. Pressure slab molding results in the generation of wastewaters. containing suspended solids and oil. The current control and treatment technology in the alloy and stainless steel industry consists of clarification of the waste water with varying degrees of recirculation of the water to the process use. One plant surveyed recirculated the water completely with only periodic batch-type blowdown of the system. No system in current use in the alloy and stainless steel industry was found to be adequate and/or necessarily usable at all other plants; treatments were adequate, but complete recirculation may not be always feasible. The water use rates of 2379-4173 1/kkg are lower than the minimum of 6172 1/kkg found in the carbon steel industry plants surveyed. The characteristics of the waste waters and the nature of the processes are similar to those in the carbon steel industry and hence there is no reason to believe that the technology in use there is not directly transferable, resulting in a very conservative estimate of achievable limitations. The BPCTCA limitations have thus been established on the basis of effluent suspended solids 644 ------- concentrations of 50 mg/1 and of 15 mg/1 oil and grease at an effluent volume of 522 1/kkg (125 gal/ton). The resultant blowdown rates are easily achievable as compared to those in either of the carbon steel plants surveyed and both carbon steel plants were achieving lower concentrations of both suspended solids and oil and grease. All plants surveyed easily achieved an effluent pH between 6 and 9. Hot Forming-Primary The carbon steel data base was examined and an average of the best plants calculated. The calculated discharge rate was based upon the average of the best loadings, which for this subcategory was the average of the loads at the plants surveyed. In some cases, where the suspended solids or oil concentrations in the effluent were less than 5 or 10 mg/1 respectively, the concentration for the purposes of calculating an average load were taken to be 5 or 10. This variance from actual data was justified on the basis of analytical accuracy, in that although we know that the suspended solids level was very low, the analytical method is not totally reliable at less than 5 or 10 mg/1. From the calculated loading, a flow representing an achievable concentration level such as 10 mg/1 for TSS and oil was calculated. This flow was used for the cost of the treatment technology, since costs are largely based on hydraulic flows. Plants E, H and D in the alloy and stainless steel industry plant survey had water uses averaging 1912 gal/ton. Using direct transfer of technology, the carbon steel guidelines for this category were scaled up to reflect the higher water use rate. Hot Forming-Section The carbon steel data base was examined and the concentrations of pollutants were adjusted if they averaged below the accepted minimum for that parameter. In some plants, more than one section operation had been sampled, so that although 7 plants were visited, information was available from 11 operating lines. The loadings were calculated for each line. One plant, H-2, which used cyclones for settling (TSS was 71 ppm) was discarded from consideration because the cyclones did not prove to be exemplary for TSS or oil removal. The plant had originally been sampled to ascertain as to the quality of the treatment provided by cyclones. The average load from the 10 plants which were determined to be exemplary was then calculated. 645 ------- Using achievable concentration levels, a discharge flow for BPT of 2626 gpt was derived. The section rolling mills in the alloy and stainless steel industry plant survey in this subcategory had water use rates which averaged to be slightly less than for carbon steel. Directly transferring the technology results in a conservative effluent limitation. Hot Forming-Flat Plate Only one exemplary carbon plate mill, K-2, was studied. No other plate mills with good waste treatment could be identified since other plate mills either discharged to central treatment facilities or had even less treatment. It had a 150 gpt discharge rate, and the pollutant concentrations for oil loading calculations had to be adjusted upward to allow for analytical methods. The BPT loadings for TSS also had to be adjusted upwards to allow for achievable concentrations in the treatment plant. Because the technology for this operation was so much more sophisticated than for the other hot forming operations, the BPT technology was established at about the level of the other hot forming operations and the limitations established accordingly. The sole specialty steel plate mill surveyed had a water usage rate twice the rate for the carbon steel mill and was judged to be inadequate from a treatment standpoint. Since the waste constituents are similar, the technology in use in the carbon segment was transferred directly, although an allowance was made for the higher flow rate in the specialty steel segment. Hot Forming-Flat-Sheet and Strip The data base was examined and concentrations adjusted for analytical methods. The average load of the four carbon steel plants studied was derived from the loads, and this average was used as the BPT limitation. The specialty steel hot strip mills which were surveyed had water usage rates which were slightly less than those in the carbon steel segment. However, none of the specialty plants were practicing recirculation. Therefore, the technology used in the carbon steel segment was directly transferred and the limitations were established as the same for both, resulting in a conservative limitation for the specialty strip mills. Pipe and Tube Six plants were studied in the sutcategory, of which three were electric resistance welding, two were butt weld and one 646 ------- a seamless plant. One of the ERW plants was excluded because it used evaporation as part of the treatment technology, which is not generally applicable to steel plants. The average load from the five remaining plants was then determined, and the technology for the cost model selected. Two of the plants achieved zero discharge through total recycle, and this was subsequently found to be the limitation for BAT. The BPT model was subdivided on the basis of pipe and tube operations integrated with other steel forming operations, and those which were isolated plants. The data base revealed that the isolated plants generally used ponds for settling and cooling, rather than clarifiers and cooling towers, since modeling all plants based on use of clarifiers would tend to overstate the cost, the subcategory was subdivided up for the purposes of calculating limitations and costs. Sulfuric Acid-Batch Examination of the data base revealed that six plants were treating the pickling concentrated acid. Five of these were achieving zero discharge via sulfuric acid recovery for three and waste acid hauling for two. The remaining plant was neutralizing together with rinse water, settling and discharging to the sewer. Sufficient data indicated that BPT limitations could be established at zero discharge for the sulfuric acid batch concentrated subcategory. Six plants were studied that had sulfuric acid batch rinsing operations. Three facilities were achieving zero discharge by treating rinses via the concentrate recovery unit, and using the rinsewater (after countercurrent use) as a diluent in the concentrate makeup. One plant had essentially no treatment, another treated along with the concentrated acid via settling and a third treated rinse wastewater by dilution with rod mill wastes. These latter three were deemed to be inadequate treatment methods. Average of best (three mills practicing zero discharge) dictated a BPT limitation of zero discharge. Sulfuric Acid-Continuous The data base for sulfuric acid continuous pickling is composed of six mills. Considering deep well disposal as a mechanism for zero discharge of concentrates, then four out of the six mills were capable of zero discharge (three out of the four were practicing deep well disposal). Out of the other two mills not attaining zero discharge, one was discharging while the other was neutralizing. Noting the fundmental differences between acid recovery and 647 ------- neutralization technologies, a provision was developed for those facilities practicing acid neutralization of concentrates. Of the six mills, only one mill achieved zero discharge of the rinse wastewater. The others were practicing either joint treatment (4) or discharging to a sewer (1) . Recognizing the difference in neutralization and acid recovery, plants with neutralization facilities existing at the time of promulgation will be permitted a discharge of 25 gpt for concentrates and 200 gpt for rinses and 25 gpt for fume hoods for BPT. The BPT treatment model will be neutralization followed by a 1 day settling lagoon. Sulfuric Acid Pickling - Specialty Steel There was only one operation identified in the alloy and stainless steel industry plant survey that could be separated from other pickling and cleaning operations for the purposes of raw waste load and treatment level specification. Since the characteristics and flows of the wastes and nature of available treatments are similar between the two industry segments, it was decided to base the BPCTCA limitations on those adopted for this subcategory for carbon steel operations. The specialty steel plant was achieving no discharge of process wastewater pollutants both for rinses and concentrations. Pickling - Hydrochloric Acid - Batch and Continuous - Concentrates Batch Pickling Operations. A relatively small number of pickling operations, predominantly rod and wire processors, use hydrochloric acid in batch pickling systems. Production rates on these units are about half of those for corresponding sulfuric acid lines, so most batch operators do not generate enough spent hydrochloric acid pickle liquor to make acid recovery units practical. Instead, the general practice has been contract hauling of batches of spent pickle baths to treatment and ultimate disposal off-site, where they may be blended with alkaline wastes from other industrial sources. Two plants of this type were surveyed, and these were either neutralizing to a level acceptable to the municipal sanitary authority, or were using contract hauling services to dispose of spent concentrates. Technology for treatment of spent concentrates from batch hydrochloric acid pickling does exist. In most instances, it is more practical to treat spent concentrates jointly with rinses in one unified treatment system. 648 ------- Continuous Pickling Operations. Plants utilizing hydrochloric acid for continuous pickling, primarily sheet and strip lines, are relatively new when contrasted with continuous sulfuric acid pickling lines. As a result, they practice more modern control and treatment technology than their sulfuric acid counterparts. Emphasis is placed on recovery of reusable hydrochloric acid from all spent pickling concentrated solutions. Typical lines run at high production rates, on the order of 1,270 to 5,440 kkg (1,400 to 6,000 tons) per day, with an average production near 2,720 kkg (3,000 tons) per day. Many plants operate more than one line at a given location. Spent concentrates are generated at a typical rate of 42 to 65 1/kkg (10 to 15 gal./ton). The three continuous HCl regeneration systems surveyed are using the same basic acid recovery process. Spent acid is evaporated in a gas-fired roaster. Iron oxide is removed from the bottom of the roaster while HCl vapors pass on to an absorber where they are converted into reusable acid. The inert combustion products pass through the absorber to a final water scrubber for removal of any residual HCl vapor and fine particulates prior to venting to atmosphere. The vent scrubber discharge is the only liquid waste from the acid recovery system, averaging approximately 830 1/kkg (200 gal./ton) in flow rate. For those hydrochloric acid pickling operations not practicing acid regeneration, treatment alternatives for spent concentrates ranged from deep well disposal to carefully controlled lime neutralization, jointly with the more dilute acidic rinse waters. Of the seven continuous HCl pickling operations surveyed, three were regenerating their spent acids, two were practicing deep well disposal, one was using contract hauling disposal services, and one was blending concentrates and rinse waters prior - to treatment via aeration, lime neutralization, polymer addition, clarification via a thickener, with vacuum filtration of thickener underflows and discharge of a clear, neutral, iron-free effluent. Pickling - Hydrochloric Acid - Batch and Continuous - Rinses A total of nine hydrochloric acid pickling plants were examined for rinse water quality during the survey, and six of these were large tonnage strip and sheet mills. Of the nine operations, three were presently providing no rinse water treatment; three attain some concentration reductions through partial neutralization or dilution; two treat rinse waters effectively using conventional lime treatment and sedimentation/clarification; and the remaining plant cascades dilute rinse waters toward the head end of the 649 ------- pickling line, thereby concentrating iron and acid levels until the rinse waters resemble dilute (1-2%) spent acid concentrated solutions. At present, this plant injects this waste and the spent concentrate to a deep well, but this mixture is amenable to acid recovery by systems described previously in the sections on Pickling - Hydrochloric Acid - Concentrates. Cold Rolling Subcategories Re ci r c ul a t io n Systems. Four of the five mills sampled had recirculation systems. Spent rolling oils are pumped to a separate storage tank and metered into an oil separator along with oily wastewater (spillage, pump leakage, etc.) from the oil cellar and machine shop, associated with the cold mill operation. Discharges from these plants ranged from 67 1/kkg to 760 1/kkg (16 to 182 gal./ton) of product rolled. The volume of discharge per ton of product rolled is highly dependent upon the width, thickness,, and type of a product, the speed of the rolling mill, the condition of the rolls and wipers, and will vary considerably on different days for the same mill, depending on the product rolled. In spite of the wide variation in flows shown above, three of the four plants achieved average discharge rates between 67 and 75 1/kkg (16 and 18 gal./ton), and 4 to 6 mg/1 of oil and grease was readily attained in the treatment plant effluent, partly due to the dilution effect caused by treating cold rolling mill wastewaters in a central treatment plant along with wastewaters from other processes. Two of the cold rolling mills at specialty plants achieved no discharge of process waste water pollutants by completely recirculating the oil or oil emulsion. The third plant discharges at a rate of 57 gal/ton but with unacceptable levels of suspended solids and oil and grease. No generally applicable treatment technology was identified in the alloy and stainless steel industry plant surveys and it was thus decided that the limitations for this subcategory would be based upon the BPCTCA adopted for similar operations in the carbon steel industry. Combination Systems. Although recent trends in cold rolling practice have aimed at increased use of recirculatTion systems wherever possibly, many plants must continue to run one or more stands on a once-through basis. This need is dictated by special customer requirements, control of dissolved solids, or the need to remove a previously applied oily coating which may be incompatible with the rolling solutions used. Plants using such a combination of recirculation and direct application stands generate considerably more wastewater than recirculation alone. For 650 ------- example, the one combination plant visited on two different occasions during this survey consisted of two different cold rolling lines and a temper mill using various combinations of recirculation and direct application, with wastewater flows averaging 1551 1/kkg (372 gal/ton) at the time of the visits. Data reported by this plant for a representative period of operations confirmed the above average, indicating a 28-day average flow of 1,530 1/kkg (367 gal./ton) to treatment. For this reason, the BPCTCA ELGs for combination cold rolling operations has been based on flow rates of 1,668 1/kkg (400 gal./ton) of steel produced. Direct Application Systems. A few cold rolling installations will continue to operate without recirculation on any rolling stand, providing only once-through direct application of rolling solutions. Although no plants of this type were surveyed, a review of the application rates utilized by the recirculation and combination types of operation in the cold rolling subcategory indicate a typical water reguirement of approximately 4,170 1/kkg (1,000 gal./ton) of product rolled. Thus this flow, together with the treatment technology utilized on the other cold rolling wastewaters (namely, equalization, chemical treatment, flocculation, dissolved air flotation, surface skimming and long-term settling) form a basis for BPCTCA ELGs for direct application plants. Hot Coatings - Galvanizing operations Four plants in the hot coatings subcategory were visited. Two of these were rod and wire mills producing galvanized wire, but one had no process wastewaters in contact with the coated product and, consequently, no raw waste load attributable to the coating step. Waste loads from the rod mill and the pickling operations associated with this production line are covered under the hot forming section and the pickling - hydrochloric acid subcategories. The remaining three mills included two large continuous strip galvanizing operations and (including one running three coating lines side by side) one continuous wire galvanizing operation. Wastewater flow rates for these three lines ranged from 557 to 2,195 gal./ton for the strip galvanizing lines, to 4,600 gal./ton for the wire mill. All lines included varying portions of noncontact cooling water from furnace cooling and from temperature control of the molten metal baths. Hot Coatings - Terne Operations 651 ------- Two plants operating terne plating lines were surveyed, and both of these were practicing tight control to minimize drag-out of solutions from process tanks. Process water flow rates ranged from 2,150 to 4,115 1/kkg (516 to 987 gal./ton), and fume hood scrubber waters contributed an equivalent load at one of the plants. Miscellaneous Runoffs-Storage Piles - Coal, Stone, and Ore These three miscellaneous runoffs are discussed together since at a minimum, all three runoffs would require the same general type of treatment; namely collection, sedimentation, and pH adjustment. This is not meant to imply that these runoffs should necessarily be collected and treated together, although that possibility need not be specifically excluded either. Nor should this analysis necessarily preclude that the above treatment is all that is needed in every case. For coal pile runoffs in particular, the presence of other undesirable contaminants (as discussed in Section V) due to their presence in the coal would be heavily dependent on the area where the coal is mined and the particular mineral makeup of the soil in that area. Miscellaneous Runoff s - Casting and Slagging Ingot Casting. Ingot casting operations employ minimal amounts of water for mold spray cooling. Water usage is so minimal that there is rarely any runoff from the area proper. In addition, any excess spray water would generally contain only suspended matter in the form of larger scale particles which would settle in the immediate spray area. A runoff that might exist at a specific site due to excessive spray water usage could best be resolved by tightening up on spray water usage. Specialty Steel Pickling, Cleaning and Coating Suspended Solids The removal of suspended solids from the treated effluent from pickling and cleaning wastes generally is accomplished by clarification. The precipitated metal hydroxides act as flocculating agents and the addition of polyelectrolytes acts to agglomerate the flocculant particles into more readily settlable form by increasing their bulk densities. Properly designed and operated treatment facilities can regularly achieve effluent suspended solids concentrations of 25 mg/1. Such a value has been determined to be attainable as a result of the carbon steel study. In the 652 ------- alloy and stainless steel industry plant survey, the treatment facilities at Plants A and O attained effluent suspended solids concentrations averaging 20 and 21 mg/1, respectively. The limitation of 25 mg/1 thus appears to be readily achievable. Chromium Chromium is optimally precipitated at pH 8.0. The 0.50 mg/1 limitation is based upon that effluent concentration which is readily achievable at high flow rates. This limitation is conservative in view of the fact that the treatment plant effluents at Plants A and P never exceeded this value and averaged 0.32 and 0.10 mg/lr respectively. Ch romi urn, He xa va1ent Hexavalent chromium compounds are highly soluble compared to the trivalent form. Treatment for hexavalent chromium consists of reduction to the trivalent form at low pH by sulfur dioxide, ferrous sulfate, sodium metabisulfite, or sodium hydrosulfite. The pH is then raised to pH 8 with an alkaline reagent, precipitating the reduced chromium as the hydroxide. Proper operation can reduce hexavalent chromium to nearly zero. The 0.05 mg/1 limitation is based upon analytically reproducible concentrations and is conservative as judged from the less-than-detectatle concentrations found in the treatment plant effluent at Plant P where hexavalent chromium reduction is regularly practiced. Cyanide Cyanides are oxidized at elevated pH levels, usually by chlorine, i.e., alkaline chlorination. The initial reaction is very fast and produces cyanates. Maintenance of a chlorine residual at a nearly neutral pH for an hour or more oxidizes the cyanate to nitrogen and carbon dioxide and essentially zero cyanide levels can be achieved. The limitation was conservatively based on 0.25 mg/1, as judged from the treatment plant effluents at Plants O and S which did not exceed 0.10 and 0.04 mg/1, respectively. Nickel, Iron, and Fluoride The limitations here are based upon one-half the maximum and/or the average concentrations found in the treatment plant effluent at Plant A. This is a well-operated conventional lime neutralization system using a solids contact clarifier and polyelectrolyte addition. Nickel is reduced here from about 15 mg/1 to an average of 0. 18 mg/1 653 ------- and a maximum of 0.22 mg/1. 0.25 mg/1 is used as the basis for the limitation. Iron is reduced from 80-105 mg/1 to an average of 0.13 mg/1 and a maximum of 1.4 mg/1. Fluorides are reduced from 150-320 mg/1 to an average of 14 mg/1 and 15 mg/1 was used as the basis. The chosen limitations for iron (1.0 mg/1) is also the limitation adopted as BPCTCA in the carbon steel industry pickling subcategories. Copper The limitations for this metal at 0.25 mg/1 are based upon the development document for the non-ferrous metals industry as representing the concentrations readily achievable by lime neutralization and clarification as demonstrated in those industries. This transfer of technology approach is judged to be the best method of establishing limitations here because much more attention and study has been devoted to treatment of these constituents in non-ferrous wastes than has been the case in the steel industries. BPCTCA for these subcategories has been based upon the attainment of the above effluent concentrations by lime neutralization, flocculation-clarification with polyelectrolyte addition, and vacuum filtration of the clarifier underflow to reduce sludge volumes for landfill. Waste waters containing cyanides are pretreated to oxidize the cyanide by alkaline chlorination as described above. Waste waters containing hexavalent chromium are pretreated to reduce the chromium to the trivalent form with the use of sulfur dioxide or othejr reducing agent as described above. Combination Acid Pickling (Continuous) The flow volume for this subcategory are based upon the plant survey data from Plants A, D, E and I to include rinsewater, spent liquor, and fume scrubber effluents. The rinsewater volumes at Plant A were from 3394-3721 1/kkg and at Plant D from 3962-4237 l/kkgr averaging 3803 1/kkg. The rinsewater volumes at Plant I equaled 7564 1/kkg of product, but no data were provided as to the tonnage pickled vs. the product tonnage. Assuming, for Plant I, that there are two picklings per unit produced, the indicated average rinsewater volume is 3803 1/kkg (912 gals/ton) of steel pickled. The spent pickle liquor volume is based upon those for Plants A, I, and E which were, respectively, 96, 98, and 112 1/kkg, averaging 102 1/kkg (24.5 gals/ton). Considering all of the above data, an effluent volume of 4170 1/kkg (1000 gals/ton) was selected as representing the best estimate for this subcategory. 654 ------- Combination Acid Pickling (Batch Pipe and Tube) The flow volumes for this subcategory are based upon the plant survey data. The rinsewater volume at Plant U provided the only basis for estimation of rinsewater volumes in this subcategory and was equal to 677 gal/ton. The fume scrubber effluent volume was based upon that at Plant F which equaled 60 1/kkg (14.3 gals/ton). The spent pickle liquor volume was based upon the average volume of 49 1/kkg, the spent liquor volumes at Plants C, F, K and the remaining plant were, respectively, 24, 60, 75 and 38 1/kkg. On the basis of these data, the waste water volume for this subcategory was determined to be 2919 1/kkg (700 gals/ton) . Combination Acid Pickling (Other Batch) The flow volumes here were based upon the plant survey data. The fume scrubber and spent liquor volumes were determined from the data as described above for the pipe and tube subcategory. Rinsewater volumes for operations in this subcategory at Plants Cr F and L were respectively, 91, 279 and 140 gal/ton, averaging 170 gal/ton. The waste water volume for this subcategory was thus conservatively estimated at 834 1/kkg (200 gals/ton). Scale Removal Kolene Scale Removal The flow volumes for this subcategory were based upon the plant survey data. The waste water volumes were, 398, 494 and 108 gal/ton, averaging 333 gal/ton. The waste water volume here was thus established at 2085 1/kkg (500 gals/ton) . Hydride The flow volume for this subcategory was based upon the plant survey data at Plant L at 5004 1/kkg (1200 gals/ton). Wire Coating and Pickling The flow was established on the basis of an observed 10- minute rinsing of a 227 kkg (500 Ib) coil at Plant K at the rate of 1.31/sec (20 gpm), i.e., 3378 1/kkg (800 gals/ton) and the flows at plants K and O which were 222 and 1828 gal/ton, respectively, for an average of 950 gal/ton. The limitations were established on the basis of 1000 gal/ton. Continuous Alkaline Cleaning 655 ------- The flow volume here was based upon the plant survey data from Plant I at 209 1/kkg (50 gals/ton). Consideration of Process Changes No in-process changes will be required to achieve the BPCTCA limitations, although recycle water quality changes may occur as a result of efforts to reduce effluent discharge rates. Many plants are employing recycle, cascade uses, or treatment and recycle as a means for minimizing water use and the volume of effluents discharged. The limitations are load limitations (unit weight of pollutant discharged per unit weight of product) only, and not volume or concentration limitations. The limitations can be achieved by extensive treatment of large flows; however, an evaluation of costs indicates that the limitations can usually be achieved most economically by minimizing effluent volumes. Consideration of Costs Versus Effluent Reduction Benefits In consideration of the costs of implementing the BPCTCA limitations relative to the benefits to be derived, the limitations were set at values which would not result in excessive capital or operating costs to the industry. To accomplish this economic evaluation, it was necessary to establish the treatment technologies that could be applied to each subcategory in an add-on fashion, the effluent qualities attainable with each technology, and the costs. In order to determine the added costs, it was necessary to define what treatment processes were already in place and currently being utilized by most of the plants within a given subcategory. This was established as the reference level of treatment. Treatment systems were then envisioned which, as add-ons to existing facilities, would achieve significant waste load reductions. Capital and operating costs for these systems were then developed for the average size carbon steel facility. The average size was determined by dividing the total industry production by the number of operating facilities. The capital costs were developed from a quasi- detailed engineering estimate of the cost of the components of each of the systems. The annual operating cost for each of the facilities was determined by summing the capital recovery (basis ten year straight line depreciation) and capital use (basis 7% interest) charges, operating and maintenance costs, chemical costs, and utility costs. 656 ------- Costs for the alloy steel segment were generally scaled down from those for carbon steel, using the "0.6" factor, as explained in Section VIII. Average plant size for alloy steel was determined by selecting a representative plant from those studied. Where there was no comparable subcategory in the carbon steel segment, a quasi-detailed engineering estimate was determined. Cost effectiveness diagrams were then prepared to show the pollution reduction benefits derived relative to the costs incurred. As expected, the diagrams show an increasing cost for treatment per percent reduction obtained as the percent of the initial pollutional load remaining decreased. The BPCTCA limitations were set at the point where the costs per percent pollutant reduction took a sharp break upward toward higher costs per percent of pollutant removed. These cost effectiveness diagrams are presented in Section X. The initial capital investment and annual expenditures required of the carbon steel industry to achieve BPCTCA were developed by multiplying the costs (capital or annual) for the average size facility by the number of facilities operating for each subcategory. These costs are summarized in Table 197 in Section X. Table 197 also shows the costs for the specialty steel segment. After selection was made of the treatment technology to be designated as one means to achieve the BPCTCA limitations for each subcategory, a sketch of each treatment model was prepared. The sketch for each subcategory is presented following the table presenting the BPCTCA limitations for the subcategory. Multi-community Economic Impact Comments submitted in response to effluent limitations proposed on February 19, 1974 (39 F.R. 6481) , contended that the proposed regulations might result in large employment reduction in the multi-community Mahoning River Valley region of eastern Ohio. Upon the promulgation of those regulations on June 28, 1974 (39 F.R. 24114), EPA concluded that it lacked sufficient information to support different requirements for point sources located in that region. Following the promulgation of those regulations, and in accordance with the preamble hereto, companies contending that the effluent limitations guidelines contained therein would cause curtailment of operations and heavy unemployment in the Mahoning Valley region were afforded the opportunity of presenting detailed technical, cost and financial information to support that contention. Similar 657 ------- opportunities to present additional information were afforded to officials of state, county and municipal governments and regional planning and economic development agencies. The data supplied by the companies and other commenters, and the evaluation thereof by EPA, through its consultants, have been utilized in the establishment of the effluent limitations guidelines, as set forth in interim final form, promulgated herein. EPA retained a consulting firm to study the data in order to determine whether conditions in the Mahoning River Valley region warrant the establishment of region-specific effluent limitations. The primary purpose of the study was to assess the likelihood that major economic dislocations would result in the region from plant closings if region- specific factors were not considered in establishing effluent limitations guidelines for facilities located therein. In order to make this assessment, it was necessary to determine whether: (1) the return on investment from continued operation of these plants was sufficient to allow the firms to make the sizeable investments required for pollution controls, and, (2) the firms would be able to raise sufficient capital to provide pollution control equipment for these plants in the context of the total capital requirements of the firms. On August 1, 1974, EPA requested that companies operating facilities in the region submit, by September 15, 1974, data concerning estimates of investment and annual costs for pollution control equipment required for non- region specific effluent limitations, analyses of the effects of such costs upon profitability, and rationale for concluding whether the necessary capital could be invested. In order to facilitate the submission of the data, which was not accomplished by the September 15, 1974 deadline, EPA delivered a questionnaire to the companies in October, 1974. The information solicited therein concerned plant physical and operating characteristics, financial management systems and policies, historical operating and financial data, pollution abatement cost analyses, and methodologies and assumptions for ROI (Return on Investment) projections. The gathering and evaluation of the data required conferences attended by EPA and its consultants and the companies, visits by EPA and its consultants to the corporate offices of the companies, and inspections by EPA and its consultants of the companies' steelmaking facilities in the Mahoning River Valley. Tentative analysis of the available data leads to the conclusion that conditions in the Mahoning River Valley 658 ------- region are unique with respect to the physical and geographical characteristics of the facilities located therein, and the importance of the facilities to the economy of the region. Tentative analysis of the available data and the consultant's evaluation thereof appears to support that mandatory compliance with effluent limitations guidelines which do not take into account these factors is likely to result in severe economic dislocation within the Mahoning River Valley region. The discussion of categorization within the industry contained in (i) supra, indicates that EPA has concluded that subcategorizaticn of the industry is inappropriate on the basis of size, per se, age, per se, or land availability (location) , per se. The type of manufacturing process employed was deemed to be the appropriate determinant of subcategorization. Data submitted by the companies operating in the Mahoning Valley region reveal a unique combination of economically disadvantageous size, age and land availability (location) factors which appear to warrant consideration pursuant to section 304 (b) (1) (B) of the Federal Water Pollution Control Act, as amended, in determining the best practicable control technologies available to facilities in the region. The plants in the Mahoning River Valley region include some of the oldest steelmaking facilities still in use in the United States. The first steel plants in the region were installed near the turn of the century. Four blast furnaces and fourteen open hearth furnaces at one facility are in the range of 60-75 years in age. In another facility, the newest finishing mill is 40 years old with the balance of finishing equipment more than 50 years old. Several antiquated units have been closed over the past several years. In addition to similar economic disadvantages resulting from age and size characteristics, facilities in the region appear to share economic disadvantages caused by locational characteristics. These include the movement of markets away from the region, constrained access to raw materials due to the unavailability of waterborne transportation and required transhipment by rail, and space limitations which prohibit major expansion of existing facilities. All eight steel plants operated by the companies submitting data are built on land surrounded by either the river, main highways or residential or industrial buildings. As a result of this combination of age, size and land availability (location) factors common to plants in the 659 ------- region, these facilities appear to be economically marginal before the addition of pollution control costs. Tentative analysis of available data and the consultant's evaluation thereof indicates that the imposition of pollution control costs is likely to substantially degrade the already marginal profitability of these plants. Tentative analysis of cash flows developed from company data submissions, calculated on a "stand-alone" basis for average case and best case conditions appear to substantiate this conclusion. The cash .flows for all evaluated facilities are expected to be negative on a stand alone basis under average conditions. On this basis, the Mahoning Valley operations of one of the companies submitting data is expected to realize a positive cash flow only under infrequently occurring conditions of maximum demand, while the operations of the two remaining companies are expected to have negative cash flows even under the best conditions. The likelihood of a plant closing in a particular community as a result of the unwillingness or inability of its owners to invest the sums necessary to meet effluent limitations does not justify the relaxation of those limitations. On the contrary, the legislative history of the Act indicates Congressional awareness that plant closings may result. Similarly, the combination of disadvantageous age, size, and land availability (location) factors which apparently results in the marginal economic status of the Mahoning Valley plants does not, in itself, require the relaxation of standards which would otherwise be applicable. What does justify a relaxation of otherwise applicable standards is the requirement in section 304(b) (1) (B) of the Act that the assessment of best practicable control technology currently available shall include, inter alia, consideration of the total cost of application of technology to the effluent reduction benefits to be achieved from such application. The total cost of application of technology includes external costs such as potential unemployment, dislocation, and rural area economic development sustained by the community, area, or region. It is this consideration of external costs in relation to the effluent reduction benefits to be achieved which established the propriety of exempting point sources located within the Mahoning Valley from required compliance with the nationwide effluent limitations based on BPCTCA. As discussed previously, the imposition of non-region specific effluent limitations to facilities in the Mahoning Valley which share region-specific economic disadvantages appears likely to lead to plant closing, the effect of which would be heavy unemployment and severe economic dislocation in this multi- community region. 660 ------- Steel production is the largest single factor in the economy of the Mahoning River Valley, a region with a population of approximately 550 thousand. In terms of jobs and payroll, the steel industry employs more people, approximately 15% and provides more wages, approximately 20%, than any other industry in the region. Of more significance than the percentages of employment and payroll, however, is the absolute magnitude of the employment and payroll statistics. Steel industry operations in the two- county region account for 27,000 jobs and a taxable payroll of $80 million. In addition, according to a study conducted for a local economic development Agency in 1972, the industry, in addition to its own payroll, purchased $90 million in goods and services from the local economy, supporting an additional 3300 jobs with a total payroll of about $31 million, and generated between 19% and 27% of the region's 201,500 non-farm jobs and a similar proportion of the $142 million in total tax revenues of local jurisdications. The relief granted from severe economic impact in the Mahoning River Valley region, which impact is likely to occur absent such relief, is the exemption of point sources located within that region from the effluent limitations based on best practicable control technology currently available. Nevertheless, the Agency fully expects that authorities granting permits, pursuant to section 402 of the Federal Water Pollution Control Act, as amended, shall not allow point sources in that region to discharge pollutants in any greater amounts than are currently being discharged by those sources. As to reguirements which will be applicable in the future, EPA is proposing limitations which establish the degree of effluent reduction accomplished by BAT, under section 301(b)(2) of the Act. The proposed BAT limitations for plants in the Mahoning Valley are identical to those reguired to be met by the balance of the industry. Section 301(c) authorizes modifications to be made in these limitations under certain circumstances, based in part on economic conditions applicable to individual owners and operators. Modifications under 301(c) may not, of course, reduce the level of treatment below that required by BPT or applicable state water quality standards. Since the Agency is not establishing BPT limits for the Mahoning Valley plants, a special provision is proposed which will confine any such 301(c) modifications for Mahoning Valley plants to 661 ------- levels comparable to a region-specific BPT installed at an economically feasible pace. 662 ------- SECTION X EFFLUENT QUALITY ATTAINABLE THROUGH THE APPLICATION OF THE BEST AVAILABLE TECHNOLOGY ECONOMICALLY ACHIEVABLE EFFLUENT LIMITATIONS GUIDELINES The effluent limitations which must be achieved by July 1, 1983 are to specify the degree of effluent reduction attainable through the application of the best available technology economically achievable. Best available technology is not based upon an average of the best performance within an industrial category, but is to be determined by identifying the very best control and treatment technology employed by a specific point source within the industrial category or subcategory, or where it is readily transferable from one industry to another, such technology may be identified as BATEA technology. With the exception of the Hot Coating - Galvanizing and Terne subcategories and the absorber vent scrubber on the hydrochloric acid subcategory, there are plants in all other categories who are presently achieving the BATEA effluent limitation guidelines for carbon steel plants. This in itself justifies the fact that technology is available and demonstrates that the limitations can be achieved on a day by day basis. Consideration must also be given to: 1. The size and age of equipment and facilities involved. 2. The processes employed. 3. Non-water quality environmental impact (including energy requirements). 4. The engineering aspects of the application of various types of control techniques. 5. Process changes. 6. The cost of achieving the effluent reduction resulting from application of BATEA technology. Best available technology assess the availability in all cases of in-process changes or controls which can be applied to reduce waste loads, as well as additional treatment 663 ------- techniques which can be applied at the end of a production process. Those plant processes and control technologies which at the pilot plant, semi-works, or other level, have demonstrated both technological performance and economic viability at a level sufficient to reasonably justify investing in such facilities may be considered in assessing best available technology. Best available technology is the highest degree of control technology that has been achieved or has been demonstrated to be capable of being designed for plant scale operation up to and including "no discharge" of pollutants. Although economic factors are considered in the development, the cost for this level of control is intended to be the top-of-the- line current technology subject to limitations imposed by economic and engineering feasibility. However, this level may be characterized by some technical risk with respect to performance and with respect to certainty of costs. Therefore, the BATEA limitations may necessitate some industrially sponsored development work prior to its application. IDENTIFICATION OF THE BEST AVAILABLE TECHNOLOGY ECONOMICALLY ACHIEVABLE - BATEA Based on the information contained in Sections III through VIII of this report, a determination has been made that the quality of effluent- attainable through the application of the Best Available Technology Economically Achievable is as listed in Tables 174 through 196. These tables set forth the ELGs for the following process subcategories of the steel industry. 3. Basic Oxygen Furnace (Wet Air Pollution Control Methods) - BPCTCA plus treatment of blowdown by lime precipitation of fluorides, followed by sedimentation and neutralization. K. Vacuum Degassing - BPCTCA plus additional lime treatment, clarification and filtration, and biological flenitrif ication, if necessary. L. Continuous Casting and Pressure Slab Molding - BPCTCA plus pressure filtration of the blowdown. M. Hot Forming-Primary - BPCTCA plus recycle of clarifier effluent to the sprays, discharge of 25 gpt (40 gpt for alloy) . 664 ------- N. Hot Forming-Section - BPCTCA plus total recycle of clarifier effluent through cooling tower to the sprays, resulting in zero discharge to navigable waters. O. Hot Forming-Flat-Plate - BPCTCA plus discharge of 150 gpt (350 gpt for alloy) and remainder recycled after cooling tower. Hot Strip and sheet - total recycle of clarifier effluent through cooling tower to the sprays, resulting in zero discharge to navigable waters. P. Pipe and Tubes - for integrated mills; total recycle of clarifier effluent through cooling tower resulting in zero discharge to navigable waters. For isolated mills; total recycle of clarifier effluent through ponds resulting in zero discharge to navigable waters. Q. Pickling-Sulfuric Acid-Batch and Continuous - Batch and Continuous Concentrates: identical to that for best practicable control technology currently available. Batch and Continuous Rinses: for those facilities practicing neutralization as of December 1, 1975; countercurrent rinses and cascade use in fume hoods to achieve 25 gpt of fume hood scrubber and rinse discharges. For those facilities without neutralization as of December 1, 1975 - countercurrent rinsing to achieve zero discharge to navigable waters. R. Pickling-Hydrochloric Acid-Batch and Continuous - For batch concentrates: aeration, followed by a settling lagoon with 2 to 5 day retention. For batch rinses: countercurrent rinsing, aeration and mixing followed by 2 to 5 day settling. For batch fume hood scrubbers: aeration and mixing followed by 2 to 5 day settling. For continuous concentrates: settling for 2 to 5 days. For continuous operations with absorber vent scrubbers: recycle to the acid absorber vent scrubber, reuse, and a settling lagoon with 2 to 5 day retention. 665 ------- For continuous rinses: countercurrent rinsing, aeration and mixing followed by 2 to 5 day settling. For continuous operations with a fume hood scrubber: aeration and mixing followed by 2 to 5 day settling. S. Cold Rolling-Recirculation, Combination, Direct Application - identical to that for best practicable control technology currently available. T. Hot Coat Galvanizing - Rinses: countercurrent rinses, neutralization by chemical addition, settling lagoon with 2 to 5 day retention. Fume Hood Scrubber: recycle, settling lagoon with 2 to 5 day retention. U. Hot Coat-Terne - Rinses: countercurrent rinses, neutralization by chemical addition, settling lagoon with 2- 5 day retention. Fume Hood Scrubber: recycle, neutralization by chemical addition, settling lagoon with 2 to 5 day retention. V. Miscellaneous Runoffs - Stock Piles - parameter collection, egualization, neutralization by chemical addition, chemical treatment and flocculation, polymer addition, settling lagoon with 2 to 5 day retention. Casting and Slagging - water conservation to prevent runoff resulting in zero discharge to navigable waters. W. Combination Acid-Batch and continous - identical to that for best practicable control technology currently available. X. Scale Removal - Kolene and Hydride - identical to that for best practicable control technology currently available. Y. Wire Pickling and Coating - identical to that for best practicable control technology currently available. Z. Alkaline Cleaning - identical to that for best practicable control technology currently available. In establishing the subject guidelines, it should be noted that the resulting limitations or standards are applicable to aqueous waste discharges only, exclusive of noncontact cooling waters. In the section of this report which discusses control and treatment technology for the iron and steelmaking industry as a whole, a qualitative reference has 666 ------- been given regarding "the environmental impact other than water" for the subcategories investigated. The effluent guidelines established herein take into account only those aqueous constituents considered to be major pollutants in each of the subcategories investigated. In general, the critical parameters were selected for each subcategory on the basis of those waste constituents known to be generated in the specific manufacturing process and also known to be present in sufficient quantities to be inimical to the environment. Certain general parameters such as suspended solids naturally include the oxides of iron and silica. However, these latter specific constituents were not included as critical parameters, since adequate removal of the general parameters (suspended solids) in turn provides for adequate removal of the more specific parameters indicated. This does not hold true when certain of the parameters are in the dissolved state; however, in the case of iron oxides generated in the iron and steelmaking processes, they are for the most part insoluble in the relatively neutral effluents in which they are contained. The absence of apparently less important parameters from the guidelines in no way endorses unrestricted discharge of the same. The recommended BATEA effluent limitations guidelines resulting from this study are summarized in Tables 174 to 196. These tables also list the control and treatment technology applicable or normally utilized to reach the constituent levels indicated. Figures 151 to 176 present the BATEA treatment models. These effluent limitations set herein are not necessarily the absolute lowest values attainable (except where no discharge of process wastewater pollutants to navigable waters is recommended) by the indicated technology, but rather they represent values which can be readily controlled around on a day by day basis. It should be noted that these effluent limitations represent values not to be exceeded by any 30 continuous day average. The maximum daily effluent loads per unit of production should not exceed these values by more than a factor of three as discussed in Section IX. RATIONALE FOR THE SELECTION OF BAT FA The following paragraphs summarize the factors that were considered in selecting the categorization, water use rates, level of treatment technology, effluent concentrations attainable by the technology, and hence the establishment of the effluent limitations for BATEA. 667 ------- to -d o X! 4J O CO wo EH EH 10 O W EH CO CTl CM O CO o r S TT~ H 1-1 I EH CO 1 M W 0 H D O ca ? o H §«, < EH S H ^ E"* D &4 &4 H \| ^4 W EH rt CQ ^^ , j o ft § s 0 g u a « 1 •2 " ^j .3 !S rH H 0 S •rl -P CU Is nace ( Vl 3 d 0) X o o •rl (0 td CQ s § EH (4 1— 1 § EH I •d d id co •$ •rl 4J d i treat d ? o -d rH ffl CQ 55 0 H EH £]£ EH M S H !H rH- OS O « O W W EH EH "• ft, (o fj n D CO ^~ M ^•^ •-I I in «,HI -^ « ^ ao & o X 0 CP^^ $4 03 04 in o o • o Cn d •H rH 4J (U 10 •d cu o a B d •rl O •rl Vl 4J O rt rH d 3 O C7> •rl 10 4J O id u M rHS •H -H MH > Oi4J CU B •rl rH tr d •H co 3 d \| treat d s 0 Blowd (N (N ^* O O • O CO 0 T3 •H Vl O rH id -p > CO CT* M-I d 0-rl rH Cr> O r4 0 X O ca •d •r) I-I o ca •d 0) 0) cu (0 3 W CU •d •rl VI o 3 ra r 668 . d> M-l Vl T3 a. d> CO •d t-H JQ •rl • CO .-» 10 • d o •d o 04 d) 4J 3 rH rH 'd id id o tr* V) 4J 0,0 o m d) rH-^r4. d) MH eg -d cu 4J d) Vl to o 3 -P M-l TJ -rl O O Vl to 10 Q4 d) O i -d •d d 3 d) d) M O d) CO O O M-l O O > rH -rl tr> to Vl M 3 d -P id to rH -rl X M-l Q) O CO >1 d) -P > •rl -rl rH 4J •rl Id d Vl rH d) •H 4J (d rH > id id d.S O 4J IIS -s 0) id •r4 id d 4-> B id to vi 4J W O w d • cocj CO Vl EH tu id 0 O (X •rl X! « > o 0) -rl X! 'd xi -P IS -H 4J > d co Q) U) tP 6-ri d 4J -P -rl Id-rl >1 0) rH rH Vl-rl 04 ^5" •d MH o d id 0) U O Vl id 6 o o o o rH cu CO Vl id o> w S Vl o -d •s to d) 4j-d (d (U T3 U M •rl -rl -d •d 3 cu d O1"-! •rl d) rH VI 1j d) 4J X! to co •d 0) rd O 4-1 -p id u 0) 0) O tn CO -H -P O _ . . Q) 0) TJ CU O 6 X! CD O 4-> 0) 4-> O 10 VI -rl d «S 3 OiH Q) CO >i -P >-! Ol d) O C O rH 0) (N M-l O d) O rH U n) id -P to c! -H O «3 o tr> d x; -H U T) C T) 0) o -a a) o c 4J _.. (U -P ., Q) CWW4JD4-P o i B •rl O D' Vl vi -p o CD 4-> -rl r-l O, ,. 0) rH O W 6 v, £ o > Vl (L) O vi-d d) •d vi d) O •rl -rl 3 -d O1 >l d Q) rH (O vi c: o -P c: d> id O M rH •H n) Oi 4^ id d id O S •r) O d -P o co -H O rtJ g 4J S i CU CO to w 6 - . . _ E H) r-i 4J IB VI ,o m , vi en m C > O id E -P >t O tr> nod •rl 10 CU d rH 4J O rH -rl .0 -P XI -rl «) M rH r-l 10 b Wl E -P -H O O -rl O X 4J rH 4J d) ------- r r CO 669 ------- Figure 151-2 MODEL COST EFFECTIVENESS DIAGRAM BASIC OXYGEN FURNACE (WET AIR POLLUTION CONTROL METHODS) SUBCATEGORY "ANNUAL COSTS = BASED ON TEN YEAR CAPITAL RECOVERY + INTEREST RATE 7% + OPERATING COSTS INCLUDE LABOR, CHEMICALS & UTILITIES •• MAINTENANCE COSTS BASED ON 3.5% OF CAPITAL COSTS THIS GRAPH CANNOT BE USED FOR INTERMEDIATE VALUES C05T BASED ON 2847 KKG/DAY {2808 TON/DAY) BOF SHOP 473,830 429,059 376,878 318,189 244,094 D (BATEA) C (BPCTCA) B (BASE LEVEL) PERCENT REMOVED 670 ------- Size and Age of Facilities and Land Availabili ty Considerations As discussed in Section IV, the age and size of steel industry facilities has little direct bearing on the quantity or quality of wastewater generated. Thus, the ELG for a given sutcategory of waste source applies equally to all plants regardless of size or age. Land availability for installation of add-on treatment facilities can influence the type of technology utilized to meet the ELGs. This is one of the considerations which can account for a wide range in the costs that might be incurred. Cons ider at ion of Processes Employed All plants in a given subcategory use the same or similar production methods, giving similar discharges. There is no evidence that operation of any current process or subprocess will substantially affect capabilities to implement the best available control technology economically achievable. At such time that new processes appear imminent for broad application, the ELGs should be amended to cover these new sources. The treatment technologies to achieve BATEA assess the availability of in-process controls as well as control or additional treatment techniques employed at the end of a production process. Consideration of Non-Water Quality Environmental Impact Impact of Limitations on Air Quality. The impact of BATEA limitations upon the non-water elements of the environment has been considered. The increased use of recycle systems have the potential for increasing the loss of volatiles to the atmosphere. Recycle systems are so effective in reducing wastewater volumes, and hence waste loads to and from treatment systems, and in reducing the size and cost of treatment systems that a trade-off must be accepted. Recycle systems requiring the use of cooling towers have contributed significantly to reductions of effluent loads while contributing only minimally to air pollution problems. Careful operation of such a system can avoid or minimize air pollution problems. The handling and storage of spent nitric-hydrofluoric pickling solutions must be done with care to avoid fumes of nitrogen oxides. One plant uses floating plastic balls on the surface of open tanks to avoid this problem. Impact of Limitations on Solid Waste Problems. Consideration has also been given to the solid waste aspects of water pollution controls. The processes for treating the 671 ------- in C/l H a H § CO o H g EH H H M D D> C •rl W (0 id 0) P 3 O id at O w a § S (O « a I ^ ^•^ £j» 1 2 °1 ~O W X.I w o J EH CJ EH EH W O trt W EH «\| XI ^ r — • <> ^^ >< § o !3 g M £" M 53 M 23 1 £-1 tS ^ 8 EH q o a! •H-M IS cd o 4J-H e ^"1 0) r^ 6 w 4J CO BJ--H 0)^0 4J g O C4J § "i^ o 2t «8 — — H W V O B H EH x~-_^ \ in in • rsi in in o EH H H !_} ^^ In o « X 0 \°i x ra CN N in vo m m o CM O O O oooo oooo oooo vo 5 . o CN (Tt ^ O ^v •r ^^ — 0 C ._i n •ri \j XJ-H O -P Vl j3 Cp (U -P C (d -H -rl EJ -P 4J Id W Q) XI AJ X! 3 C 4-) 01 Id •rl rH S H X>^ O C 4J «^ Vl (U C O tn (U ^ MH O e c vi 4J O W 4J C Id -rl Id -rl 0 a) 4J cn a -ri M Id 4J 4-> U Vi MH id •rl (!) O N fi MH x! -rl B-rH 4J -d H M o id id t3 -P fi (D Vl 5 -rl (d -P 4J O C W 3 •H i id w o< ^^ 4-> m M X! owe MH (d -rl tPrH a) 4J (U O <1) 4-> "J rH W -P XI C (d MH O X) O U O 1 V) tr> C ft ^ O 4J U1 VI rH O CJ rH a o, id (Q 13 •rl j f"1 O CO CRITICAL PARAMETERS Suspended o G •H N Manganese Lead ^^ ro O ^* '0 Nitrate (a CP-P 0 a 0) rd M -rl t) 3 4J o 4J O W 0 CT tn C -H C O Ul -rl MH T3 C T3 c -a 0 o c 0) 4J -rH (1) C M tn 4J O fd -H (d 0) 4J XI rH 4J t> O Vi >i g „, •rl o Cr< Vi 2 M .o o a) G 4J -r\| rH ft 0 o M o g c Vi .C M CJ U tr O W g 0) -rl > E IT rH 4 > Id :J In X! fd E >-i tr> id e CP-H rH -rl W '5-§ tr« o O 4J d 4-> O W • id H 4J 3: o w M >i o en 4J Vl U C •rl 4-> id w -P -H 0) -rl > O O < u u c: •H g 4-l-H •H O X rH 4-) Q) 03 ft 672 ------- f i 673'* ------- FIGURE 152-2 MODEL COST EFFECTIVENESS DIAGRAM VACUUM DEGASSING SUBCATEGORY * ANNUAL COST = BASED ON TEN YEAR CAPITAL RECOVERY •f INTEREST RATE 7% + OPERATING COSTS INCLUDE LABOR, CHEMICALS & UTILITIES + MAINTENANCE COSTS BASED ON 3.5% OF CAPITAL COSTS THIS GRAPH CANNOT BE USED FOR INTERMEDIATE VALUES COST BASED ON 472 KKG/DAY (520 TON/DAY) VACUUM DEGASSING OPERATION SUSPENDED SOLIDS C (BATEA) B (BPCTCA) (BASE LEVEL) 100 PERCENT REMOVED 674 ------- wastewaters from this industry produce considerable volumes of sludges. Much of this material is inert iron oxide which can be reused profitably in melting operations. Other sludges not suitable for reuse must be disposed of to landfills, since most of them are chemical precipitates which could be little reduced by incineration. Being precipitates they are by nature relatively insoluble and nonhazardous substances requiring minimal custodial care. Impact of Limitations Due to Hazardous Materials. In order to ensure long-term protection of the environment from harmful constituents, special consideration of disposal sites should be made. All landfill sites should be selected so as to prevent horizontal and vertical migration of these contaminants to ground or surface waters. In cases where geologic conditions may not reasonably ensure this, adequate mechanical precautions (e.g., impervious liners) should be taken to ensure long-term protection to the environment. A program of routine periodic sampling and analysis of leachates is advisable. Where appropriate, the location of solid hazardous materials disposal sites should be permanently recorded in the appropriate office of legal jurisdiction. Impact of Limitations on Energy Requirements. The effect of water pollution control measures on energy requirements has also been determined. The additional energy required in the form of electric power to achieve the effluent limitations proposed for BPCTCA and BATEA amounts to less than 2% of the electrical energy used by the carbon steel industry in 1972. Limitations proposed for BPCTCA and BATEA amount to less than 1.5 to 3.7 percent of the power required for alloy production. The enhancement to water quality management provided by these effluent limitations substantially outweighs the impact on air, solid waste, and energy requirements. Consideration of the Engineering Aspects of the Application of Various Types of Control Techniques The BATEA level of technology is considered to be the best available and economically achievable in that the concepts are proven and available for implementation, and may be readily applied through adaptation or as add-ons to proposed BPCTCA treatment facilities. Basic Oxygen Furnace Operation 675 ------- vo H (0 2 H 3 GUIDE J» o H Ic i M EH D h) b U \| W EH (U CO to OJ a. oS en c • l__ to 0 nuous H-> C o 0 g H EH S EH DJ EH i-? § EH 2 8 r £5 B 1 rH A UH •• O m 3 C rH O ft -H -P < ^ >1 n ^ fi 4J 0 X! -P •P id en O«n 4H 0) rH m «.^ 3 rH 4J id co ^ id • o 4) rH rH X) CU id a) XI -P o w o 17 w tn-P o t id S X * W CO O D4 O rH •P id rH 4J id U en 0) O I rH CO 111 t t rn ft CO w »w id ' rH O 6 i Id -rt O 4J -P •H fi W e co w o CO-H JC 'd rfi -P 04 0) 0) d) -P to •P -P -rl to id w o co o rH-d a> 0) rl -p o ra fi o o o en w x 3 "X rH O vi e 0) -rl ex W •o C •P H to c id -d 0) O 3 >i.C rH rH 4J CO w ri e cu id W -P to w fi H (U O cu 0 e co rH -H 4J 5 X fi W «M CO CO CO Cn O 6-rl fi 01 JJ 4J -rl >1 0) Id -rl >< •P > tU rH rH •rl -H rl -H Q4 rH 4J -P O 6 •H n} n3 O _o ci rt M-i O m fc c rH CO •H -P Id rH rH > id o tn-P - c c fi -rl O O -P O •rl CD •P ftrd id 6 fl) O M •d w to id •H C id tu •P M CM O -P CM C w o C -H O W T3 C 'O CO O CO -P -H 10 W -P (d ri id XI rH 4J 3 tt) Cn M -POO) •H H a rH O C rl M .C O O U GI a) to -P C (/) 0 3 CO -rl ffl rH 4J CO H VH id •p W 10 -p fi W -rl o O fi CO 0) fl> to 3 n i Cn o rt o -p O rH o -a en c co c i! w •rH U -rl t: -P o1 >i c CO CJ rH id Oi-P M fi CO C! O "d 'd o to fi R f! CO id -P O M rH ,jj aj -H id ft r: CO -P X M id fi id m P O f. u o Ou U) p id M C71 Id m-H rH >, - W M "d -rl m c ro > -P W rH Id -rl > O S < U o w fi -p >-i o w g. -'-J i-l U (d tO CD C rH -P ^ -rH G -P -H O O -H O X CJ -P rH -P CO ft CM 676 ------- Hjv 677* ------- FIGURE 153-2 MODEL COST EFFECTIVENESS DIAGRAM CONTINUOUS CASTING AND PRESSURE SLAB MOLDING ANNUAL COSTS = BASED ON TEN YEAR CAPITAL RECOVERY •f INTEREST RATE 7% •f OPERATING COSTS INCLUDE LABOR, CHEMICAL & UTILITIES + MAINTENANCE COSTS BASED ON 3.5% OF CAPITAL COSTS THIS GR^-PH CANNOT BE USED FOR INTERMEDIATE VALUES COSTS BASED ON 544KKG/DAY (6CO TON/DAY) CONTINUOUS CASTING OPERATION B (BATEA) A (BPCTCA) 60 Percent Removed 80 100 678 ------- The only direct contact process water used in the EOF plant is the water used for cooling and scrubbing the off-gases from the furnaces. One method used is the wet gas cleaning system which uses a venturi scrubber and a gas quencher- The use of wet air pollution controls is rare in the alloy and stainless steel industry. The water use at one plant producing alloy steel in a EOF was 870 gals/ton. The water was used once-through and the only treatment provided was clarification where the BOF waste-water was combined with blast furnace gaswasher water. The technology identified as used in the alloy and stainless steel industry was judged to be inadequate. The water use rate lies within the range found in the carbon steel industry plant surveys (542-4250 1/kkg) and there is no reason to believe that the technology in use there is not directly transferable, since the characteristics of the waste waters and the nature of the processes are similar. The BATEA limitations have thus been'established on the basis of an effluent suspended solids concentration of 25 mg/1 at an effluent volume of 208 1/kkg (50 gals/ton). The blowdown rate of 5.9 percent is being achieved in at least one carbon steel plant and at least two such plants are achieving this effluent concentration of suspended solids. The pH of the scrubber water effluent from the alloy steel BOF averaged 7.4, so that no difficulty with a pH 6-9 limitation is foreseen. The BATEA limitations for carbon steel operations also specify a limit for fluoride based upon an effluent concentration of 20 mg/1 attainable by lime precipitation and sedimentation. The alloy steel BOF surveyed indicated fluoride present in the raw waste at a concentration at 10 mg/1 vs. 14 mg/1 found in the carbon steel survey. Similar treatment to reduce the expectedly high concentrations in the blowdown are thus similarly attainable in alloy steel operations. Vacuum Degassing Subcategory The direct contast process water used in vacuum degassing is the cooling water used for the steam-jet barometric condensers. Although most systems use steam ejectors to draw the vacuum, dry mechanical pumps are also used. The vacuum degassing systems surveyed used water once-through with little effective treatment, completely recirculated the water with no discharge, or used mechanical pumps. It was judged to be unduly restrictive to impose a zero effluent discharge limitation for BATEA, because all plants may not be able to completely recirculate the water or convert to mechanical pumps. The water use rate determined 679 ------- Q H gg sa i- ti a. 5 g , 3e b< O S3 •H JJ BI "1 !£ co VO CO § s O iH O O id h § JJ JJ .. i 01 M h 3 O H 01 Id O VI 0] C 0} X) (0 9 XI ij u-i JJ 4) ft O JJ •n jj -H 0) ITJ e e g i c o 5 -H um o O En h 0) e s -H •H jj IM id 01 Tl C rt 3 01 -H -C 11^ •H H -H V4 JJ 0 rt 01 C H-l O JJ O n PH O * rt 4J E"«w ft -H lHO (J C J-l A O Q1S ^ CD UJ E ft k4 M ft U O OI-HOX T) 3 01 T3 ep"ac DO)coio JJ L ft 01 JJ uj n o S en o> S5 U 0 £8 v jj g 8 rt C 14-1 O U U •§ MJ e o t-4 ID rt u id 01 X no >1 -p o to Sif O H &JS CD U M£ JJ 10 CP M •H 0 JJ i JJ O * 4J V ft 01 -O 0 -H JJ 111 X) » S-H H 3 • JJ O* 01 O id « rt U JJ •giV^ D> C M CO >, 0) ; e rt id ' -H C .JJ 01S i rt 0) i-t •§ id O O -H JJ n c 01 01 0) "x B 01 O 01 ?:i id co jj h JJ jj \ 01 t) •H >O C i M O C 01 •H m rH 0 C § -H JJ a \| 01 CO n o u 01 01 > -H JJ a c 1-1 01 JJ rt Id » c -H § -H n H n 01 o rt > 0> •a jj c id rt ft id e •H a jj c 833 O 18 01 01 C JJ O 01 O U 01 ft 0) JJ H o rt c id 10 S 8x! rt Id to •o •H i "S -S e S, B 3 to 01 i o •o c id rt •H O - d)rt~ g rH • ra i-i i w to o o I O -O rt -01 rt K g ft 01 Q^JJrtJJ Id 01-H-H1 0,01 C > JJ rt M >, S V -H llOJJOJJCOCjJcO IdUrtiHldeg 1-1 Cn-H-HC M 01 5 ft HI rtrtOO 01 CD o O SJJ 10 H I O >> O I JJ rt tu en i O O -H I U ft 680 ------- 681* ------- 453^67 FIGURE 154-2. MODEL COST EFFECTIVENESS HOT FORMING)- PRIMARY 5UBCATEG\|ORY ANNUAL COST- BASED ON TEN YEAR CAPITAL RECOVERY + INTEREST RATE. 7 % + OPe.WATIN(a COSTS INCLUDE LABOR, CHEMICALS 4 UTILITIES •(•OPERATING) AND MAINTENANCE. COSTS BASED OKI 3.9% OF CAPITAL COSTS COST BASED OM 3 ------- Figure 154-A Hot Forming - Primary - Specialty Annual Cost = Based on Ten Year Capital Recovery + Interest Rate 7% + Operating Costs Include Labor, Chemicals & Utilities + Operating & Maintenance Costs based on 3.5% of Capital Costs Cost based on 2,144 kkg/day (2,364 tons/day) of steel rolled. This graph cannot be used for intermediate values. SIB 62 3\,->&3 E faTc.TC.4j teo 683 ------- •f JrH 3 S S (N 00 M g H J § §g tO H 5 IT .-.5 §§&& H fH 0 rl IMJUOO. 5!!;0 »SoW O in M S, JJ I i-H IM IM W IM O S a •H • M M oS 3* i! ^ « 4J t-( O u JJ ?. u a «i •H 0) T3 >1 •5 -H M O O, oi u n So P jj 0 6 to o A £ o a jj ea u g co Q. b 684 ------- 685 ------- F/GUGE ISS-'L MODEL COST SFFECT/VEKESS O/AG&AM HOT FQGMING- SECT/O/V SUBCATSGO/2Y ANNUAL COSTS = BASED ON JEN VEA& CAP/TAL •+/NTE/ZEST /S.ATS 7% / OP£i2A7(N<5 COSTS /NCLUDE LAQO&, CHEMICALS 4L/T/LITK +OPEKAT/UG AMD MAINTENANCE COSTS BASED ON 3.5% O^ CAP/TAL COSTS COSTS BASED ON/l/79KKG/DAY0300TO^JS/DAY)of:-STEEL HOLt-ED THIS GRAPH CANNOT BE USED POR IMTEKMED/ATE VALUES 774,039 673,010 50,741 36,539 CBATEA^ IOO 686 ------- Figure 155-A Hot Forming - Section - Specialty Annual Cost = Based on Ten Year Capital Recovery + Interest Rate 7% + Operating Costs Include Labor, Chemicals & Utilities + Operating & Maintenance Costs based on 3.5% of Capital Costs Cost based on 327 kkg/day (360 tons/day) of steel rolled. This graph cannot be used for intermediate values. too 687 ------- CO M U gs H «l £5 & O w H 5 II 3 5 ' 1 ^fj 3 ' &4 O 6 H 1 § < s Ig E -~ O n jj jj •— to x. o> o JJ B i-l E a •H JJ JJ O Oi a* * «• rH rH 0 «J JJ E A 01 &H S g rt "si co e B O •H 3 •H rt 0* O "! 01 III H -H U UH JJ oi 10 H O H JJ JJ - iH S 0) -H O O M-I O M CV 0> 3 TJ rl CO C co g >i U •o a ° 01 TJ C g S° rH JJ rH E 10 O O M IH -rl JJ JJ rH •H O UH a-ri MH g 01 -rl 9 H M 3 10 O O rH IB CO O > .B CO 0) n o c a. jj a ischarge of ewater Poll' Q JJ CO 22 ^^ f) in TT in o d d ••i! CO G\ CO O^ O O s a, CO o B rH 14 IH S 0) O 0) CT, •H E 14 O "« 0 > system system in S jj £ « H fl en -H 1 B skimming by natur CO -0 9 JJ 8S •H rH » f-H a 01 CO rH 0) 10 5 g UH g H a 0> -H 01 •H n clarif •H 10 •H n 13 S § O H co oi JJ •H UH rH JJ B rs B CO •A • adsorp and/or jj o i a IH O M £ E UH UH Ol IH ~ 0 m u 01 jj •H O §01 •rl £ § .3 to1 rH >, US 01 M 4-J 0) ? r-4 So & S 2 £ •H JJ H £ O 3 H HI probable v, jj I M 01 JJ B £ C71 E •n jj o 3 • E \| rH 10 S1 •rl 2 o al/ton) ; ex< t^ o D) B JJ B JJ 3 E a M O CO B O •rl JJ B e combin 3 •H 10 CO a H H B JJ rH IU 01 CO 1 H g 0) 5 a 3 rH O B •rl rH rH B V, necessaril; jj g n •H .B . 0) tJ O JJ o) J5 B H B 0) -H H 3 "O JJ & 01 01 u O H -rl ° 0 S » JJ rH 0 10 B rH O JJ IH -H E UH 0) - -H e iH Q H <0 6 O OB nd chemi liminary e only ii B 01 H O Oi 1 0 I rH O O UH JJ CO 0 B o> co >1 JJ JJ jj x co •H 01 O rH 0 "B jj S > n (0 -H «O X 01 > 01 JJ 0 CO 1 •H 0) H JJ > JJ B iH O glo" •H B U • a o) co B JJ 01 H O CO ID -H rl > O CJi 01 JJ C 13 O -H B JJ JJ IH 01 E CL 0) £ E S §6 jj 0 B CO Ol gS J«? IS« s,§a TJ 0) O CO 0 •o o S 5 £ jj "s -rt Ou \| UH 0 JJ n 01 u 10 u B •0 0> rH rH B JJ CO •rl C 01 I u f 1 a B B •H 5 * g1 •rl JJ CO X 0) re normally B f •H 1 B nless steel •H B JJ n •2 n 3 H O CO B O 688 ------- 689 ------- FIGURE IS6-Z MODEL COST EFFECTIVENESS HOT FORM INS- FLAT- HOT STRIP AND SHEET SUBCATESORY ANMUAL COSTS * BASED ON TEN YEAR CAPITAL RECOVERY + INTEREST RATE 1% + OPERATING COSTS INCLUDE LABOR,CHEMICALS 4 UTILITIES + OPERATING AND MAINTENANCE COSTS BASED ON 3.s1> OF CAPITAL COSTS COST BASED ON 344-7 KKft/DAY (38OOTONS/DAY) OF STEEL ROLLED THIS GRAPH CANNOT BE USED FOR INTERMEDIATE VALUES 1,970, 103- 1,310,214- 789,817 440,169 • <3 (BATEAU IOO 690 ------- FIGURE 156-A MODEL COST EFFECTIVENESS DIAGRAM HOT FORMING - FLAT - HS & SHEET ANNUAL COSTS « BASED ON TEN YEAR CAPITAL RECOVERY + INTEREST RATE 7 % + OPERATING COSTS INCLUDE LABOR, CHEMICALS & UTILITIES + MAINTENANCE COSTS INCLUDE LABOR & MATERIALS COSTS BASED ON 1851 KKG/DAY (2041 TONS/DAY) PRODUCTION THIS GRAPH CANNOT BE USED FOR INTERMEDIATE VALUES 1,404,120 1,254,809 SUSPENDED SOLIDS 274,487 54,249 32,011 G (BATEA) E (BPCTCA) D B A (BASE LEVEL) 100 PERCENT REMOVED 691 ------- I X JJ gl . a •H JJ in S I rH rg .s. GU TE s Is a 5h S J " II JJ C s II IM JJ 01 iH rH IM £« >i IB U M o> a, h n is 2jj 9 . rH M and ion ol on pit ica O -H Ul 0 0,0 0) en _a.s iH iH rH JJ H O a a c rl rH 0 JJ U H id •H IM -H IH o > i§ § 55T6T Oi IJ «J C 3 -H •H JJ M 185 o ft c • •H id n •rt "O id A S rH X id a 18 rH JJ H •H » O O 18 JJ * X > » TJ Id -H T) C * & a - 01 JJ B a JJ o n 1 e •H 0) -rl 18 J > JJ -H 18 -rl 0 CU P JJ W O 18 18 rH C rl • C Sai n -H i gs 5 I O O d d •0 (0 9 o o d d w o j3 > u o D< 01 x m o JJ f •-! 18 i +10 o m S •H i! a 9 to 5 JJ JJ 16 0) B HI 01 U O IM o M U £ O O JJ 18 3 692 ------- 693 ------- FIQURE 157-2 MODEL COST EFFECTIVENESS DIAGRAM HOT FORMIWG,-FLAT-PLATE SUBCATEQORV ANNUAL COSTS-BASED ON TEN VEAR CAPITAL RECOVERV t INTEREST RATE 7% + OPE«TIM^ COSTS INCLUDES LAEK5R ,CWftM4CAA. t UTILITIES •t-OPERATING, AMD MAIMTCMAKJCE COSTS BASED OM 3.5?, OP CAPITAL COSTS COSTS BASED OM 1814 KKQ/DAV (3OOO TONS/DAV^ OP STEEL ROLLED THIS GRAPH CAM MOT BE USED FOR INTERMEDIATE VALUES (3 (BATEA') fo4,07O 47,573 B AfREFERENCE 2O too PERCENT REMOVED 694 ------- Figure 157-A Hot Forming - Flat - Plate - Specialty Annual Cost = Based on Ten Year Capital Recovery + Interest Rate 7% + Operating Costs Include Labor, Chemicals & Utilities + Operating & Maintenance Costs based on 3.5% of Capital Costs Cost based on 479 kkg/day (528 tons/day) of steel rolled. This graph cannot be used for intermediate values. C 6, 0 A fi 2.0 ted 695 ------- i w H U u < 2 rH EH M 00 < rH iH 1 H SO] i e P 3 § 1 S H 1 O, g S - § IN JJ JJ — m X 13 O 0) U a rH la i H * «. d g i-t U S jj S 01 U) rH 2 I S 1-1 X . i1 B 3 s ^ •rt 2 13 X O < CUM ja «^ to jj 01 10 18 Cu rH S •rt JJ •rt IH O r- « in rH r- •-( d o ro m in m n CO iH o o §u* 0 C fc a 4J -HO 3 q' s1" > S Id 0 rl « OJ E ° ? c s o 10 6 O 01 -rl -rt JJ •rt jj > JJ 01 10 CP Id rH r4 E 6 o o JJ S -H •rt >irH JJ rH UJ U rt tQ O •rt 01 UH >i 0 IJ rl tO O H •- rl >, 0 0 9 « 8 O to M — >1 rH tO Ql J3 o S ic 55 S Z to •rt 01 a to 9 01 rH cn a B rl IS S! M JJ tO >, B H A -rt -rt 0) «H 0 0) 0 B 9 9 -rt O B 0 rH •rt rH O C JJ rH 01 O BO -rt 8UH pl JJ B Qi 4J -rt H •O -rt rH 0 B Q! JJ 01 « JJ -0 oi oi a 10 rH 10 01 Id rl • rH O O O VJ UH n jj x 01 $ E^S Ja o -H * JJ O M ""' S e -rt oi E UH g Q, UH IH Q, rl -rt Id 01 -rt O rl -rt •O 9 to 10 -O E D* "0 rH 01 D 01 Id 0 E 10 i rH 3 03 3 9 JJ & •rt Ql UH 0 rS rl & n rl 01 JJ •rt rH • O 01 B JJ O to id jj SS o> 01 B •rt JJ rt rH 01 rH a >, g rl O 6 9 0) 01 rH JJ B O U tC tl JJ Qi 01 E IH O D £ 0 •rt JJ rH irt ki 10 11 Id rH > O X 01 01 rH "§ S U X Ql rH » "" O O > o S rH « l^l > E id S n 0 4i -H Cn •rt M 9 "0 E JJ JJ O 01 -rt Id 01 rl >i JJ O IH -rt rt 2 O B 01 O 01 JJ O H O §JJ rH MH a a o O rH O JJ UH -rt E JJ 10 UH 4) rH B »-rt g 9 o to •o oi to •rt rH Q rl 01 S S8 B* B ^>,^« jq oi n >i to 6 J3 E rH 10 O O -rt B 0 60-0 •O -rt 01 0) B rH 01 rH rH 10 0) rl rH a * ^W2 n B cm to id UH 5 B 8, H°jg- tu jj tfl C rH 0 E « rH 01 tO 01 10 >! JJ JJ J3 JJ x to JJ tH 01 O 01 U rH 5 > 0) -rt TJ Id rH i B rH J3 UH ana 01 rH JJ rl rl -H - 0 O 10 JJ JJ X jj > to JJ rH )H Id -rt tO Qi 1 "g .B ci to oj m -rt > 10 JJ 0) J5 •rt rH U JJ 10 10 « -rt -rt 9 rl > * i-H O O> 0) 0 JJ E -O Oi B D -rt E •rt Id JJ JJ -rt UH 01 E JJ rH Qi 0) 01 irt JC S E -rt 10 o p S x 50 id 0) "8 H 4) IH >• •rt B rl JJ rH M O 01 rH SJ3 TJ O » j c e 10 E 10 C 01 -rt "O O U -Q 41 rH C 01 E JJ O B 0) O rl 01 Q, 01 JJ M JJ 01 rH E 18 O 13 01 O % O to dr >i n rt •rt O O» S A • m o JJ * •O to ,rH Id 3 "8 i -rt 8 •rt JJ h U B JJ rH 01 Id 01 -rt -rt I > JJ rH iri 41 -rt a JJ >i JJ J3 u 6 E rd E JJ id rH 01 g 01 UH 0 6 I JJ B £> to JJ Q, 01 J3 10 JJ 10 0) 01 u oi to 01 u 6 0) rl O H O JS fH JJ O J-> 10 JJ rH ------- 697 ------- FIGURE I5S-2. MODEL COSTS EFFECTIVENESS DIAGRAM PIPE AND TUBES SUBCATE.QORY INTEGRATED PLANTS (THOSE WITH NO LAND AVAILABLE.) ANN UAL COSTS = BASED ON TEN YEAR CAPITAL RECOVERY + INTEREST RATE 7% •t-OPERATING. COSTS INCLUDE LABOR, CHEMICALS £ UTILITIES + OPERATING AND MAINTENANCE- COSTS B466D ON 3.5 7. OF CA^I TAl_ COSTS> COSTS BA5&O ON 3fe3 KKfi/DAY (400 TONS/DAY) PRODUCTION TWI5 GRAPH CANNOT BE-USfrD FOe INTB2.MEDIATE- VAl_u&<=>. 24937O 235,760 q (BATEA FOR. SEAMLESS) F (SEAMLESS ONLV) 169,728 155,516 E'(BPCTCA FOR 120,798 98.B34 37.Z35 33,730 ALL EXCEPT SEAMLESS) A (RErERENCE. LEVEL) i r i 4O 6O PERCENT REMOVED 80 IOO 698 ------- for the once-through system (3022 1/kkg) lies in the range found in the carbon steel industry plant surveys (813-3750 1/kkg) and there is no reason to believe that the technology in use there is not directly transferable, since the characteristics of the waste waters and the nature of the processes are similar. The BATEA limitations have thus been established on the basis of an effluent suspended solids concentration of 25 mg/1 at an effluent volume of 1014 1/kkg (25 gals/ton). The blowdown rate of 3.H percent is being achieved in at least one carbon steel plant and, of course, in the completely recirculated system mentioned above. The pH of the once-through alloy steel system averaged 6.5 (within the specified 6-9 range) . Limits for zinc, manganese, lead, and nitrate were also established for this subcategory of the carbon steel industry. The raw waste concentrations of zinc, lead, and nitrate were not found to be significant in the vacuum degassing effluents at Plants E and G in the alloy and stainless steel industry plant survey; maximum concentrations found were 0.37, Zero, and 17.6 mg/1, respectively. Fluoride and manganese concentrations were found at 35 mg/1 each at Plant E, but were negligible at Plant G. Accordingly the BATEA limitations for this subcategory of the alloy and stainless steel industry include a limitation for manganese on the basis of an effluent concentration of 5 mg/1 and for fluoride on the basis of 20 mg/1. Manganese and suspended solids removals are based upon the use of sand filtration as in the carbon steel industry guidelines. Fluoride removal is based upon the use of lime precipitation and sedimentation as for the BOF subcategory above. Continuous Casting and Pressure Slab Molding Subcategory Continuous casting and pressure slab molding are processes by which primary steel shapes are cast or molded from molten steel instead of being rolled from ingots. The molds are cooled by indirect water circulation. The spray cooling water system is a direct contact cooling of the cast product. As the cast product (slabs, blooms, or billets) emerge from the molds, the water sprays further cool and harden a thicker skin on the cast product. The principle waste contaminant in this contact water is suspended solids and, additionally, oil from machinery lubrication finds its way into this water effluent. Pressure slab molding, in a manner analogous to that found in the case of continuous casting, results in the generation of wastewaters containing suspended solids and oil. The current control and treatment technology in the alloy and stainless steel industry consists of clarification of 699 ------- i rH CO o 5 4J p S8 I in fM f! S\| «S \| 4J 4J 0 O •rt > >l QI a 0 0 >< rH 4i I id O e S ID I « 5 a I «5 a a •H > S? > -H ^ g > rH H IH » 4J 0 j; o -o g S B S S 5 lr S S ±1 " _ o 0 -H tp JS H >, C o e 0 £ t ° " n SS3 0 £33 n wo §» -H 6 B "5 0 I IH IS33 > -H e •O -H 0 0 C rH 0 rH rH Id 0 H «H •P fl 0 O 0 U H 0 > rH A g rH JS SrH * H •H - Q O 0} k v > 0 c a > o o n i e •6 -H 0 -S «j rH C - H • e 0 B 0 01 -H > 0 4J 0 & ft rH O -P 10 CO B -H -H 9 H > > SJ C "O O> ^ SS^5 • % S »^i S -5-0 * S,g\| 2 6 c l1^ rH 0 1 0 I O S B ------- 701 ------- F/GUB.E /5<=>-2 MODEL COST EFFECTIVENESS D/AGQAM P/PE $ TUBE'S SUBCATEGO/QY /SOLATED PLANTS (THOSE W/W LAND AVAILABLE FOR LARGE ANNUAL COSTS /3A5EO ON TEN VEA/2 CAP/TAL + INTEREST GATE 7% + OPERAT/NG COSTS /NCLUDE LABOG ^CHEMICALS $ UTILITIES + OPERATING. A>NC>tA\WTE.NfrvNCE COSTS BAiSEta ON 3. 5^0 C>FCAP\|TO\_C.C»5TS COSTS BASED O^ 3C.-5 KX.Q/DKY (4OOTON3/D^Y) PRODUCTION USEO' 81,17 -\| 1-£ (3AT£A) 66,966 PREFERENCE LEVEL) /OO ------- the waste water with varying degrees of recirculation of the water to the process use. One plant surveyed recirculates the water completely with only periodic batch-type blowdown of the systems. No system in current use in the alloy and stainless steel industry was found to be adequate and/or necessarily usable at all other plants; treatments were adequate, but complete recirculation may not always be feasible. The water use rates of 2379-4173 1/kkg are lower than the minimum of 6172 1/kkg found in the carbon steel industry plants surveyed. The characteristics of the waste waters and the nature of the processes are similar to those in the carbon steel industry and hence there is no reason to believe that the technology in use there is not directly transferable, resulting in a conservative estimate of achievable limitations. The BATEA limitations have thus been established on the basis of effluent suspended solids concentrations of 10 mg/1 and of 10 mg/1 oil and grease at an effluent volume of 522 1/kkg (125 gal/ton) . The resultant blowdown rates are easily achievable as compared to those in either carbon steel plant surveyed and one carbon steel plant surveyed was achieving lower concentrations of both suspended solids and oil and grease. The suspended solids and oil and grease removals were established on the basis of using a flat bed filter system as in use at this one carbon steel plant. All plants surveyed easily achieved an effluent pH between 6 and 9. Hot Forming-Primary • The best plant in the subcategory was used in calculating the best available technology limitations. In this case, it was plant L-2. However, because the water usage rate for this plant was smaller than the average of the other plants, an increase in the loading was made, based on water usage ratios. Using direct transfer of technology, the guidelines for this category were scaled up to reflect the higher water use rate for alloy operations to arrive at the guidelines for specialty steel operations. Hot Forming-Section Of the ten process lines surveyed for this subcategory, four were practicing either tight or total recycle. Two of these plants had effluent flows of 584 1/kkg (140 gal/ton) and 1,555 1/kkg (373 gal/ton) of product. The third plant containing two process lines had zero aqueous discharge, with the only "blowdown" being the water content of the wet sludges generated by the treatment processes. 703 ------- < 0> M -H iH * . &B1 o e o) o JJ O M U » 4J H 000 •H O JJ m \| S 3 :> o n JJ o o> n y -y 9 n IH H h Ol3ii 41 0. 0 5 • 000 •SS2 45 ? & a jj -H n > ISS k* ID •H -a •O 01 i-l C JJ O o H s £ o CO « CO •o §! -H O S iH I T> JJ §S 8j2&! u jj 0 jj a 704 ------- 5 % ul n» J O i/1 or a i . (fl tJ 8 uJ * (N» 705 ------- FIGURE ieO-Z MODEL COST ££TECr/VEAfESS D/AGBAM PtCKL W<5 - 5ULFUAIC A C/D - GA TCH ANNUAL COSTS = BASSD ON JEN YEAR CAWTAL + INTEREST SATE 7% y- OPERATING COSTS INCLUOE LA8QRtCHEMKAI-S + OPERATING AND MAINTENANCE COSTSBASED ON 3.5% OF CAPITAL COSTS COSTS BASED ON Z27 KKG/DAY (ZSO TONS/DAY) OF STEEL PICKLED THIS GRAPH CAUNOT BE USED FOR INTERMEDIATE VALUES TOTAL COSTS POR LEVEL B' INCLUDE CREDITS POR ACIO RECOVERY AND AL&O REFLECT SAVIMQS DUE TO E.LIMINATIOM OF OFF-SITE. DISPOSAL COSTS WHICH WERE INCLUDED IN LEVEL A. COSTS SHOWN FOR LEVEL B ARE ^ROSS COSTS, WITH MO CREDITS I55.46Z DOLLARS SPENT FOR "COLLECTION SYSTEM AND HAULINQ WASTES FOR OFF-SITE DISPOSAL IN LEVEL A. THIS MEANS OF DISPOSAL IS ABANDONED AND REPLACED BY A SYSTEM UTILIZING, COUNTER CURRENT RIK1SIN& TO REDUCE RINSE WATER FLOWS TO A VOLUME SUITABLE FOR USE AS MAKE-UP TO PICKLE TANKS. SPENT PICKLE LIQUORS ARE REGENERATED IN A EVAPORATIVE RECOVERY UNIT, PRODUCING, H25O4 AND I 20 I I I I I PERCENT REMOVED 706 I ffO (BPCTCA i LEVEL) (BPCTCA 4 /oo ------- One plant operating two bar mills was recycling so effectively that no aqueous discharges were required. From the data base, the best available technoloyg indicates that the water discharged for BPT should he passed over a cooling tower and then recycled totally to the sprays resulting in zero discharge to navigable waters. The section rolling mills in the alloy and stainless steel industry plant survey in this sutcategory had water uses which averaged to be slightly less than for carbon steel. Directly transferring the technology results in a conservative effluent limitation. Hot Forming-Flat Plate Limitations here are based on the present performance of the best plant. The limitations for alloy steel are based on those for carbon steel, with allowance made for higher water usage. Hot Forming-Flat, Hot Strip and Sheet The best plant in the subcategory was used for the basis of BAT determinations. This plant was achieving zero discharge. The specialty steel hot strip mills which were surveyed had water usage rates which were slightly less than those in the carbon steel segment. However, none of the specialty plants were practicing recirculation. Therefore, the technology used in the carbon steel segment was directly transferred and the limitations were established as the same for both, resulting in a conservative limitation for the specialty strip mills. Pipe and Tube As indicated for BPT, one of the electric resistance welding plants was eliminated from the discharge flow determination because it used evaporation to achieve zero discharge and this treatment technology is not generally applicable to all steel plants. Two of the six plants sampled achieved zero discharge through total recycle, thus indicating the best plants in the subcategory. The BAT technology and limitations are based, therefore, on total recycle resulting in zero discharge to navigable waters. The BAT effluent limitations guidelines are for both isolated and integrated mills. Sulfuric Acid-Batch 707 ------- m CD rH S3 i c ~ 0 V JJ JJ — 01 X •S8" ^ H O JJ JrH JJ5* X m rH d a s z 1 tfl u tn to z is GUIDELI TES AND TO < H Z EH E rt U H O £ U H J 1 § 3 2 z b H is \| g ' Is a u u H D U3 1 O z H 8 H Oi S rH O 1 JJ e id 1C rH 2 JJ § u 01 TJ •« 0) 01 01 JJ TJ 0 S S rH » JJ " .fi g-S 3 rH • •O « C S^5 « JJ o a •u 13 IH e o tr « n •H id IH C71 'c ° "x ci e -H IH 0 e IH -H 3 JJ > • fj (ft rri rn IH M C C O -H fH fH JJ rH 0100 jj 5 A id IH id 01 fH IH 3 -O JJ rrl Q) Cl IH Cl IH fH •° . g. SC Cl O M §JJ rH CO t3 iH U JJ UH fH C UH 0> to c o rH Q IH s Ji flj (0 r1 0 H a C C fH n M -8 £ r, r,g • e -H 01 01 3 3 rH rH UH U UH C 01 -H 01 rH JJ fH >1 rH rH fH on 209 cessar •oS o 0] JJ IH to 01 -H JJ JJ IH 01 8,3 E U^ id O rl rH 58 rH JC H U •££ ^ m , m Q § JJ I id Cl •u JJ O C oi n >, jj jj ilabilit , and ex otal cos id jj jj > 01 Id fH TJ M Cl > 01 jj •H 8 -H JJ > JJ Id fH 01 O Id IH • 01 01 10 o) JJ Cl •rH O tn ic -H IH > Se> o C TJ O fH 10 JJ JJ UH oi e s 8 « 01 Cl 01 IH C U JJ O 0) o.S'c £« * •O 5 rH C JJ 0 Ql Cl 4J OJ rH C •0 01 0 01 U > >i TJ O O> 01 in o 4J rH Id f fH IH U C SS S" 01 >, jj j: ffl C JJ 01 B Q! jj id ci trj ci o 0 U U U JJ 10 s f. JJ fH c fH rH ------- 709 ------- FIGURE IG-li-Z MODEL COST EFFECTIVENESS DIAGRAM PICKLINQ SULPURIC ACID- CONTINUOUS SUBCATEQORV TREATMENT VIA NEUTRALIZATION ANNUAL COSTS = BASED ON TEKl VEAR CAPITAL RECOVERS -• INTEREST RATE. 7% + OPERATING COSTS INCLUDE LABOR, CHEMICALS i UTILITIES ••• OPERATING ^ MAIKITENANCE COSTS B.ASED OKJ -3.5% OP CAPITAL COSTS COSTS BASED OMIO88K KG/ DAY f 1100 TOKJS/DAY) OF STEEL PICKLED THIS GRAPH CAMNOT BE USED FOR INTER MEDIATE. VALUES c (BATEA) A (REFERENCE B. L (BATEA) TOTAL COSTS FOR LEVELS B' AND C1 REFLECT SAVINGS DUE TO ELIMINATION OF «4fe6,,OOO OP CONTRACT HAULINQ COSTS WHICH WERE IMCLUDED IN LEVEL A. COSTS SWOWN FOR LEVELS B AND C ARE COSTS WITH NO CRtDITS. 60 60 IOO 710 ------- Examination of the data base indicated that the BAT technology and limitations are identical to those of BPT. SuIfuric Acid-Continuous For plants with neutralization facilities existing at the time of promulgation, the BAT limitations are based on the use of countercurrent rinses and cascade use in fume hoods to achieve flows of 25 gpt of concentrate and 25 gpt of fume hood scrubber and rinse discharges. For those plants presently without neutralization, BAT limitations are set at zero discharge for both concentrate and rinses. Pickling-Hydrochloric Acid-Batch and Continuous-Concentrates Concentrates The most modern pickling installations in use today utilize hydrochloric acid continuous pickling, with continuous regeneration of spent pickle liquor to produce reusable hydrochloric acid and sinterable ferric oxides. Such systems are discussed in Section IX, where the BPCTCA limitations were set using such a system to recover spent concentrated acid, discharging only the wastewaters from the absorber vent scrubber. A significant reduction in discharge flows from this system can be obtained by adding a recycle loop on the absorber vent scrubbers, and treating the blowdown from this system via aeration, lime neutralization and sedimentation. A system such as this has not been tested; however, the key to the system is keeping the water flows in balance. Systems similar to this are in use in the sulfuric acid subcategories with considerable success. Based on the above, the BATEA limits for pickling operations utilizing HC1 regeneration have been established for each critical parameter as discussed below. For those hydrochloric acid pickling operations not practicing acid regeneration, joint treatment of spent concentrates and rinse waters was recommended to achieve the BPCTCA limitations. This technology is further advanced through use of countercurrent rinsing to reduce flows from that source to less than 209 1/kkg (50 gal./ton), which when taken together with the wastewater flow from spent concentrates gives a total flow to the treatment plant of 333 1/kkg (80 gal./ton of product) . Although the only plant surveyed which was discharging flows approximately twice as 711 ------- ^ w \|8 13 I o a I Q) ^ H •O 0 O flj 04 ft O flJ CD ra S Sol n e « id -H $ * &I ss~ to p .9 Si H H 01 4J IH -O co O -H >i u n e id .So,S -P 4-> 01 O -H > 9 n o o d tn m c M -rt as A rH I O n u m oi n g •"•> o e S2 . 3 CO IH rH h O rH 0) O 4-> 01 d Id Id 01 0) .C ** rH U Id A n » id •H 0) Cr a J -H n > 3 U II f> D> o c h -H Q, rg .r3 to u o h S 4J H O oi id oi • E > 4J o ta 4J o S •s 5 id p a, b aea 712 ------- 4» 0 2 O 5^ -j- o i1! a Ul a Ul 713 ------- MODEL COST EFFGCT/VE/VESS O/AGRAM SULFURIC AC/D - CONT/NUOU5- T&EATMEMT V/A AC/D RECOVERY 519,961 513,409 ANNUAL COSTSBASED ON TEN YEAR. CAPITAL &ECOVE&Y V- INTEGERST GATE 7% i-OPE/SATING COSTS /NCLVOE LA&O, CHEMICALS ^ C/T/L/T/ES + OPERATING AND MAINTENANCE- COSTS BA56D ON 3.5% OF CAPITAL COSTS COST BAftB.0 ON lOftft HfcG /DAY ( I7OO TONS/DAY) OF- STEEL. TWI5 GRAPH CANNOT BE U5K) FOR INTERMEDIATE- VALUES. * TOTAL COSTS FOR l_£YEL B1 INCLUDE CREDITS FOR ACID RECOVERY AMD ALSO REFLECT SAVINGS DOE TO ELIMINATION OP OFF-SITE DISPOSAL COSTS WHICH WERE INCLUDED IN LEVEL A. COSTS S.HOWKI FOR LEVEL B ARE 5ROSS COSTS WITH NO CREDITS B (BPCTCA BATEAU IT 3 I 2,739 -DOLLARS SPENT FOR COLLECTION SYSTEM A.ND HAULIN^ \WASTRS FOR OFF-SITE DISPOSAL IN LEVEL A TMIS MEANS OF DISPOSAL is ABANDONED AND REPLACED BY A SYSTEM UTILIZING, COUNTER-CURRENT RlNSINCj TO REDUCE RINSE WATER FLOWS TO A VOLUME SUITABLE FOR USE AS A MAKE-UP TO PICKUN^ TANKS. SPENT PICKLE LIQUORS ARE REGENERATED IN AN EVAPORATIVE RECOVERY USIVT, PRODUCING AND SUSPENDED SOUDS AND DISSOLVED IRON 20 4O 6O PERCENT REMOVED 80 [A ('REFERENCE LEVELS /do 714 ------- large as the recommended flows, two of the other plants, one using regeneration and the other deep well disposal, were successfully concentrating rinse water flows to 50 gal./ton or less. In fact, the plant using deep well disposal methods achieves flow rates of only 3.3 gal./ton of spent pickle liquor, plus 5.9 gal./ton of rinse water using a cascade system, indicating how efficiently such rinse water conservation practice may be. Pickling-Hydrochloric Acid-Rinse Waters One of the two plants providing more or less complete treatment of rinse waters in this subcategory has been used as the basis for establishing all BATEA Effluent Limitations Guidelines. This plant provides equalization, blending, lime addition to pH 8.0, mixing, aeration in dual chambers, polymer addition, clarification in either of two identical thickeners used in parallel with vacuum filtration of underflows, and final settling in a large lagoon with discharge of overflow to a receiving stream. An effluent of extremely high quality results. All parameters listed below are effectively removed using the above equipment and treatment technology. Cold Rolling The degree of effluent load reductions achieved via the treatment and control technology required to attain the BPCTCA limitations for recirculation, combination and direct application cold rolling operations as described in Section IX is equivalent to the best available technology economically achievable at this time. To achieve additional reductions would require expenditures of capital and operating costs out of line with the benefits derived. For this reason, the BATEA limitations for the cold rolling operations are identical with the BPCTCA limitations in all cases. Hot Coatings-Galvanizing Operations Flow information relative to the four plants visited is discussed in Section IX, along with the BPCTCA limitations. Hot Coatings-Terne Operation Since both of the terne-plating lines surveyed were discharging wastewaters after once-through use without treatment, but rather with control to minimize dragout, BATEA limitations for all parameters were set at levels in 715 ------- 38 u « •P P K H -3 H H 1C o o £SIe .jj ftSr, g* JJ O • -rt 10 B JJ 9 C 01 o E tr o c rH JJ U 10 in i T3 > JJ jS'SSt 585 JJ 01 X 01 rH 0 JJ H 10 -rt -rt H > > jj c -n IT O -rt B Q JJ JJ -rt ------- Si ^ g33 ' --- 1 --- ' I ° £ > I S I UJ •V w Is ST TR RY D»- * oo g$Ss ------- FIGURE COST MODEL COST EFFECTIVENESS P/AG,KAM PICKLING HYDROCHLORIC /9C//D - CONCENTRATED 5U&CflrEGOF?y - ALTERNATE _T COST-&ASED OH TEN Y&A& C.APITA.L + IN T&K.&S T «A T£- 7 % + OPERATING COSTS INCLUDE LA&OK, Cf-/EM/CALS $ UTILITIES + OPERATTINCSi ANt> tAA.\NTE.N KNCE COSTS a .5% OF C-A^rroL. c.o«»-rs TUX'S /,//9,322-• -A TOTAL 5PSMT f=-OR. A. 7W/S MEANS- ' DISPOSAL IS AND REPLACED WITH AND IRON OX/Di WITH I LEVEL &, INCLUDE t=K.£DlTS FOK, I tOO 75 h PERCENT ADDED \ SO I O I SO PERCENT REMOVED /OO 718 ------- 719 ------- F/6URE /G4-2 PICKLIMG-HYDROCHLORIC ACID-RINSE SUBCATEGORY ALTERNATE / ANNUAL COSTS = BASSO OM TBM YBAR CAP/TAl- ff£COVeBY 3/3,288 TBM YBAR 7% + opea AT/MS COSTS + OPERATING, AND MAINTENANCE COSTS BASED ON 3.5% OF CAPITAL COSTS COST BASED OH Z7ZI KKG/DW(3OOOTOHSI DAY) OF STEEL PICKLED THIS GRAPH CAN NO T BE USED FOR INTERMEDIATE VALUES /OO PEI3CEMT ADOSD 720 ------- effluents from systems similar to those used in the Hot Coatings - Galvanizing subcategory. Miscellaneous Runoffs-Storage Piles Coal, Stone and Ore These three miscellaneous runoffs were discussed in general terms in Section IX, but no BPCTCA limitations were specified, indicating instead that such limitations will be deferred until such time as BATEA limits apply. The best available technology economically achievable is considered to be perimeter collection, storage, chemical flocculation, neutralization and sedimentation. The use of impervious liners or other means to preclude subsurface drainage has not been included in the BATEA technology due to the absence of demonstrated cost effectiveness. Concentration limits on specific pollutants present in the wastewater which are due to leaching from the stockpile must be set on an individual basis wherever appropriate. The .stockpile size and surface area is calculated from the raw material usage, storage capacity, bulk density, and stockpile height parameters. The rainfall value chosen represents the greatest mean maximum 2U hour rainfall generally experienced in the western, north central, and northeastern part of the United States. (Source: The 1970 National Atlas of the United States.) The runoff coefficient of 0.90 was assumed since the proposed subsurface and surface runoff collection systems should collect all rainfall except that accounted for by evaporation. It should be particularly obvious that the system costs based upon the above set of criteria and assumptions represent only one specific case of the probable cost of such a system. A great variety of alternatives in size and cost exist for this basic treatment concept and must be determined and applied on a site-by-site basis. The particular system described above, although not rigorous for all applications, does provide a reasonable cost estimate for the particular set of criteria and assumptions used. The basic concept of collection and storage is justifiable in every application. Even though logistics and economics may preclude the application of provisions for impervious sealing of the stockpile base for existing piles, there should generally be no restriction to prevent perimeter collection of a large part of the runoff. Once collected. 721 ------- V Is in r- o § I S gg. " S18 s sys CO § o in cs m § o § o m § 0 In ro M 0 § 0 0 o en I o VO So c •H >i-H a SU g m & > • n vi •H 01 O 01 rH O > O O. 5 ' S-S10 g1 (8 JJ JJ Ti IH $ e JJ a o> m -H iO o •gj?^c «•• ^ II m •a •2 S o n m 3 £ 0 « H Oi IJJ >i JJ J= O c « c jj IB I S Ijj1" a 01 5 o, oi iJ5iJ 722 ------- 723 ------- F/GURE ICoS-2. MODEL COST EFFECT/VENESS DIAGRAM P/CKLING - HYD&OCHLOR 1C AC/D- CONCENTRATED/WDRINSE- £UBCATEGOGY-ALTERNATE!! ANNUAL COST -BASED ON T&N VEAE CAPITAL. QeCOVEEV + j/vreffe-ST RATS T7. + OPERATING COST INCLUDE LABOR,CHEMICAL* * UT/L/r/C-5 i- OPERATING AND MA/MTBNANCE COSTS B45E-O O/V/v3.57. OP- C4P3/TAL. COSTS COSTS BASED ON 2.7Z KKG/&AV C3OOO 7-QM5/OAY) OF 5TE£L ^/CKLED THIS GRAPH CANNOT SE USED r<3& //VTE/SMED/ATE VALUES _l_ X? SPENT PICKLE LIQUOf? A(OD RINSE WATER TREATMENT COSTS ^BA5£ INCLUDES DOLUfcBS •JENIT FOe COtLeCTlOKJ SY^TfeM A^>5P HAULIVJ& OF l"5 ^BAWOMfcCJ AMD CtPLACtO BY KJ&UTEAUWTIOW 5Y5TEM Bfr(JIKJIs)\|ioG \yfrM LfeVEL eTMUS ELIMINATING '(,044,000 OF LEVEL A COSTS _ . ft (COSTS CARRt FORWARD) PERCENT ADDED I o 50 /oo •(* PERCENT REMOVED 724 ------- at least minimal treatment for suspended solids and pH should be applied under BATEA wherever site or area specific pollutants appear in excessive concentrations in the runoff. The treatment of these specific pollutants where they are identical to critical parameters identified in this study, should follow the treatment and control technology and effluent guidelines established for these parameters in other subcategories. In other cases, treatment and control technology and limits will have to be formulated and applied on a case-by-case basis. Since it is not possible to present a uniform set of parameters on which to design, size, and cost these systems, some discussion of the variables involved and their impact on the completed system is in order. They can be described as follows: Stockpile Surface Area. This, of course, depends heavily upon the capacity of the ironmaking facility, its production rate, the number of days stockpiled inventory, the height of the pile, and the amount of sinter charge employed. Although coal is converted to coke before charging to the blast furnace, the coal supply will generally keep pace with blast furnace production since coke produced is generally used immediately in the blast furnace. Rainfall. Rainfall intensity, frequency, and duration can vary significantly from area to area in this country. In certain areas, the use of mean maximum 24 hour rainfall to estimate the load on the system may be sufficient. However, in other areas, the use of figures for the 2 year, 5 year, 10 year, etc., 24 hour storms may be more appropriate. In other areas, where definite wet seasons occur, the system design may have to be based upon maximum consecutive days of rainfall in the area. Each case will depend on weather conditions specific to the area and will have to be determined on that basis. Runoff Coefficients. Again, case-by-case estimates may be needed. Runoff coefficients are generally average numbers reflecting runoff throughout the storm cycle. During the peak of an intensive, long duration rainfall, the coefficient may approach 100%. However, during brief rains, at the start of rainfall, and after rainfall has ended, these coefficients may be considerably lower. The coefficient in all cases will require conservative estimation to avoid underdesign of the system. Treatment Alternatives. As mentioned previously, the basic treatment system for will require sedimentation and pH 725 ------- 1 i •H s i JJ 5 •H £ Jj! CO \ O w- u JJ 1 i jj I rH 1 MH 0> IH o M nt Technolo ! a 01 » § 1 1 _ f\ kg/kkgU) (lb/1000 11 o s Critical Param« CO rl .M 0) co o - * 5"H 1 u o I gf jj in » 1 0) 11 JJ O rH CO «r KC * tJ V O & O \D O rH 0 N rH O tH C7> 000 D, X OOO * OOO CO M O 01 CQ in S 11 ~e H CO O & s « •g s -g C B rH 11 Id O a, n * n rH n 5 3 5) 5) SS rH CO O O ft tu « -H TJ c K 5 Id rl > O O> B 1) M >1 rl JJ rH 01 O M 01 Q< O JJ rl OrHCld 3 »< ------- adjustment, with more specific treatment processes employed under BATEA where additional constituents appear. However, this does not preclude the possibility of using treatment facilities associated with other subcategory facilities in the mill. With the right combination of rainfall load and storage capacity, flow may be effectively metered to allow such a possibility. In addition, in some areas of the country where evaporation exceeds rainfall, it may be possible to collect and store the runoff during wet periods, and later spray evaporate runoff during dry periods and thus achieve zero discharge. Another factor that may affect the size of treatment facilities will be land area available for storage of runoff. Where land is at a premium, pond area will have to be minimized and treatment capacity maximized. Where land availability is not restrictive, the opposite may be true. The 2.5 inch 24 hour rainfall used as the basis for runoff collection and treatment facilities for storage piles is based upon mean annual maximum 24 hours rainfall data in the USGS National Atlas, This data map indicates that the vast majority of steel industry production is centered in areas of the country having a mean annual maximum 24 hour rainfall equal to 2.5 inches or less. Although it is realized that maximum rainfall data is highly site specific, and in many cases should be based upon 10, 25, etc. years storms, no other source of data was available that could provide a general estimate covering most of the areas of the country where steel production is located. Specialty Steel Pickling and Coating Operations It has been determined on the basis of a review of the available technology, the engineering aspects of the application of various control techniques, energy requirements, and the costs of application in relation to the effluent reduction benefits to be achieved that the BATEA limitations for the specialty steel pickling, cleaning and coating subcategories should be the same as the same as the BPCTCA limitations: Cons ideration of Process! Changes No process changes are envisioned for implementation of this technology for plants in any subcategory. The treatment technologies to achieve BATEA assess the availability of in- 729 ------- g 8 en 2 O H EH g H M 1-J n ui N VO 0 . 0 0 . 0 r> VO Zj g 2 O • O U < •3 5 •O a to I M ? 2 ^. 5 H 35 »H a a. (H && 01 4J i-4 •O S «H §0 <0 9 O ^ >i 64 M O 10 (A V) n M M 4> 0 0 r-1 4-> O S^ -3 0 U9 0 rt 4-1 10 U °a s^ « H tJ O 0 4J JJ u o 10 0 S8 000 0 JJ C 01 W O <0 -H O M o w o 5 C5 g °l J C O E -H 4) 0 -O 4J £{ c 4J 4> 4J 0 Oj B S-8 J •H -H W <8 to a rementa •H -H O "8 <0 0 u jj n 6 >i - O W TJ H ifl 0 P > V 10 >0 y >s 0 9 g n E 6 4J 2 _ •5'H 0* >i 0 >H 10 M B •A°* \| 4J Ifl fi 10 ?r! 'J o •-• -^ 0 ID a jj 0 10 ,3 Q, g _ -. O O I ^ •H O B rH ------- 731 ------- FIGURE MOD&L COST tFFfcCTlVEKJfcSS COLD eOLLIUG-COMBIVJATlOM AKJKJUA.L CO«5TS » BAStD OU TEKJ Yfc\e CAPITAL + IMT6B65T RATE: T/u •»• OPEPATlUG COST^ WCLUDE Lvt>OR> OPERATIKIG ^MAlMTEWAKJC-E. COSTS BASED OK) 3,5% CAPITAU COSTS COSTS BASED OW »3 ------- process controls as well as control or additional treatment techniques employed at the end of a production process. Consideration of Costs of Achieving the Effluent Reduction Resulting from the Application of BATEA Technology The costs of implementing the BATEA limitations relative to the benefits to be derived is pertinent, but is expected to be higher per unit reduction in waste load achieved as higher guality effluents are produced. The overall impact of capital and operating costs relative to the value of the products produced and gross revenues generated was considered in establishing the BATEA limitations. The technology evaluation, treatment facility, costing, and calculation of overall capital and operating costs to the industry as described in Section IX and which provided the basis for the development of the BPCTCA limitations was also used to provide the basis for determining the BATEA limitations, the costs, and the acceptability of those costs. The initial capital investment and total annual expenditures required of the industry to achieve BATEA limitations are summarized in Table 197. After the treatment technology to be designated as one means to achieve the BATEA limitations for each subcategory was selected, a sketch of each treatment model was prepared. The sketch for each subcategory is presented following the tables presenting the BATEA limitations for the subcategory. Cost Versus Effluent Reduction Benefits Estimated total costs on a dollars per ton basis have been included for each sufccategory as a whole. These costs have been based on the wastewaters emanating from a typical average size production facility for each of the subcategories investigated. In arriving at these effluent limitations guidelines, due consideration was given to keeping the costs of implementing the new technology to a minimum. Specifically, the effluent limitations guidelines were kept at values which would not result in excessive capital or operating costs to the industry. The capital and annual operating costs that would be required of the industry to achieve BATEA was determined by a six-step process for each of the subcategories. It was first determined what treatment processes were already in place and currently being utilized by most of the plants. Secondly, a hypothetical treatment system was envisioned 733 ------- >S e Cn O 01 i o 10 n •a •rl 0) C. rH D) O Sa n U H •O S -0 .•s 4j tin CT> O 318 h §S > v 01 01 JJ i—i n 1* S en "•a 4J I £ 3 W 8 » rH 0) O •rl -rl 3! rH O P S, fel I JJ 10 •§ I-l rH s v S a «H 0 n 1 o n 0 0 O Q S3 rH rH JJ o to V S5 9 o UH U 0) C 0) i-l JJ IS W gi JJ m ; to jj 28 M n 01 -H ! JJ V M >* O M -H rH JJ O £ O 5\|2 Sg§ o S-H S5S •c-s ~ $ C rH 01 rH 10 0> rl rH rl 10 10 irj Pj JJ g cm 3 «H 5 e rH O 6 -rl IH jj a e 0 g . S >i JJ JJ JO JJ X M rH«8S! 01 O M 01 a. oi jj M 0) rH C 10 •a o o . ": ° -g 4P >i 0 >H O UT QJ £ ",5 « + 1 o o to a u S n S u •rl Oi JJ •rl § JJ s tes V n v 5 c a IH •O rH IH a iB o H rH i-t O -H 0) X H 10 01 -H -rl > JJ H 0) -H &SSS -Ujj1" «S5 &? o> n ai o rl O U U jj u jj a 734 ------- 735 ------- MODEL CO«5T fcFFtCTlVfcKJfc^, DIAGRAM COLD EOLLIKX5-DIBECT APPLICAJIOK) AUUU/U- COSTS • fcASfcO OU Tfc»0 •t- IkJTfcBfc'ST BATE + OP6BATIIOG dOSTS CAPITAL IWCLUDfc UT\HTIES OF RO t5OCT\ON e> (BPCTCAi Av CKEf/TRENCE LEVEL) IOO 736 ------- which, as an add-on to existing facilities would treat the effluent sufficiently to meet BATEA ELGs. Thirdly, the average plant size was determined by dividing the total industry production by the number of operation facilities. Fourth, a quasi-detailed engineering estimate was prepared on the cost of the components and the total capital cost of the add-on facilities for the average plant. Fifth, the annual operating, maintenance, capital recovery (basis 10 years straight line depreciation) and capital use (basis 1% interest) charges were determined. And sixth, the costs developed for the average facility were multiplied by the total number of facilities to arrive at the total capital and annual costs to the industry for each subcategory. The results are summarized in Table 197 which also shows total costs for the specialty steel segment. Mahoning Valley For steel plants wihtin the Mahoning Valley which apply for a Section 310(c) exemption, the modified limitations shall not be less stringent than the industry-wide BPCTCA limitations for the following subcategories: Cold Rolling Hot Coating - Galvanizing Hot Coating - Terne Miscellaneous Runoffs - Storage Piles, Casting and • Slagging Combination Acid Pickling Seale Remova1 Wire Pickling and Coating Continuous Alkaline Cleaning For steel plants within the Mahoning Valley which apply for a Section 301(c) exemption, the modified limitations shall not be less stringent than those set forth below. Hot Forming-Primary-Mahoning Valley: Effluent Effluent Characteri st ic Limitations Maximum for Average of daily any one day values for thirty consecutive days shall not exceed (Metric units) kg/kkg of product (English units) lb/1000 Ib of product 737 ------- i S S Tfi v ) •— a O O S 3 •o 3 S8 1-58 g'o SS€S e -e « P C -H 4J E 4J O O "H « E 0 -H -rl H -3 4J H 5 X n o> «j a H n n M I 3 i-l •* C 01 -rt -rl O IH iH at C - kj > 9 n M o A »> BAM * 3 e .... o h > « i-i e > o * > p p c H -^ p "•sS1^8 s ^ X Dl e ;5 x. S sl B S i S iH S s •H S >n N £ o in iH i-l 0 0 0 0 •H I-l s •o ! ! o > in N » 88.3 IH o n P O B S ** "* OHO 00 rt "S "0 « « w B8:S •a IH B § ° 8 p o> -5 &S « S^13 » is g.U « H >i JSU1U a * •-i o »] IW S § • si, gfigS "g fr" li£: :i§* «3Si las» 3* I* "o c * w o B m &«** 3«8g! 21^5 gs«. to a •rt 9 iH 5 5 A •H - O O SS^ "•g-ss §sls 32:3,3 3 ~H to O. B!»-.S "S S5 B « iH -H «-,8> •o o> IS i> 0 O 4J > 9 e -H 9§« H H IH O IH £ — 0 -H \|B3 p 0 id M JJ «j 5 S 8 § g "•si8 isiS 0 Oi 0 « pap «§ "3 P I >< CO '3 52 •H « O •b 0 IH c 6 r-i 5 n rH rH O 41 3 H IH i o) IH B 0 :\|» B p In 738 ------- 739 ------- MODEL COST EFFECTIVENESS HOT COATING - GALVANIZING-5UBCATEGORY ANNUAL COSTS = BASED ON TEN YEAR CAP/TAL RECOVERY + INTEREST RATE 7% i-OPERATING COSTS INCLUDE LABOR,CUEMICAL5 f'UTILITIES ^OPERATING AND MAINTENANCE COSTS BASED OA/3.5% OF CAPITAL COSTS COSTS BASED ON 635MG/DAY(7OOTONS/DAY) HOT COATING OPERATION THIS GRAPH CANNOT BE USED FOR INTERMEDIATE VALUES VI 8 NO INCREASED COST'S. ARE A OF SETTS'R. A (REFERENCE LEVEL} o I I I I I PERCENT REMOVED /OO 740 ------- Oil and Grease TSS PH 0.5391 0.1797 0.8238 0.2746 Within the range 6.0 to 9.0. Hot Forming Section-Mahoning Valley: Effluent Characteristic Maximum for any one day Effluent Limitations Average of daily values for thirty consecutive days shall not exceed (Metric units) (English units) Oil and Grease TSS PH kg/kkg of product lb/1000 Ib of product 0.7062 0.235U 2.2560 0.7520 Within the range 6.0 to 9.0. Hot Forming-Flat-Sheet & Strip-Mahoning Valley: Effluent Characteristic Maximum for any one day Effluent Limitations Average of daily values for thirty consecutive days shall not exceed (Metric units) (English units) Oil and Grease TSS PH kg/kkg of product lb/1000 Ib of product 0.7758 0.2856 1.7661 0.5887 Within the range 6.0 to 9.0. Pipe and Tube-Ma honing Valley: Effluent Characteristic Maximum for any one day Effluent Limitations Average of daily values for thirty consecutive days shall not exceed 741 ------- u> W «2 H W Q H D U W 11 IZ C S 2 I— EH B V) r4« 1 «— EH w a H1 lj H -H « iJ 4-1 •< IB » U J23 D 0 p £ >H 7 \| < EH W < EH O < « n D •<«• O -* EH EH Q W V. U O (/>• EH CJ Mr3 EH EH W O tJ1 W EH « «/> ro x^ t. O 2 o EH EH u § EH < ^ (•8 o « £-1 § ° d — rH W X. K 0" 0 g H t"J ^ \|H r^J ,q W P rl < CPO « « 0 ^s g 2 w M W EH § H e>4 • O CM 0 01 g r-l 1-0 9 -H 3 0) K 3 O c m a 144 U) S > 3 O H 3 >! O 0) -H C C O +J O -rl O Vl W •rl 4J rH O) 4? -O •O 14 > H G C O H 4J ttJ O -rl O> !- Oi S o 0 i JJ o ! o. •a 11 4J o o o o> C X o •H H 4J 0) 304 •rl 4J 2 3 3 M-t 1) IM G 01 EC W O. 0 01 n 0> 4J -H in M r^ » rH o -a1 to •H 11 0 3 • rH O1! fl 1 > 0 • o 2 "^ in « vo o ~- o in >H m rH rH D4 vO O O o o o to 0 O 0 S 01 c o 4J l_l a o ^ "S * 3 B _J -O • o~ O rH -H 3 Id 4J 18 O 11 O 3 rH O O< io O -H 3 3 rH TJ tw rH O O nj &4 > >• O rH 0) 0-1 H TJ '>, ia •• TJ « rH H TJ D ^4 Qj Q) D H -H 6 4J 4J -rl 3 O -H U O1 U XI C -P „ ° Z o -H g •H id D id e c n -P >n(i> O-P Xi -H TJ O C rH G W Id •H nj "S ,7 41 C •-1 m ti "X 01 0) C D W C O > -H •H -r4 i 4-> 4V) » t! id nj to -H o G 1) 3 OHO 4-1 > C W rH U -H id nJ "d 4-1 01 S G" G 'x id 64 id «-H <4-l g O rH 3 JQ O o JE3 to 10 x: — cc M O C O-P -HO -t-ig -H-O TSO 4J TJ 4J 1) 0) Q4 O O V4 Ul l» ' ^ ^ OrHx;B4Jitjnj>x!W'-i fHrHUIHtO ------- ~fl I A rV-in 743 ------- FIGURE 170-Z. MODtL CO5T EFFECTIVENESS DIAGRAM HOT COATING-TERNE SUBCATEGORY ANNUAL COSTS BASED ON TEN YEAR CAPITAL RECOVERY + INTREST RATE 77. •••OPERATING COSTS INCLUDE LABOR, CHEMICALS t UTILITIES 4- OPERATING £ MAINTENANCE COSTS BASED ON 3,5% OF CAPITAL. COSTS COSTS BASED ON €>35 KKG/DAY (700 TONS/DAY) HOT COATING OPE.R. TUIS GRAPM CANNOT Be. USED FOR INTERMEDIATE VALUES 2O34OO 164,980 111,688 tr § 1 NO INCREASED COSTS. IMPROVEMENTS AREA RESULTOF BETTER OPERATING PRACTICES (REFERENCE LCVEt) 4O 60 PERCENT REMOVED 80 100 744 ------- (Metric units) kcr/kkg of product (English units) Ib/IOQO Ib of product Oil and Grease 1.0527 0.3509 TSS 4.2597 1.4199 pH Within the range 6.0 to 9.0. Pickling-Sulfuric Acid-Mahoning Valley: Rinses Effluent Effluent Characteristic Limitations Maximum for Average of daily any one day values for thirty consecutive days shall not exceed (Metric units) kg/kkq of product (English units) lb/1000 Ib of product TSS* 0.0705 0.0238 Dissolved Iron 0.0282 0.0094 Oil and Grease* 0.0282 0.0094 pH Within the range 6.0 to 9.0. * This applies only when these wastes are treated in combination with cold rolling wastes. Concentrates: There shall be no discharge of process waste water pollutants to navigable waters. Fume Hood Scrubbers: Effluent Effluent Characteristic Limitations Maximum for Average of daily any one day values for thirty consecutive days shall not exceed (Metric units) kg/kkg of product (English units) lb/1000 Ib of product TSS* 0.0156 0.0052 Dissolved Iron 0.0063 0.0021 Oil and Grease* 0.0063 0.0021 745 ------- * This applies only when these wastes are treated in combination with cold rolling wastes. 746 ------- ON r-l W a M« EH 01 O •O C fl 01 UI rH fl 1 01 rH W -H W 0- ^ Q) >-3 a H tH Q O y w w U i tn 01 g OH 3 »H O o H C EH 3 ,< « § I H 01 i-l C fl EH ,_( 2 oi W u O 01 r-3 -H fe S H PS . S W Q W \ & E < 3 ¥• j o «• H U EH H WOO1 W EH X SX W 2 O EH r ( M M ft W § m •« (/)• CM r- o 1C IN vD ^J CO CM o o o o o d O rH CO in ui CM 000 o' o' o rO ^ iH s VJ o r-J 0 2 ffi o u EH r . £ y £-» H I-ZJ o ^ o o 1 rH fl fl J-> U B B 0 01 'H J3 -a U 01 in o « cn C fl O )H -H O 4J 4J fl 01 N •rH - rH c a O IH •H 4J 4J 3 U 01 o a rH rH .- 8 § •rH VJ -P 01 fl 4J rH 01 3 e o •HOC n o o 0) rH -rH 0) OH 4J ^^. cs ,-H V tr e in CM -"» tT»o fctf o ^ 0 ^^ m CO o d tn •d eg CJ H M U S 12 "< 0< rH «§ 01 1 * (0 \|J (^ EH 8 in in rH 0) OH O 0 c c fl 3 U IH i OH 01 O 3 rH rH 0) r* fl IH -H > 0 4J O 01 'H rH rH jq fl 0 O in ^ rH ft 4J O Ul Q 01 e 4J °Gl O H 01 OH * fl 01 C C o o •rH Q, 4-1 3 is 801 id A o •H 0) (0 11 e •H 01 -H > U O c 'i a« 3 4J 01 4J O C O 01 T3 13 C C 01 fl ft o> in T3 O iB >i O H rH O E • 01 rH 01 i! > 1 X 01 01 S o o 01 X fl M Tl 01 01 4J 4J fl fl rH U •H O 01 fa O< 1 ^^ M C O •p 0 o o in " * fl in ^j> o ft 4J ' fl •° "q O ~v^ in rH cn 0 m fl •O rH 01 •8 01 c o u m rH fl • W 4-1 0) -H 4J rH g O fl 5 OH fl C TJ -H 01 X H fl O g 4-1 1 in C O O -H en >i X id H H .01 01 01 ft •O 4J rH 01 fl C §5 ° in P • c 01 S O -P 0 0 O X! Z U 01 rH 01 fl • (H •H — Id 01 o in 4J 4-1 4J W -rS S rH rH fl fl M Cn -. 01 T3 O J9 01 r- rH O — 0 •P O 01 >, O fl iH OH TJ N. 0 01 VH A 01 0) rH .a ft — rH tl d o 3 ^x rH W fj> M O (U CJ 0) ft J= « EH 01 rH •a id C -rH • a n >, O 0) rH ft -P C id O IH £; O W ? 4-1 * fl -H NUB fl -H VH )H C Oi O O ft 4-1 -rH 01 4-1 T3 fl 01 OH ^ 01 CP 01 C X O o a c 0 O rH U 01 01 rH ft 01 fl fl •H OH 01 O 0) 4J C -H ft S OH fl fl O U 01 I/I rH T3 rH fl 01 01 S-H H rH O 01 cn 0 01 OH J" 4-1 O m fl rH O c .3 0 OH 3 4J O W o s o> •H O -H M rH J3 4J OH 4-1 01 e 10 >H o H C OH 0) O ft 01 •0 C 0) 01 O 6 0) -H fl fl 4J H J3 fl cn 4J rH >, 0 •H fl -3 ^ T3 rH r-l U o c s Jf 01 0 OH 01 1 rH OH OH OH O C 3 •O 01 n fl XI o 01 •d &l fll o 01 •rH r-H ft ft fl 4J •H iH C O •H 4-1 10 •p c 01 o c o u IH $ •H rH o! W i 14 •rH «H H •H S CN OH O 01 C o fl 4J 3 01 ft H O (f) C o •H 4J fl C 6 6 o 01 rH •rH 01 01 & iH r-( fO ^j . o 01 rH OH 01 4J •H 01 Q) O T3 VH g 01 •H 01 3 rH O C •H rH rH fl ^ •H rH fl 01 01 01 O 01 C 4-1 O c B •H T3 01 •p 01 •H H •>, 81 • rH 01 o -a s& 0 4J 01 0) •p I 01 4J rH C n QI fl 0 •H fl fl 01 > rH rt 4J " UI - c •a o 01 -H 4-1 4-> fl • fl ft 01 >H 01 e >H nt M 3 fl a 4J in >, ui q oi id id n XJ 01 CT C P) SC "H •H M S C 0) s o o £ • O 01 3 > • - 01 OH Id O in id rH J3 4J i-H OH fl 0] rH O O 01 fl fl •H Si rH OH 4-1 E id A C B 01 Vi 01 .e p Cn fl -H 0 S C V4 0 O -H -H •O 45 r« rH OH G W fl fl OH fl e 3 oi in i c o TJ 4-" C C O C 01 O fl fl O IH OH rH O -H 01 OH OH rH >i y c 0 fl fl 3 •P TJ 13 H X O \ C 4J 4J " fl fl •H 01 rH T3 C - T3 •H (B O 01 C J3 4-1 4-1 01 fl fl S ,C rH 6 O O - •H -.H O C TJ fl 4J O -rH 01 > 01 in T3 fl td " m -rH •• en (N o C • X K -O t3 X TJ ft •H 01 01 4J ,H in 01 01 fl -rH CO U -H O 3 in X O D1 ^ 0) 01 rH 0) 01 IH fl P rC in o o fl W Oi fi C c d -H J2 O 'H 13 U -H > rH in 3 4-1 V4 3 • 01 Id 01 0 i C 4-1 01 S^ fl OX 1 t> 01 01 ^T 1 Cn M CNI rH B n o •rl C C B TJ cd d fl C O U rH 0) -C rH B O ft 01 -H OH 01 -u e •a o TJ 3 >i 01 C g 4J -N rH fl -H -rl M 01 >< U fl UI » fl fl > , e 17 Js tn O 01 O fl o 4-i x: g rH 01 4J 01 O cn W C • 01 fl 4J S rH H H in o fl oi o O 0) 0 J3 4J O 4J U s tn s' 747 ------- 748 ------- z — o «r H »~H S Q W v» HO w o r* 1 "1 O\ •1— W ^ m $ to w ^ H * tj W D g O W z o H EH rfj £-4 H E H £_, W D (u ft, w g C-t eC CO ^. CO 3 O 3 C •rl 4J d o u •tff a c •H rH A; O &, •C •rl O C O •rl JJ C •H •§ O $4 K o £~* g m D W ^, PO '- ^H O O fcj 0 2 03 O w £H ^ E W £ f-t ES a w -3 o a f_t 2: O o .— . IN ^* rH N in & Z E O H H E-" « H i4 K •— M rH 0 rJ ~-0 •D^ O »it^ f-> N CU X JJ o 41 JJ O.C 0 JJ O C 01 C 3 0 rH C lJ rH 01 rH 18 M rl CT o> c JJ -H •rlTJ rH 3 rH <: r- x O rH 4J_ o (X 10 rv CO -rl C o en e JJ «; 41 x JJ rH to tn 18 S f^t 01 < U) W O rIO O 0 in 0> tn IN o 3 T3 1 1 1 1 rH 01 inooor-i 05 • 41 ^» 01 U rl 0 rH 0 (D • J3 »J V 0 O rH • M 41 cr. nr-rHorsvo^o a, a> c 3-rH(NrHa'(N JJ'rt Oaj-OOOtf) JJtOH HOOOOO tn o oooooo SOU CQ X "" tn rH« «c w CJ EH gg: ^ e in 3 M — -rl rH V E 4) •M 41 o rH 0) tH O 0 n) .e -H o 2 -M C o w M •D CJ -C T) T3 Oi 4) 4) CU 0) T3 -O > > > tJ C C rH rH rH .rl 4) 18 O O O (Xi . w tn tn w rH tn n 3 -rl -H .H -rl rH W co o o a D tn a, O 3 §3 i JJ en •o N tn 41 rH O 0) 18 fjj w er 41 rH O O rH 0 O IB an jj -" u rH 4) 01 T3 rH 41 41 KH JJ W 41 tn w ti 4) <H 0 JJ 0 0 -rl tn & w TJ 41 C rH O 3 4) -O O 4) O-JJ rl n o o c o m O O 41 -H > en-H u J«: tn 41 ^ 3 a rH M u tn 41 c •o DJ-H 3 JJ rH , 0 C rH 0) a 41 IB t3 3 0 E W 4! ..oS tn C 4) rH 10 S IB -P O » IB 4) •H JJ 41 w rl O •rl JJ XI X JJ 4) -a c 41 w IB > 4) Q > rH S3 •rl O 18 "" I -O c at 60 0) o u-i O -fO (8 41 •rl ja 01 c 18 Ui-H rH E •rl O 4) IB o ,n > JJ >B 0) Vj JJ % tu a c: £ 41 o s o , .rl U JJ 13 IB 18 41 O JJ O O O JJ 1 m u cn tn 3 w tn c •r\| O rl -H 0) 4> IB ff! W W IB OT O O 5 's> I JJ TJ C'O) •8 C rH -rl e 18 O 1 c •rl 0) JJ IB 83 U rH a ro H r- 01 rH 4) £± JJ W C O O £ O O 01 tnJJ OljJjJr-lrldCW C 18 U O S -H 18 ft) 18 fi CO O JJ > c J^ tn O W -rl 4> O JJ O _ c .n o) -H x cn w O JJ JJ W 4) 41 CO O 3 IB JJ £! •H tn jj o tn >,jj tn C 'rl O rH C C 41 VIH O rH C 18 01 749 ------- \J £ . •?- v j~ !>• ^ ±» i IL1" . v. i5 $4* > \ ^vj^ I^^O ^ ^\ 5^-5 cy ^ ir &}• $ u K 750 ------- Figure 172-1-2 Combination Add Pickling - Continuous Annual Cost = Based on Ten Year Capital Recovery + Interest Rate 7% + Operating Costs Include Labor, Chemicals & Utilities + Operating & Maintenance Costs based on 3.5% of Capital Costs Cost based on 1,255 kkg/day (1,384 tons/day) steel processed. This graph cannot be used for intermediate values. 520,495 E-i CO o o A (BATEA- BPCTCA) Chromium Nickel Iron 20 40 60 80 100 PERCENT REMOVED 751 ------- CM 1 CO CD W t-) m ft. EH CO W 2 H W O H D CJ W Z 0 H EH H S H 1-1 EH Z W D 6-1 U. w 1 rtj W EH «J 3 EH •O C ID U Q •rl 04 O 4J (rt S O c •H I ^^ CJ •rl ft. •a •rl O < C o • rl ^J id c •rl E O U ^•4 K O pd EH rtj ^j 0) D co 2 — O a EH — H N D CO » W O EHO grHOf H<« f-fH X WON UfH W ~ C2 ^< C5 S o EC U £H E™* fc M J£ ^H EH 03 j C K Z C 0 ^, fN ^« rH N w o Z E O M s . EH CQ H J E — K5 "0 J^ V i-l U 41 nl C 4J O C O 3 e rH 0 y^ C 4-( _j (A nl u 41 fj> P C •rl -rl • rH -O H rH a as EH CN 41 CQ to •rl -— rf» E O 11 «P W 4J V 5! W rH S >i is co w tr n o O o H4 f* in — in CN o 0) « i « • 3 "O inoooHin rH4) CNrH rH IS tO > 10 i O 9> ^ • 0) 5 r< OV rH O 41 1 Q Jj ^j o rtj Cu (0 t A S VO OH ^4 41 tyi ocNinr-cr>co O, OJ C "OO\rHOCN'y1 V'rl r-CNOOO=» 4JWrH ooocoo to o oooooo EOO Suspended Solids Oil and Grease (5) Dissolved Chromium Dissolved Nickel Dissolved Iron Fluori.de pH S rH tu § (0 rH W (0 BIM I 01 O W M rH W ID W B C 0> H 0) IS T< -H £ J-l O «4J .r» JJ C rH t) W (!) -H C .H E O ra x -u a 01 ID l 41 W rJ 01 T3 C5 5 O "3 «J 41 M-l> 4> 0 O • 10 O rH rH 4J IS O C -H IS C O <4H .Q O -O O O 01 DI O 01 -H > t i-H c! VJ tji -H tfl -iH •* T) -rl UJuJtOtlrt-POIP 4i^3O>l'-PcT' DJ ^ W U 4J W U C 01 flj Di IS 4* E O U c D 4J O C O •H Eco'OM o c w 4J .,H 0) -H M c 4J V) O OlitlOiOiO E O .C UH -rl 4" 73 4J 4J TJDlJWMllCUC 41 .W W O P O O 'rl 4) M rH C a rH P rH CN O 01 CN U O ' «H no O T3 Q> 1) P O « "H •P JD rH ° '^ r? u P o 4J 41 41 O O E O 01 C tfl -P W O C CO P -H O rt5 ^ •H 'iH CT^TJ >- 4J O 11 rH ' 4J O O 'H O I 3 3 C 3 4) r) (0 § 0 o 4> •H A E 8 0) V4 H) • 0> 4J 0) C 4) r( O 41 c! 41 u o P 0) a W C ^lO'-PcS OCCOO .rl , : Q E n) 41 o > 4J o us m 4> C "9 •rl £ >. •P rH C 41 •rl S -P 0 • W rH .P •rl rH C X id 41 4> E H3 U^3H 6-P-rl-O V O O 0 ^ -H .X £ < atj P &.P M -rl M O X? O C H in 752 ------- ------- Figure 172-2-2 Combination Add Pickling - Batch Pipe & Tube Annual Cost = Based on Ten Year Capital Recovery + Interest Rate 7% + Operating Costs Include Labor, Chemicals & Utilities + Operating & Maintenance Costs based on 3.5% of Capital Costs Cost based on 19 kkg/day (21 tons/day) steel processed. This graph cannot be used for intermediate values. CO CO EH CO O u 23,782 A (BATEA- BPCTCA) CHROMIUM NICKEL IRON 20 —r~ 40 60 100 PERCENT REMOVAL 754 ------- pH Within the range 6.0 to 9.0. This applies only when these wastes are treated in combination with cold rolling wastes. Pickling-Hydrochloric Acid-Mahoning Valley: Rinses Effluent Effluent Characteristic Limitations Maximum for Average of daily any one day values for thirty consecutive days shall not exceed (Metric units) kg/kkg of product (English units) lb/1000 Ib of product TSS* 0.0627 0.0209 Dissolved Iron 0.0249 0.0083 Oil and Grease* 0.0249 0.0083 pH Within the range 6.0 to 9.0. * This applies only when these wastes are treated in combination with cold rolling wastes. Concentrates: There shall be no discharge of process waste water pollutants to navigable waters. Fume Hood Scrubbers:. Effluent Effluent Characteristic Limitations Maximum for Average of daily any one day values for thirty consecutive days shall not exceed (Metric units) kg/kkg of product (English units) lb/1000 Ib of product TSS* 0.0156 0.0052 Dissolved Iron 0.0063 0.0021 Oil and Grease* 0.0063 0.0021 pH Within the range 6.0 to 9.0. 755 ------- Z ? 8 X Q W w o EH O H rt! « EH EH X WON W En V» 1-1 «-i I 0) O W U W IT) tn m m r- w ^J m EH s z H J H Q s o z o LJ a EH M s H kJ EH § t> fc! H 1 EH 2 4J IT) m 01 .c 4J O Cr C •rl ,_) Xi o •rl O. T3 H 0 •0 •H 4J IT) C •H .Q E 0 U Oi CM H ffl CO CO z o H EH EH H E M r3 ff a EH CQ — , PI ^ >H U o ij 0 z u w EH fr w g i EH (& tJ O \|-y J2 o CJ ^^ rj ^•« rH X E « ( ~] ^•h iH O •— O e«o X X X CQ « ~ g O Q. m to rtj M s 2 CO in l/l CS 0 • t t 1 in o o o i-i in CM H H 0 1 Q\ J, 9 JD o^ ro «• (M oo in O 00 O O O (M (N O O 0 0 rH O O O O O O O O O 0 0 0 M ID 0) 4J (X C o 4J 0 c 01 C 3 O rH C UH H 0) H . It) (A 4J .H a j vn o eo 01 «•* CD •H -~ E O 0) 4-J 4J X to H co tn rl O o o >W (N O ** 3 -O H 0) 10 10 > CO t 01 -I-. 01 U rl rH 0 W A H 4J O H rl 01 (7> a. oi c 4J .r\| 4J tO rH to o so 8 CD - pu 4J 41 0 0 •H j' lj Jj rH H 4J IT) •H IT) C J3 O T3 IT) cr o 0) rH C rl •H -H T3 -H ITJ 4J 01 3 > o) -u tr (Tj ex id o) » 0 -H C O t3 M O C 4J I 'rl 0) -H CO 4J M O I it) 0) (U O o o e 01 U 01 -rt C I -D E 4J in 3 W "••* H •O E ! C rH CO U O O o > > -a C C H H H ------- .,„.»,!• _. , ,,.-.,!„* «SSSSWSS! ------- Figure 172-3-2 Combination Acid Pickling - Other Batch Annual Cost = Based on Ten Year Capital Recovery + Interest Rate 7% + Operating Costs Include Labor, Chemicals & Utilities + Operating & Maintenance Costs based on 3.5% of Capital Costs Cost based on 131 kkg/day (144 tons/day) steel processed. This graph cannot be used for intermediate values. 0 20 ?frc.fr>f "Re-?" Of e 758 ------- 88 §° gj H< e- 0 0 CO 0) K K O H 0) EH H < 10 H O H CO H 0) i-l C 01 fM i"4 e o frl ^ D ti fo 0£ W O O 1 w 8 S jrf Q « co X x ti 5 ^ g o z ffi H ^i H z Jg f-1 w g fed h-1 § e 0 u M U a > o c o r-4 O w C e •-I -H rf 3 M r^> P»I H CO O (J OX 03 1^ (0 CO ^l ^^ rf C e o W 0) 4J E 4J N < CO H CO >i Ifl W O> w o O o M . o o> •-. • 0) 0 U 0) rH 0 0) 1 O M ii H o M Oi nj < H . • J3 C-i 0 w »J M HO kJ —0 tr>o SiSN! HX-CO < 0-i-J \o o ^H M 0) C7^ (N O ^-4 O CM 4J .^ in o o o o w (n 1-4 O 0 O 0 O W O O O O O O £OO CO ?sh H W H Z •O C TJ TJ a> o> a) V •o i-i > o» > C HJ -H tJ H 01 > O -H O* a n) or e m (0 X CO rg (0 ' 0) >H ><-H K K Q O Q (X S T> § J H ^ -S ' O . a 01 18 4) IB 01 • 3 e y 4J o • ••«> o o -n Si-l 0> H 'D V m en w w in o o> O> a o r- 4J -H •H CO 0 4J c c u o « C W O +1 in S C fi w O O W-H q)ocre£OI-H K 0) rM 4-> O -U -U W 01 4J moo m +) M 4J CJ W >, C -H O •- M C.H 6 O U 41 JJ iJ 10 ^ E O'o-Hoc;i e c w w •rl&>C7>OO> kifl'OH M 4J O -i-l (XT) C 0) rt 4J -H i-l i> O> 0> •"< 4J E H C C ^ U .C -H >-, HI Vj 41 O fl U lj 0> & 0) £ <8 +J a -P o > 0) O 0) W 6 0) X-Q e It) r-l 0) n> M .Q H >H en m £ O >H -H (A 4J w w •H E U •-< -M -H o> +; Jd \|j -co 9 aw o> IT) O « w4 E O W 4J J 4J 0> -H CO C O i 0) - -H -H " sa-b 0 759 ------- •<; » x • 6 S M si d> P, Q> -v 55! t IT >?£ w I fcs 760 ------- Figure 173-2 Scale Removal - Kolene Annual Cost - Based on Ten Year Capital Recovery + Interest Rate 7% + Operating Costs Include Labor, Chemicals & Utilities + Operating & Maintenance Costs based on 3.5% of Capital Costs Cost based on 26 kkg/day (29 tons/day) steel processed. This graph'cannot be used for intermediate values. 23,702.- 4- BA I Of 761 ------- 88 M < S (0 I H D co a M M a 2 S H £ r, H I 5 EH (0 O CO 01 T) •H W z o g £4 M H -l rf W H m (5 Q r^ O 0 ^ t4 § g W a EH Id o £ o o c 0) en 3 C H.rl 4) H V4 01 0) — 4J O 14! GO 4J O OS f> OH O in 10 cu ^ m to •rl O « E 0 4) C IW 0 -rl OH CN ^ i in in DUO CN O in O 3 CM O .... H 0 in 0 O 0 rH (OH (N > 4) -P o oi u . 4) 4J (0 01 H CO 4V •Q l^J l+j Q •» ^ H~o ^-0 dS r-l N« Ci ,J I .900 vc 0 ^ t7^ C r-irrnino QtX Q in i-< o > iO H H > O O m m in X to w 4) -H -H K cc a a a •O N 4>H (0 ID in tr (V i 8O r O b (N QoH > IB 0) T) H 41 4) 4 4J (0 01 W W M 4) tU Q 4J 0 O -rl. (0 Q< (A TJ 4» C H O 3 4) T) O 0* ajj w to o o c o o H > tn-H 0) .* 3 a H u o w 41 c T) Q.-«4 D 4J H Q CH • T) C to e oi H 10 6 O «. «S 4) •H ; 4» W E (A M 0 01 -rl J 43 J3 X -P U 0) TJ C 01 TJ M (0 t> C 4) 0 (0 > H Jj •H O 10 ?^iJTJ io e g oi H M o u 01 U >H i JJ l-l 4-1 &i (0 •H c 0 JJ 4J a (0 0) c 4J W +J 0) oi • o> a e E c £ o) a) 0 3 O H O u H 0) trj 4> e o w q 4J O O 4J (8 H 01 4) •-( "O -H C w M 4> .^ 0) -rl ->i0V43 OHCr. CT« 0 O tt) CP WV^MCC C U O ? -H 0 n) C W O +> -HIH.3 C 4^ 0) 4J UOM-H m.CQ>.ri X 4J u j u v> v 3 a m 4J E M 4J O W >1 U C -H O rH a> c «j IM u 1-1 a o e .H s J T> r-t B 4J X! H -rt U • O C 0) 73 4J >«4J U M >< C C U 0> •HOienOO) » nj TJ XJ ti 4J O -rt CUT) G 0) (0 4J -i-l H 4J O) 4) -rj 4J EHCC lO-HSO ^ jC •rl >• 0) H -H -H a W E E <0 ' o > . aw- u 0) co I 01 >0 O • -H I H E O W 4J (7< -H iH -i-l M 0 H •<-! (0 JJ C O H 41 .4 -H x E «« O H X 4* <0 4(j IM oi d ------- 763 ------- Figure 174-2 Scale Removal - Hydride Annual Cost = Based on Ten Year Capital Recovery + Interest Rate 7% + Operating Costs Include Labor, Chemicals & Utilities + Operating & Maintenance Costs based on 3.5% of Capital Costs Cost based on 55 kkg/day (60 tons/day) steel processed. This graph cannot be used for intermediate values. \oo •fere en"! 764 ------- 03 U O z c H -rt S Jk! Q 0 M .rt D A w c Z m o H & EH C rt 'rt EH -P 1"^ tf S 0 M O tJ D 1 S p h >» b> « W O 1 W S o rt O 0) CQ s? "^ EH D W fdO (HO ^ Hrt EH tn WO W EH W § M rt S 33 •"•• H H t-4 • e g X v» , i i eri 9 •N i M i i IM 0 o> _fr* S C5 S o 1 EH g S rt H &£> g K g O O M 41 P- ^1 41 3 rH 0> CQ 0) •rt rH 3 CO 0 H ft ^ PH CQ W -rt H i 52 ^ rt CQ CO rN g E tn tn in in CN (N O (N i I i 4) i t i • o in o 3 vnOOrHOrHrH rH CN (8 > o • 41 ^^ »~H 1 A 0 (8 ^m. PQ O o tro rij ^ r- t . w x x g^ m x j Jflj m . T M » X) wO O w ^rHf-t^— IrHCNtN OOOOO^vOO «P •HOOOOOOO W OOOOOoOO S 03 OS U H W e ,-rt -rt -rt -rj rrt-rt « r-» tr C •rt rH O JJ IT) d 0 u o H Id Q, •rt •a o X 4J. "c 0 4J X en o o 0 ^ T3 01 (A (I) Q 8, • rH M 41 -P 40 (8 1 ^ C O •O \ 4) H 0} (fl w tr> a> o o 0 o M O rH 4) T3 4) 4) •P n (0 CO 41 <4J O 0 6 W CO DJ T) C rH 2 * O 41 Oi-P ffl O 0 <« 0 O rH M ^ a^ n a! TJ Pi C a +-' as n rl rH O <H T3 4> 41 CQ CQ CQ U 41 41 U 4J O -rt M rH f) rH r^ 41 rH _jj CQ C 0 o o 4> e CQ S JS O (H •rt O) lj ^1 41 rH E rl 41 s.a 0} E R) rl CT (Ji-rt O rH rH rH « E 4) H .a •rt CO CD 0 a H f-H (8 JJ O 4) 4i U 4J •rt CQ g TJ M g 41 > •rt W rH g .4 rH rH m >. H •rt S CQ 41 O § •P O C w a> CO i-H >i tr o o o 41 41 2 (8 rH •rt (8 rt "* \| to 73 O -G 4J E 4J 4) E (0 4) •P O n g •rt •P 4J 3 E 4) rl CQ 0 ') p •rt JD u H IN m fc 0) rH U •rl E 0 T? c (0 t3 c rH 0 •p •rt rH •rt jQ (8 H •rt (0 (8 k C O •rt •P io o o rH W (8 (A M S O l n) n •P Q O ^^ fit 4^ c 0) > X > A at in O 4) -rt TJ y a C "H » (8 > 41 W »« 41 4} "f4 tn w P 3 £3 "Stf W (S (fl 01 41 IH > M •rt > a> •P CD (C-a o 5S5 •8 H 4) H O > O^ C (fl G 0 •rt o -a •P 4) 1) TJ M a 4) -rt E 4J 3 o a v O O 4) •rt M 4) T3 W C W 0> -rt +J x: (o 3 0) O xs-o 4> "^rH 4J i> (0 O CX 4J 41 41 e H O 4) 4> 0 E tfl m 4) CJiV C O 'rt H TJ O 41 >i C rl rH £ -rt C O 3 O 41 C JJ 0) 41 rl M •P IT) C U 41 c e 6 0 9 •P -rt O J> J X3 rl 5 •P -rt (0 MH M »-rt W T3 -a o rtj i"H QJ ^i fl •P fl O 41 -rt •rt 4) •P 0) (fl M E HMH w W O W •p C (fl rH a (fl e •rt ' t/i C •rt V 5 SN H g o a 8 m (0 01 4J (0 (8 D< c •rt H H a •o o o ,f* ___J •s T) 4) C •rt •8 8 2 w 0) (0 <8 Ss 01 n 0) ^j 1 i .^ rH 0 $ rH -p' H C ££ O i3 n) n) O v H rl JJ n H IM ^^ 765 ------- ------- Figure 175-2 Wire Pickling and Coating Annual Cost = Based on Ten Year Capital Recovery + Interest Rate 7% + Operating Costs Include Labor, Chemicals & Utilities + Operating & Maintenance Costs based on 3.5% of Capital Costs Cost based on 497 kkg/day (547 tons/day) steel processed. This graph cannot be used for intermediate values. 0 •2.0 10 ti' C,c \oo 767 ------- a w w o H H E-< W O W EH vo O1 f> W S EH W W SS M J W o H D O tfl O H t gn H £ M g B £ t. w 1 s Jj. W ^ O 3 PI O •i-i E e o flj t5 0) H O E^ 0) M C SB •rt F 3 fi> j< a M Si ft. to 3 iJ 0 O D « ^ & •H e •P O e u o rl O 0) m pt 4J C c o 0> 3 C H O M-i C 0) •-! H 10 10 j^ 0) &i •P C •>: s U 0> H E-i 0 O O (NX p4 0) CQ to ^™" •rt S EC 0> 0 M 4J 4J £ WN u w to is >< in o o P", ^^ O fs O " M i-l J- N in o cs (w \n •t» * m . o H o 01 CM 3 TJ H in i CQ K 0 11) — DO • 01 O M W H 9> H O 4) H 1 A rl 4J <: H H ra HL_3 H •B* H r-l O tJ — O cro ft X. i-i wu: s E-i N CQ < CTiJ PP !i ** w ^ w wB H S cu O > fi- Hi-lr-l 0) O O 0 •• a w to to j to to to u> o 3 -rl r\| H W H 13 C 01 0 10 4J in s 0) H ' U <8 i QjO 4J in o i-H •— 0) 0) i-l 0) iQ 4-l 4J 0) 0) tn to u to U-l 0) 4-1 O O 'rl o w w C r! 0) • y tn -H -H x a> m o> u » O .rl •H i« > tO e c o> W O . 8 (0 C C 4) i U H > 4> O O O > « r-l C w • -. o O". W T3 « J 4) fl ax H ^ O -P tO rl C 01 a rH J o .P ^ c 18 Oi (Q 4) E O Ui » 0 -H C O T) W 0 C -P •rl Oi -H W i+J O S o 4-> CJ e O 0) O W 4J W 0 C CO -P -^ O 18 >i •rl 144 O^iO -P O 0) -H W WC.H o MH TD O t) 4» a) jj C 10 W 3 3 C 3 EWJS& vj o a) 01 C 01 ft O 4J we W Cr-P C 5 C it) -rl O W) T3 E J3 4J 4J 0 -H E Vj< ,» O 4> ^lVJt!Ei-ltfl 6 a) j >i •< x O (8 U O 01 >> 41 US J OliDMC >. r-4 Ei'-rt'dH JQ e a) >-i 41 -t4 4J fl W+J^JrHmE MtA 4) G W g o O M •••» 0 768 ~~------- to >»' m 769~~ ------- Figure 176-2 Continuous Alkaline Cleaning Annual Cost = Based on Ten Year Capital Recovery + Interest Rate 7% + Operating Costs Include Labor, Chemicals & Utilities + Operating & Maintenance Costs based on 3.5% of Capital Costs Cost based on 131 kkg/day (144 tons/day) steel processed. This graph cannot be used for Intermediate values. I O 0 770 ------- 4J £ iH rH 0> fd rd 6 •H p p 4J -H W •H O, D H U C H < rH P (0 id in EH P O < -H U m a. nj u> r ) TI f "x W U f-« rH C -rH cn " H id .p W g 3 ' 2 t) EH C <1) g M C ft g D r? 51 F z <: n Co --1 5 « o c S tS EH rH rH tl) CQ r-' nl nl C* ]3 (Si m id g 5 ' W -H .P P fi O EH P -H W ° •? W -H Q< OJ W «r O C id > OT g ^ o HOC M U !? Po U 0 S ft W M -H O {£ ° E- O" t-°Wu ° c 5 o> C9 CJ ,-. , b i H S FH ^ rH (d -p •2°° E- DM W c/3 KJ 3 £ (U 9 Jz; ^3 ^ ^ o ^ ^ M pf ^ „, f-\ ^"^ O OJ -M ^j W p_ n 14.4 g 0^^ E 0 n) j E- J3 O, ~J O ca cn co CO CO C"> oj 00 T oo vo c; o o m ro o ^ CN oo rH co vo r~- 01 r^ o CT> fO «.' jj. rH i — i r j o o m o oj f "3" vo cn zf ro Co rH cn ro r- o rH co o ro r— in oj cn L"; r~ o o cn r~ rH f~- <i r-^ ^ S V ** ^ •• rH C' VO ^ rH CM oj Os in cn o in in ^ co VO CO 3 rH rH rH in m o o o o r- oj o r-^ in cd rH oi oo CM in w 0) rH e id a) in -P a, 01 M p o in 0) OH (/I H Id rH 0) ^g ^ LO a, cu ii •H -P iiid in T) t) tjl -P rH QJ QJ Q) C W R« X) JJ -P f; VI O 1 1 EH H M H fd -H Cn U^ 0f^-p4-JpL3vUO fi( -H U id a _C rH -H (J O H P in rX id H o pa •H (Xi OOO OOov0-_Or" OCNO oororHinSo^- oocnco ovO0gQgQi/> 1 I/I O O III OVOr-io^O1" OOJrHCO OOO OVOinrH°oto lojoco ill cocncnoj'T.ooco •Hcnoi in vooTeSf-Tco if cn LO ^~. ^rooo'* oinin oinr^o ooo oj-cj'^^ r^^j-o movO'ySocn ooor-vr inrocn r~Or-»ojgc3cO cominoo rocor^ vor>-cMoj*io^~ •q-rorOrH rHooco rOrHCncMlOOLn r^r^vo vor~ro rooi-^cncno oJcn en"* vorHmrHrMcncM CM CM CO » !? OTOOJ o i/i in omcnojOo1"" 51 oinoJin comcM ^rinc-.r-,o'~] Jj VOrHinrH CO^Tin COCOcO^rO'"1 jj mcnr-in ininco cncnornoca O rovorHcn r-oi1^ rovooJvoO10 ^ cnvocMf vocnoj rocnojvo ** ^ 31 C C ^* ^-J ^J "H OJ r^l 1^ rH 4J £ ® 0) IH rj o -H m 01 HOG" DrH-PN rH£M\|\|j "O 4J -P g -W -H O ^^US g co1^ S'S.S'5 llft:^ ' -r\| -HrHW+T ZUJCJ"' P ^ ^ 23 m MUG 0011 Id ,UO.H S^J'fl •H-r( CO 'SO gl-llOB SH >H o o o -H '9 2 w * ••-; •'j 33-rH-rH -rHCrH CP Ji^^Q, H3J<^ >Mm^iHC"Poauic ??•-i-HOididai.H,1-;1.S (rt^^^» P4JMMce;.rHXl(l)O>Cc-'c-'H'>, O'O-O'"' CCIM'U O(5HCJrHM_,_.0)o (J - — O 00>, >, TJWO-H ------- SECTION XI EFFLUENT QUALITY ATTAINABLE THROUGH THE APPLICATION OF NEW SOURCE PERFORMANCE STANDARDS INTRODUCTION The effluent limitations that must be achieved by new sources are termed new source performance standards. New Source Performance Standards apply to any source for which construction starts after the promulgation and publication of the standards. The standards are determined by adding to the considerations underlying the identification of the Best Practicable Control Technology Currently Available, a determination of what higher levels of pollution control are available through the use of improved production processes, and/or treatment techniques. Thus, in addition to considering the best in-plant and end-of-process control technology. New Source Performance Standards are based on an analysis of how the level of effluent may be reduced by changing the production process itself. Alternative processes, operating methods, or other alternatives are considered. However, the end result of the analysis is to identify effluent limitations which reflect levels of control achievable through the use of improved production processes and practices (as well as control technology) rather than prescribing a particular type of process or technology which must be employed. A further determination is made whether a limitation permitting no discharge of pollutants is practicable. For purposes of developing the BPCTCA and BATEA technologies and limitations, the industry was divided into the following subcategories: G. Basic Oxygen Furnace (Wet Air Pollution Control Methods) K. Vacuum Degassing L. Continuous Casting and Pressure Slab Molding M. Hot Forming - Primary N. Hot Forming - Section O. Hot Forming - Flat P. Pipe and Tubes Q. Pickling - Sulfuric Acid - Batch and Continuous R. Pickling - Hydrochloric Acid S. Cold Rolling T. Hot Coating - Galvanizing U. Hot coating - Terne V. Miscellaneous Runoffs W. Pickling - Combination Acid-Batch and Continuous X. Scale Removal - Kolene and Hydride Y. Wire Pickling and Coating 773 ------- Z. Continuous Alkaline Cleaning With the exception of the Hot Coating - Galvanizing and Terne subcategories and the absorber vent scrubber on the hydrochloric acid subcategory, there are carbon steel plants in all other categories which are presently achieving the BATEA effluent limitation guidelines. This in itself justifies the fact that technology is available and demonstrates that the limitations can be achieved on a day by day basis. Therefore, in those subcategories where an existing facility is currently achieving the BATEA guideline BADCT is the same as BATEA and the New Source Performance Standards are the same as for BATEA. In the subcategories apart from these the flow basis corresponds with the BPCTCA technology but with the BATEA concentrations. NSPS DISCHARGE STANDARD For the following subcategories, refer to rationale as discussed in Section X - BATEA. G. Basic Oxygen Furnace (Wet Air Pollution Control Methods) K. Vacuum Degassing L. Continuous Casting and Pressure Slab Molding N. Hot Forming Section O. Hot Forming Flat P. Pipe and Tubes Q. Pickling - Sulfuric Acid - Batch R. Pickling - Hydrochloric Acid (if spent liquor is neutralized) S. Cold Rolling V. Miscellaneous Runoffs W. Pickling - Combination Acid-Batch and Continuous X. Scale Removal - Kolene and Hydride Y. Wire Pickling and Coating Z. Alkaline Cleaning For the remaining subcategories: M. Hot Forming Primary The New Source Performance Standards are based on the performance of the best carbon steel plant operating today. Using direct transfer of technology, the guidelines for this category were scaled up to reflect the higher water use rate for alloy operations to arrive at the New Source Performance Standards for alloy plants. R. Pickling - Hydrochloric Acid (B) Absorber Vent Scrubber 774 ------- If acid regeneration is used the NSPS limitations are based on the BATEA treatment technology (and concentrations) and on the BPCTCA waste volume; i.e., recycle of the regeneration unit acid absorber vent scrubber water is not a basis for the NSPS limitation. Thus with acid regeneration, the NSPS limitations are based on a flow of 833 1/kkg (100 gal/1000 Ibs) as in BPCTCA limitations. The recommended recycle of scrubber water is BATEA technology which has not been practiced as yet on an actual operating acid recovery unit although one surveyed plant is modifying their system to accomplish this. For this reason, the NSPS limitations were based on once-through discharge of the treated scrubber waters. For rinse water flows, and for fume hood scrubber flows, the NSPS limitations are the same as the BATEA limitations. T. Hot Coating - Galvanizing U. Hot Coating - Terne New source performance standards (NSPS) for these subcategories use the same flow basis as the effluent limitations for BPCTCA. As yet, neither recommended BATEA flow reduction technique has been applied to full scale galvanizing operations, although they are used successfully in pickling operations and in gas scrubbing systems in iron and steel furnace operations. However, all parts of the end-of-process treatment technologies are currently in use at existing plants in this subcategory. BATEA concentration limits were therefore used to establish loads, even though BPCTCA flows had to be used. 775 ------- SECTION XII ACKNOWLEDGEMENTS This draft, contractor's reports from which this document was prepared was written by the Cyrus Wm. Rice Division of NUS Corporation, for the Carbon Steel segment and by Datagraphics, Inc., for the Alloy and Stainless Steel segment. The preparation and writing of this document was accomplished by Ms. Patricia E. Williams and Mr. Edward L. Dulaney, Project officers, EPA, Mr. John G. Williams, Assistant Project Officer, EPA, and through the efforts of Mr. Thomas J. Centi, Project Manager, Mr. Joseph A. Boros, and Mr. Wayne M. Neeley of C.W. Rice, and Dr. Henry Bramer, Project Manager and Mr. Edward Shapiro of Datagraphics. The support of the project by the Environmental Protection Agency and the excellent guidance provided by Mr. Walter J. Hunt, Chief, Effluent Guidelines Development Branch, and Ms. Patricia E. Williams and Mr. Edward L. Dulaney, the Project Officers, is acknowledged with grateful appreciation. The members of the working group/steering committee who coordinated the internal EPA review are: Walter J. Hunt - Effluent Guidelines Division Edward L. Dulaney - Effluent Guidelines Division (Project Officer) Patricia E. Williams - Effluent Guidelines Division (Project Officer) John G. Williams - Effluent Guidelines Division (Assistant Project Officer) Hugh Durham - Office of Research and Development Lee Evan Caplan - Office of General Counsel Barry Malter - Office of General Counsel James McDermott - Region V, EPA Matt Miller - Region III, EPA Dennis Ruddy - Office of Permit Programs Robert Burm - Region VIII, EPA Al Brueckmann - Office of Planning and Evaluation Steve Besse - Office of Planning and Evaluation The excellent cooperation of the individual steel companies who offered their plants for survey and contributed pertinent data is gratefully appreciated. The operations and the plants visited were the property of the following 777 ------- companies: Allegheny Ludlum Steel Corporation, Armco Steel Corporation, Avco Thompson, Bethlehem Steel Corporation, Branford Pacific Wire, Cabot Corporation, Carpenter Technology Corporation, Colorado Fuel & Iron, Copperweld Steel Corporation, Crucible Steel Company, Dominion Foundries and Steel Limited, Fitzsimmons Steel Company, Inland Steel Corporation, Interlake Steel Corporation, Jessop Steel Corporation, Jones 6 Laughlin Steel Corporation, Joslyn Stainless Steel, Kaiser Steel Corporation, Lasalle Steel, Latrobe Steel; Company, Lone Star Steel corporation. National Steel Corporation, Nelson Steel & Wire, Phoenix Manufacturing, Republic Steel Corporation, Sawhill Tubular, Sharon Tube Corporation, The Steel Company of Canada, Ltd., United States Steel Corporation, Universal-Cyclops, Walker Wire, Washington Steel, Wheatland Tube Corporation, Wheeling-Pittsburgh Steel Corporation, Wire Sales, Inc., and Wisconsin Steel Corporation. Acknowledgment and appreciation is also given to Ms. Kay Starr, Word Processing-Editor, to Ms. Nancy Zrubek and Ms. Alice Thompson of the Effluent Guidelines Development Branch secretarial staff, for their efforts in typing of drafts, necessary revisions, and final preparation of the original documents and revisions. 778 ------- SECTION XIII REFERENCES 1, Aarons, Ralph and Taylor, Robert A., "The DuPont Waste Pickle Liquor Process", Proceedings of the 22nd Industrial Waste Conference, Purdue University, pp. 120-125 (1967). 2, Adams, J. I. and schaeffer, G. H., "Five-ton Vacuum Induction Melting Furnace", Iron and Steel Engineer Year Book, 1965, pp. 123-129. 3. Allen, Jones E., "Tin Line Conversion to Chrome", Iron and Steel Engineer, 47, pp. 88-92 (May, 1970). 4. Allison, R. J., et al, "Method for the Regeneration of Hydrochloric Acid from Spent Pickle Liquor and Like Solutions", United States Patent, 3,669,623, (June 13, 1972) . 5. American Iron and Steel Institute, "Annual Statistical Report, 1972", Washington, D. C. 6. American Iron and Steel Institute, Directory of Iron and Steel Works of the United States and Canada, American Iron and steel Institute, New York (1970) . 7. American Iron and steel Institute, "The Steel Industry Today", Submitted by Domestic Member Companies of-American Iron and Steel Institute, pp. 1-38 (May, 1971) . 8. Anderson, J. R., Luttinger, L. B., and Schwoger, W. L., "Gravity Dewatering of Metal Hydroxide Sludges", Plating, 59, pp. 1,135-1,139 (December, 1972). 9. Andon'ev, S. M., et al, "Increasing the Service Life of Emulsions on Cold-Rolling Mills", Steel in the USSR, 1, p. 966 (December, 1971) . 10. Andrews, D. M. , "Regeneration of HCl Waste Pickle Liquor at stelco's Hilton Works", Iron and Steel Engineer, 48, pp. 53-55 (August, 1971) . 11. "Annual Review Developments in the Iron and Steel Industry During 1972", Iron and Steel Engineer, 50, pp. Dl- D48 (January, 1973). 779 ------- 12. "Annual Review Developments in the Iron and Steel Industry During 1971", Iron and Steel Engineer, 49, pp. D2- D52 (January, 1972). 13. Ardito, V. P. and Shaw, R. B. , "The AVR (Allegheny Vacuum Refining) Process", Iron and Steel Engineer, August 1972, pp. 58-65. 14. Armco Steel Corporation, "Limestone Treatment of Rinse Waters from Hydrochloric Acid Pickling of Steel", Water Quality Office, Environmenta1 Protection Agency, Project No. 12010DUL3171 (February, 1971). 15. "Ashland Inaugurates HC1 Acid Regeneration Plant", 33 Magazine, 10, pp. 30-32 (December, 1972) . 16. Ashmore, A. G., Catchpole, J. R. , and Cooper, R. L., "The Biological Treatment of Carbonization Effluents - I, Investigation into Treatment by the Activated Sludge Process", Water Research, 1, pp. 605-624 (1967). 17. Ashmore, A. G., Catchpole, J. R., and Cooper, R. L., "The Biological Treatment of Carbonization Effluents II, Studies of the Influent of Liquor Composition", 2, pp. 555- 562 (1968) . 18. "A Solution to Pollution 'Compound1 the Problem", Mechanical Engineering, 94, p. 49 (October, 1972). 19. Association of Iron and Steel Engineers, "The Hot Strip Mill Generation II", AISE, (1970). 20. Balden, A. R. and Erickson, P. R., "Reuse, Not Just Treatment...", Water and Wastes Engineering, 8, No. 1, pp. A2-A4 (January, 1971). 21. Balzhi, N. M., et al, "Effect of Water Quality on the Service Properties of Emulsion", Steel in the USSR, 2, pp. 810-812 (October, 1972). 22. Barker, John E., Getter, Richard W., and Pettit, Grant A., "Armco1s 100,000-GPM Mill-Scale Wastewater Treatment Plant", Water Pollution Control Federation, Journal, 4IN.2 Pt. 1, pp. 301-307 (February, 1969). 23. Barker, John E., Foltz, Verlin W., and Thompson, Ronald J., "Treatment of Waste Oil: Wastewater Mixtures", Chemical Engineering Progress Symposium, Series N.107, 67, pp. 423- 427 (1971) . 780 ------- 24. Barker, John E. and Pettit, Grant A., "Water Reuse", Industrial Water Engineering, pp. 36-39 (January, 1968). 25. Barnes, F. W. and Denner, E. J., "Armco-Middletown's 86 In. Continuous Hot Strip Mill", Iron and Steel Engineer, 47, pp. 59-69 (January, 1970). 26. Battelle Memorial Institute, "A State of the Art Review of Metal Finishing Waste Treatment", Federal Water Quality Administration U.S. Department of the Interior, Program No. 12010 EIE (November, 1968) . 27. Baughman, G. M., "Preparation for a New Product: Tin- Free Steel", Iron and Steel Engineer, 19, pp. 91-101 (September, 1972). 28. Baughman, M. D., "High-Speed Continuous Galvanizing Lines", Iron and Steel Engineer, 47, pp. 134-141 (August, 1970) . 29. Bayr, R. B., "Interlake's Water Pollution Program", Blast Furnace and Steel Plant, 57, pp. 370-373 (May, 1969). 30. Berkebile, David G., "Water Conservation by Reuse at Republic", Metal Progress, 98, No. 6, pp. 64-65 (December, 1970). 31. Berne, Francios, "Treatment of Industrial Effluents", Effluent and Water Treatment, Journal, 12, No. 4, pp. 2-5 Supplement C. 32. Bethlehem Steel, "Pollution Control: Bethlehem Meets the Challenge", Bethlehem Review, p. 9 (November, 1966). 33. Bethlehem Steel, "Pollution Control: Bethlehem Steps Up the Pace", Bethlehem Review, pp. 9-10 (February, 1969) . 34. Beyer, Stanley, "Continuous Regeneration of Ferric Sulfate Pickling Bath", United States Patent, 3,622,478, (November 23, 1971) . 35. Blackburn, T. L. and Dixon, Norman G., "Lone Star Steel's Cold-Drawn Tubing Facility", Iron and Steel Engineer, 48, pp. 37-47 (October, 1971). 36. Blanchard, Thomas A., "Incinerators for the Metal Working Industry", Metal Progress, 98, No. 6, pp..57-58, (December, 1970) . 781 ------- 37. Bland, Marshall, "Three Ways to Minimize Water Pollution in Cleaning, Finishing", Metal Progress, 98, No. 6, p. 60 (December, 1970) . 38. Blatchley, Peter G., "Steel Plant 'Descales' Waste- water", Water and Wastes Engineering, 9, pp. F14-F16 (November, 1972) . 39. Bongartz, Roy C. and Steffel, G. L., "Bright Annealing of Stainless Steel", Iron and Steel Engineer, November, 1973, pp. 43-47. . 40. Borgotte, Obering, "The Treatment of Hydrochloric Acid Rinsing Water and Concentrates in Wire Pickling Plants by Ion Exchange in Conjunction with HCl Process for the Regeneration of Hydrochloric Acid Pickling Solutions", Wire World International, 11, pp. 57-60 (March/April, 1969). HI. Borgotte, Obering, "Methods of Pickling and Problems of Effluent Treatment in Industries Which Use Iron and Steel", Wire World International, 14, pp. 49-53 (March/ April, 1972) . 42. Bowman, G. A., "Pressurized Deep Bed Filtration Systems for Hot Mill Scale Pit Water", Iron and Steel Engineer Yearbook, 1969, pp. 131-136 (1969). 43. "Brackenridge Adds Dual Waste Control Facilities", Iron and Steel Engineer, August 1972, p. 90. 44. Bramer, H. C., and Gadd, W. A., "Magnetic Flocculation of Steel Mill Wastes", Purdue Industrial Waste Conference, May, 1970. 45. Bramer, H. c. "Iron and steel". In Industrial Wastewater Control, New York, Academic Press, 1965. 46. Bramer, Henry C., "Progress Reports Closed Cycle Industrial Water Use System'.1, Engineering Society of Western Pennsylvania Annual Water Conference, pp. 167-171 (1971). 47. Bramer, Henry C., "Pollution Control in the Steel Industry", Environmental Science and Technology, 5, pp. 1,004- 1,008 (1971). 48. Broman, C., "The Operation of Pressure Type sand Filters for Hot Mill Wastewaters", Iron and Steel Institute, Chicago Regional Technical Meeting, pp. 143-147 (October 15, 1970). 782 ------- 49. Brown, Daniel L., "Recovery of Acid from Spent Pickle Liquor", Iron and Steel Engineer, 47, pp. 68-73 (September, 1970) . 50. Burtch, Jack W., "POR1 Hydrochloric Acid Regeneration Process", Iron and Steel Engineer, pp. 40-42 (April, 1973). 51. Carlson, R. F. and Shaw, R. B., "Stainless Steel Melting by Two Low Cost Processes", Iron and Steel Engineer, August 1972, pp. 53-58. 52. Caswell, Charles A., "Water Reuse in the Steel Industry", Presented at the National Conference of Complete Water Reuse Sponsored by American Institute of Chemical Engineer and Environmental Protection Agency-Technology Transfer, April 23-27, 1973. 53. Catchpole, J. R. and Cooper, R. L, "The Biological Treatment of Carbonization Effluent III - New Advances in the Biochemical Oxidation of Liquid Wastes", Water Research, 6, PP- 1,459-1,474 (1972). 54. Chalkley, Brian, "A Major Step Towards Anti-Pollution Pretreatment", Industrial Finishing, 48, p. 40 (November, 1972) . 55. Chalmers, R. K., "The Use of Water and the Treatment of Effluent in the Metal Finishing Industry", Chemistry and Industry, pp. 1,387-1,392 (October 31, 1970) . 56. Channabosappa, K. C., "The Use of Reverse Osmosis for Valuable By-Product Recovery", Chemical Engineering Progress Symposium Series, Water, 67, No. 107, pp. 250-259 (1970). 57. Clark, W. W., "Gary's 18-in. No. 2 Bar Mill", Iron and Steel Engineer, July 1972, pp. 41-46. 58. "Clean Up at Armco and Jones and Laughlin Tagged •Unique' and 'Biggest'", Irc-n Age, 210, p. 21 (November 30, 1972) . 59. "Cold-Rolling at Burns Harbor", 33 Magazine, 9, pp. 22- 25, (July, 1971) . t 60. Coleman, F. S., "Ohio Seamless Invests $232,000 in Pickle Liquor Treatment", Water and Wastes Engineering, pp. WWE/1 33-WWE/l 35 (May, 1968). 783 ------- 61. conley, Ronald C., "Armco-Middletown's 86 In. Tandem Cold Mill", Iron and Steel Engineer, 49, pp. 63-66 (July, 1972). 62. "Control Pollution Without Capital Outlay", Iron Age, 209, pp. 48-50 (March 2, 1972). 63. "Costs Dive as Weirton Reuses Mill Roll Coolant", Steel, 162, N.24, pp. 78-80 (June 10, 1968). 64. Council on Environmental Quality, "A Study of the Economic Impact on the Steel Industry of the Costs of Meeting Federal Air and Water Pollution Abatement Requirements, Parts I, II, and III", Washington, D. C., (July 27, 1972). 65. Croushore, John F., "Simonds Steel Utilizes Electrically Heated Annealing Furnaces", Iron and Steel Engineer, September 1972, pp. 113-115. 66. Culotta, J. M. and Swanton, W. F., "Case Histories of Plating Waste Recovery Systems", Plating, 57, pp. 251-255 (March, 1970). 67. Culotta, J. M. and Swanton, W. F., "Control for Plating Waste Recovery System", Plating, 58, N.8, pp. 783-785 (August, 1971) . 68. Culotta, J. M. and Swanton, W. F., "Recovery of Plating Wastes: Selection of Lowest Cost Evaporator", Plating, 57, pp. 1,221-1,223 (December, 1970). 69. Curran, J. and Machu, W., "Control of Pretreatment Pollution", Metal Finishing, 70, pp. 54-58 (October, 1972). 70. Davenport, John, "The Special Case of Specialty Steel", Fortune, November 1968, pp. 129-135. 71. Davis, W. R., "Control of Stream Pollution at the Bethlehem Plant", Iron and Steel Engineer, pp. 135-140 (November, 1968) . 72. Davisson, G. and Ullman, P., "Spent Pickling Liquors as Precipitating Agents for Sewage", Chemical Abstracts, 76, 10, p. 246 (1972). 73. Dean, John G., Bosqui, Frank L., and Lanouette, Kenneth H., "Removing Heavy Metals from Wastewater", Environmental Science and Technology, 6, pp. 518-522 (June, 1972). 784 ------- 74. 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"Today's Pollution Control Practices in the American Steel Industry", 33 Magazine, 10, N.I, pp. 33-36 (January, 1972) . 243. Toureene, Kendall W., "Wastewater Neutralization", Iron and Steel Institute, Chicago Regional Technical Meeting, pp. 99-117 (October 15, 1970). 244. "The Making, Shaping, and Treating of Steel", United States Steel Corporation, Pittsburgh, Pennsylvania, 9th Edition, 1971, 1,420 pages. 245. "Treatment of Wastewater-Waste Oil Mixtures", Federal Water Pollution Control Administration, Water Pollution Control Research Series, Program 12010 EZU, May, 1970, 137 pages. 246. "Universal-Cyclops Installs New Blooming Mill at Bridgeville Plant", Iron and Steel Engineer, August 1973, page 78. 247. "Up-Flow Filters Help Chicago Area Mine Mill Clean Its Cooling Water", 33 Magazine, 10, N. 6, pp. 50-51 (June, 1972). 248. U. S. Department of Commerce, Bureau of the Census, Census of Manufacturers, 1967, Washington, D. C. 249. U. S. Steel's Fairless Works, "Modifications to Fairless Pickle Line Improves Strip Quality", Iron and Steel Engineer, 48, p. 87 (November, 1971) . 250. "U. S. Steel's 'Texas Works' Euilt With Ecology in Mind", Water and Sewage Works, 118, p. 241 (August, 1971). 251. Vorga, J. and Lownie, H. W., "A System Analysis Study of the Integrated Iron and Steel Industry", Battelle Memorial Institute (May 15, 1969). 252. Vasil'ev, V. I., et al, "Selection of Types of Equipment for the Clarification of Neutralized Iron Containing Acidic Wastewaters", Chemical Abstracts, 77, 4, pp. 349 (1972) . 798 ------- 253. Vivian, Gordon, "Disposal of Cyanide Heat Treating Wastes", Metal Progress, 98, N.6, p. 61 (December, 1970). 254. Wagstaff, R. S., Stock, G. E., and Layne, G. N., "Continuous Casting of Stainless Slabs at Atlas Steels Quebec Plant", Iron and Steel Engineer Year Book, 1966, pp. 479-484. 255. Walton, G. L., "Effluent Treatment in Steel Works", Metal Finishing Journal, 18, pp. 276-279 (September, 1972) . 256. "Water Pollutant or Reusable Resource?", Environmental Science and Technology, 4, N.5, pp. 380-382 (May, 1970). 257. Water and Sewage Works, 113, "Bethlehem Steel's Burns Harbor Wastewater Treatment Plant", pp. 468-470 (December, 1966) . 258. "Water Use in Manufacturing", 1967 Census of Manufactures, U. S. Department of Commerce, Bureau of the Census, MP67 (l)-7, April, 1971, 361 pages. 259. "Watkins Cyclopedia of the Steel Industry", Steel Publications, Inc., Pittsburgh, Pennsylvania, 13th Edition, 1971, 533 pages. 260. Weinberg, H. I., "Inland Steel «s New 80 In. Pickle Line", Iron and Steel Engineer, 49, pp. 70-76 (January, 1972). 261. Welded Steel Tube Institute, Member Companies, p. 2 (1967) . 262. Weymier, R. C., "Operation of Wastewater System at Inland's 80 In. Hot Strip Mill", Iron and Steel Engineer Yearbook, 1968, pp. 183-191 (1968) . 263. "When it Comes to Pollution Control, Steel Isn't Dawdling - It's Acting", 33 Magazine, 10, pp. 23-29 (January, 1972). 264. Whither Goest Thou, U. S. Steel Industry?", .33 Magazine, 9, pp. 36-55 (April, 1971) . 265. "Whither Goest Thou, U. S. Steel Industry?", _33_ Magazine, 9, pp. 50-55 (May, 1971) . 266. "Whither Goest Thou, U. S. Steel Industry?", 33 Magazine, 9, pp. 38-43 (June, 1971) . 799 ------- 267. "Who's on First In Wide Hot Strip Mills", 33 Magazine, 8, pp. 88-101 (March, 1970). 268. Wiedemann, Chester R., "Control Considerations in Washing, Painting, and Soluble Oil Removal", Metal Progress, 98, N. 6, pp. 66-67 (December, 1970). 269. Wiedmann, H., "Regeneration of Pickling Hydrochloric Acid by Liquid Anion Exchange", Chemical Abstracts, 76, p. 306 (1972) . 270. Wight, R. D., "A Unique Water System for an Integrated Steel Plant", AIChE workshop. Industrial Process Design for Water Pollution Control, Vol. 3, April 1970, 116 pages. 271. Wight, Robert D., "Water System for an Integrated Steel Plant", American Water Works Association Journal, 61, pp. 432-435 (1969) . 272. Wilcox, Michael S. and Lewis, Roy T., "A New Approach to Pollution Control in an Electric Furnace Melt Shop", Iron and Steel Engineer Year Book, 1968, pp. 839-846. 273. Wilthew, Robert M. and Davidson, Robert M., "Youngstown1s 84 In. Hot Strip Mill", Iron and Steel Engineer, 49, pp. 5363 (May, 1972). 274. Wittman, I. E. and Shephard, G. S., "Integrated Steel Pickling Rinse Water Treatment System", Iron and Steel Engineer, 49, pp. 69-71 (February, 1972). 275. "World's First Continuous Cold Mill Ready to Roll", 3_3 Magazine, 9, pp. 30-33 (April, 1971) . 276. Wykoff, Richard H., "Major Filtration Development at New Steel Mill", Water and Sewage Works, 117, pp. IW8-IW10 (July/August, 1970). 277. Yunghahn, R. J., "Profitable Pollution Control", Modern Metals, 26, p. 62 (July, 1970) . 278. Zievers, J. F. and Novotry, "Recovery of Mixed Rinse Water by Means of Ion Exchange", Plating, 58, N. 5, pp. 482- 485 (May, 1971). 279. Zievers, J. F., "Pressure Filtration of Clarifier Under-Flow", Chemical Engineering Progress, 67, N.12, pp. 47-48 (December, 1971) . 800 ------- 280. Zievers, J. F., Grain, R. W., and Barclay, F. G. , "Metal Finishing Wastes: Methods of Disposal", Plating, 57, pp. 56-59 (January, 1970) . 281. Zievers, J. F., Grain, R. W., and Barclay, F. G., "Waste Treatment in Metal Finishing: U. S. and European Practices", Plating, 55, pp. 1,171-1,179 (November, 1968). 801 ------- SECTION XIV GLOSSARY Acid Furnace. A furnace lined with acid brick as contrasted to one lined with basic brick. In this instance the terms acid and basic are in the same relationship as the acid anhydride and basic anhydride that are found in aqueous chemistry. The irost common acid brick is silica brick or chrome brick. Air Cooled Slag. Slag which is cooled slowly in large pits in the ground. Light water sprays are generally used to accelerate the cooling over that which would occur in air alone. The finished slag is generally gray in color and looks like a sponge. Alloying Materials. Additives to steelmaking processes producing alloy steel. Annealing. A process for producing certain physical properties in steel. The process consists of raising the temperature of the steel to a pre-established level and then slowly cooling the steel at a prescribed rate. Alkaline Chlorination. The oxidation of undesirable substances with chlorine under alkaline conditions. Alkaline Cleaning. A process for cleaning steel where mineral and animal fats and oils must be removed from the surface. Solutions at high temperatures containing caustic soda, soda ash, alkaline silicates, and alkaline phosphates are commonly used. Apron Rolls. Rolls used in the casting strand for keeping cast products aligned. Bar. A long, thin, relatively stiff steel shape. Bar is produced by rolling from billets. It can be round, square, hexagonal, or rectangular in shape. It is generally handled straight in cut lengths of 20 or more feet long as contrasted by rod (which may be larger in diameter than some bars) which is coiled in lengths of several hundred feet. Basic Brick. A brick made of a material which is a basic anhydride such as MgO or mixed MgO plus CaO. See acid furnace. 803 ------- Basic Furnace. A furnace in which the refractory material is composed of dolomite or magnesite. Basic Oxygen Steelmaking. The basic oxygen process is carried out in a basic lined furnace which is shaped like a pear. High pressure oxygen is blown vertically downward on the surface of the molten iron through a water cooled lance. Billets. A bar shaped intermediate steel product which is rolled from a bloom. While billets are usually smaller than blooms, all billets are not necessarily smaller than all blooms. Blooms are rolled from ingots, while billets are rolled from blooms. Bjllet Mill. The area and mechanical equipment for hot rolling blooms to billets. Black Plate. A steel generally used in the manufacture of containers. It is similar to tin-plate except that it is not coated with tin or any other metal. Blast Furnace. A large, tall conical shaped furnace used to reduce iron ore to iron. Bloom. A semi-finished piece of steel, which has a cross- sectional area that is square or slightly oblong and not less than 36 sq. in., that has been rolled or forged from an ingot. Blooming Mill. The area and mechanical equipment for hot rolling steel ingots to blooms. Slowdown. A relatively small bleed-off discharge, continuous or periodic, from a recirculated closed system. Briquette. An agglomeration of steel plant waste material of sufficient strength to be a satisfactory blast furnace charge. Carbon Steel. Steel which owes its properties chiefly to various percentages of carbon without substantial amounts of other alloying elements. Steel is classified as carbon steel when no minimum content of elements other than carbon is specified or required to obtain a desired alloying effect. Charge. The minimum combination of skip or bucket loads of material which together provide the balanced complement necessary to produce hot metal of the desired specification. 804 ------- Checker. A regenerator brick chamber which is used to absorb heat and cool the waste gases to 650-750°C. Cinder. Another name for slag. Clarification. The process of removing undissolved materials from a liquid by settling or filtration. Closed Hood. A system in which the hot gases from the basic oxygen furnace are not allowed to burn in the hood with outside air infiltration. These hoods cap the furnace mouth. Coagulant. A substance that enhances the aggregation of undissolved suspended matter. Coke. The carbon residue left when the volatile matter is driven off of coal by high temperature distillation. Cold Metal Furnace. A furnace that is usually charged with two batches of solid material. Cold Rolling. Cold rolling is a form of cold working which is the general term for reducing the size (or thickness) of an ambient temperature piece of steel. Cold working causes significant changes in the physical properties of steel. Cooling Bed. The area in a process line where product speed and temperature are controlled to provide a required cooling rate. Continuous Casting. A new process for solidifying liquid steel in place of pouring it into ingot molds. In this process the solidified steel is in the form of cast blooms, billets, or slabs. This eliminates the need for soaking pits and primary rolling. Descaling. The removal, through the use of high pressure water sprays, of the iron oxide scale formed on the steel product during hot forming processes. Double Slagging. Process in which the first oxidizing slag is removed and replaced with a white, lime finishing slag. Drags. Flat bed railroad cars. A drag will generally consist of five or six coupled cars. Duplexing. An operation in which a lower grade of steel is produced in the basic oxygen furnace or open hearth and is then alloyed in the electric furnace. 805 ------- Electric Furnace. A furnace in which scrap iron, scrap steel, and other solid ferrous materials are melted and converted to finished steel. Liquid iron is rarely used in an electric furnace. Electrolytic Pickling. Removal of surface scale and rust from steel by an induced current in an acidic bath. Electrostatic Precipitator. A gas cleaning device using the principle of placing an electrical charge on a solid particle which is then attracted to an oppositely charged collector plate. The collector plates are intermittently rapped to discharge the collected dust to a hopper below. Evaporation Chamber. A method used for cooling gases to the precipitators in which an exact heat balance is maintained between water required and gas cooling; no effluent is discharged in this case as all of the water is evaporated. Fettling. The period of time between tap and start. Finishing Mill Stand. The mill stand in a process line where the product is rolled into its final shape. Flocculation. The aggregation of undissolved suspended matter into larger conglomerates. Flux. Material added to a fusion process for the purpose of removing impurities from the hot metal. Flying Shear. A shear that moves with the product while operating. Fourth Hoie. A fourth refractory lined hole in the roof of the electric furnace which serves as an exhaust port. Fugitive Emissidns. Emissions that are expelled to the atmosphere in an uncontrolled manner. Fume. A collection of micron or submicron size dust particles. Horizontal Stand. A mill stand having the work rolls in a horizontal position which is parallel to the mill table. Hot Forming. The processes by which hot steel ingots are converted by rolling under pressure of steel rolls to slabs and blooms. The processes by which slabs, blooms, and castings are further shaped through rolling, forging, or 806 ------- extruding into various finished or semi-finished products such as plates, strips, pipes, bars, structural shapes, billets, and special shapes. Hot Metal. Melted, liquid iron or steel. Generally refers to the liquid metal discharge from blast furnaces. Hot Metal Furnace. A furnace that is initially charged with solid materials followed by a second charge of melted liquid. Hot Rolling. A form of hot working of steel where the steel is heated to about 1,800°F and passed through a rolling mill. Hot Saw. A circular saw used for cutting semi-finished steel pieces at elevated temperatures. Hot Scarfing Machine. A machine which utilizes oxyacetylene burner nozzles for removing surface defects from blooms or billets by desurfacing. Ingot. A large block shaped steel casting. Ingots are intermediates from which other steel products are made. An ingot is usually the first solid form the steel takes after it is made in a furnace. Ingot Mold. A mold in which ingots are cast. Molds may be circular, square, or rectangular in shape, with walls of various thickness. Some molds are of larger cross section at the bottom, others are larger at the top. Inhibitor. Any substance added to a solution that lessens acid attack on the steel itself, while permitting preferential attack on the iron oxides. Iron. The product made by the reduction of iron ore. Iron in the steel mill sense is impure and contains up to 4% dissolved carbon along with other impurities. See Steel. Iron Ore. The raw material from which iron is made. It is primarily iron oxide with impurities such as silica. Iron Oxide. Compounds containing metallic iron and oxygen in various proportions including ferrous oxide (FeO), ferric oxide (Fe2Q3) and magnetite (Fe2[O4). Kish. A graphite formed on hot metal following tapping. 807 ------- Lime Boil. The turbulence created by the release of carbon dioxide in the calcination of the limestone. Manipulator. A steel fingered device that seizes the bloom and turns it so that all four sides will be kneaded evenly. Meltdown. The melting of the scrap and other solid metallic elements of the charge. Mill Scale. The iron oxide scale which breaks off of heated steel as it passes through a rolling mill. The outside of the piece of steel is generally completely coated with scale as a result of being heated in an oxidizing atmosphere. Mill Stand. The portion of the mill eguipment that houses the work rolls. Mill Table. The portion of the mill equipment composed of a framework and small rollers used to convey product to, fromr or between work areas of a mill. Molten Metal Period. The period of time during the electric furnace steelmaking cycle when fluxes are added to furnace molten bath for forming the slag. Normalizing. Heating of the sheet to its upper critical temperature and then cooling at a rate which permits the proper ferrite grain size. Oil Quenching. A method of cooling which changes the chemical properties and structure of steel. Open Hearth Furnace. A furnace used for making steel. It has a large flat saucer shaped hearth to hold the melted steel. Flames play over top of the steel and melt is primarily by radiation. Open Plate Panel Hood. A 4.5 meter to 6 meter square, rectangular or circular cross sectional shaped conduit, open at both ends, which is used in the EOF steelmaking process for the combustion and conveyance of hot gases, fume, etc., which are generated in the basic oxygen furnace to the waste gas collection system. Ore Boil. The generation of carbon monoxide by the oxidation of carbon. Oxidizing Slags. Fluxing agents that are used to remove certain oxides such as silicon dioxide, manganese oxide, phosphorus pentoxide and iron oxide from the hot metal. 808 ------- Pass. The movement of product once through a mill. Pelletizing. The processing of dust from the steel furnaces into a pellet of uniform size and weight for recycle. Pickling. A process where scale is removed from the surface of steel by the action of strong mineral acids. Steel is usually pickled between the hot working and cold working phases of the operation. Piercing. The operation of making the hole down through a length of seamless pipe. Pig Iron. Impure iron cast into the form of small blocks that weigh about 30 kilograms each. The blocks are called pits. Pinch Rolls. Rolls used to regulate the speed of discharge of cast product from the molds. Plate. A product rolled from a slab. Plate is more nearly square than a slab which is generally much longer than it is wide. Plate is generally made by rolling slabs both crosswise and lengthwise to obtain greater width. Polyelectrolvte. A substance that enhances the flocculation mechanism. Pouring. The transfer of molten metal from the ladle into ingot molds or other types of molds; for example, in castings. Quenching. A process of rapid cooling from an elevated temperature by contact with liguids, gases, or solids. Reducing Slag. Used in the electric furnace following the slagging off of an oxidizing slag to minimize the loss of alloys by oxidation. Refining Oxidation cycle for transforming hot metal (iron) and other metallics into steel by removing elements present such as silicon, phosphorus, manganese and carbon. Reversing Mill. A type of rolling mill that passes product back and forth through the rolls or initiates rolling from either side of the rolls. Rinse Water. Water that is used for removing a concentrated solution from a material prior to further processing. 809 ------- Rod. A long, slender, generally round steel intermediate product produced by hot rolling. It is generally handled in coils of a hundred feet or more in length. Rolling Mill. The machinery and equipment that is used to change the shape and chemical structure of steel by passing the steel between rollers under pressure. Roughing Mill Stand. The first mill stand in a process line where the product receives its first reduction. Runner. A channel through which molten metal or slag is passed from one receptacle to another; in a casting mold, the portion of the gate assembly that connects the downgate or sprue with the casting. RunQut. Escape of molten metal from a furnace, mold or melting crucible. Scale. The by-product of hot rolling operations composed primarily of various iron oxides. Scarfing. The operation of removing surface defects from blooms, billets, or slabs (primary rolled products) before reheating for secondary reduction. This is done with a high temperature torch similar to an oxyacetylene cutting torch. Sheet. A product made by cutting strip into shorter lengths. Sheet is handled as a pile of flat pieces. Skelp. A narrow strip of hot rolled steel generally used in the manufacture of pipe. Skin Rolling. A cold rolling operation that effects a relatively light reduction in thickness of the rolled material. Slab. A thick, heavy, slab shaped piece of steel rolled from an ingot. It is the primary intermediate product from which strip, sheet, plate, etc., are made. Slabs bear the same relationship to the above products as blooms do to billets. A typical slab is 8 in. thick by 48 in. wide by 20 ft long. Slag. The mixture of the oxides formed during the oxidation of various compounds in the steelmaking and finishing processes. A product resulting from the action of a flux on the nonmetallic constituents of a processed ore, or on the oxidized metallic constituents that are undesirable. Usually slags consist of combinations of acid oxides with 810 ------- basic oxides, and neutral oxides are added to aid fusibility. Soaking Pj.t. A form of reheat furnace. Soaking pits are used to heat and equalize the temperature of ingots prior to putting them into a rolling mill. Spent Pickle Liquor. The pickling solution that has progressively become saturated with ferrous salts and the bath has become ineffective in removing scale. Steel. Refined iron. Typical blast furnace iron has the following composition: Carbon - 3 to 4.5%; Silicon - 1 to 3%; Sulfur - 0.04 to 0.2%; Phosphorus - 0.1 to 1.0%; Manganese - 0.2 to 2.0%. The refining process (steelmaking) reduces the concentration of these elements in the metal. A common carbon steel 1020 has the following composition: Carbon - 0.18 to 0.23%; Manganese - 0.3 to 0.6%; Phosphorus - less than 0.04%; Sulfur - less than 0.05%. Type 316 stainless steel has the following carbon composition .08%; Manganese 2% max; Phosphorus less than .045%; Chromium 16 to 18% and Nickel 10 to 14% and Molybdenum 2 to 3%. Steel Ladle. A vessel for receiving and handling liquid steel. It is made with a steel shell, lined with refractories. Stools. Flat cast iron plates upon which the ingot molds are seated. Strand. A term applied to each mold and its associated mechanical equipment. Steel. Any alloy of iron containing less than 1% carbon. Iron that has been refined. Strip. A long, thin, flat, wide piece of steel produced by hot rolling of a slab. Strip is handled in coil form. Sump. Storage area, normally located below ground level, used for collecting liquids or solids. Support Rolls. Rolls used in the casting strand for keeping cast products aligned. Tandem Mill. A rolling mill with more than one stand where the steel passes through the stands in sequence with each stand taking a reduction over that taken by the previous stand. 811 ------- Tap Hole. A hole approximately fifteen (15) centimeters in diameter located in the hearth brickwork of the furnace that permits flow of the molten steel to the ladle. Tapping. Transfer of hot metal from a furnace to a steel ladle. Tap to Tap Period of time after a heat is poured and the other necessary cycles are performed to produce another heat for pouring. Teeming. Casting of steel into ingots. Temper Mi11. A cold rolling mill that takes a very small reduction on the cold steel to alter its physical properties by cold working. Terne Metal. An alloy of lead and tin. Tundish. A preheated covered steel refractory lined rectangular container with several nozzles in the bottom which is used to regulate the flow of hot steel from the teeming ladles. Universal Mill. A reversing mill, which has vertical and horizontal rolls, used for hot rolling steel. Vacuum Degassing. A process for removing dissolved gases from liquid steel by subjecting it to a vacuum. Venturi Scrubber. A wet type collector that uses the throat for intermixing of the dust and water particles. The intermixing is accomplished by rapid contraction and expansion of the air stream and a high degree of turbulence. Vertical Stand. A mill stand having the work rolls in a vertical position which is perpendicular to the mill tables. Walking Beam Furnace. A furnace that conveys the product in a step type motion. Waste Heat Boiler. Boiler system which utilizes the hot gases from the checkers as a source of heat. Water Tube Hood. Consists of steel tubes, four (4) centimeters to five (5) centimeters laid parallel to each other and joined together by means of steel ribs continuously welded. This type hood is used in the basic oxygen steelmaking process for the combustion and conveyance of hot gases to the waste gas collection system. 812 ------- Wet Scrubbers. Venturi or orifice plate units used to bring waterintointimate contact with dirty gas for the purpose of its removal from the gas stream. Wetting Agent. An organic compound which lowers the interfacial tension between the steel and the liquid. 873 ------- TABLE 198 METRIC UNITS CONVERSION TABLE MULTIPLY (ENGLISH UNITS) ENGLISH UNIT acre acre-feet British Thermal Unit British Thermal Unit/ cubic foot British Thermal Unit/pound cubic feet/minute cubic feet/second cubic feet cubic feet cubic inches degree Fahrenheit feet gallon galIon/mi nute gallon/ton horsepower inches inches of mercury million gallons/day mile pounds pound/square inch(gauge) pounds/ton square feet square inches tons(short) yard TO OBTAIN (METRIC UNITS) ABBREVIATION ac ac ft BTU BTU/cu id BTU/lb cfm cfs cu ft cu ft cu in «F ft gal gpm gal/t hp in in Hg mgd mi Ib psig Ib/t sq ft sq in t y CONVERSION ABBREVIATION 0.405 1233.5 0.252 9.00 0.555 0.028 1.7 0.028 28.32 16.39 0.555(°F-32) 0.3048 3.785 0.0631 4.17 0.7457 2.54 0.03342 3,785 1.609 0.454 (0.06085 psig+1)* 0.501 0.0929 6.452 0.907 0.9144 ha cu m kg cal kg cal/ cu in kg cal/kg cu m/min cu m/min cu m 1 cu cm °C m 1 I/sec 1/kkg kw cm atm cu m/day km kg atm kg/kkg sq m sq cm kkg m METRIC UNIT hectares cubic meters kilogram - calories kilogram calorie/ cubic meter kilogram calories/kilogram cubic meters/minute cubic meters/minute cubic meters liters cubic centimeters degree Centigrade meters liters liters/second liter/metric ton kilowatts centimeters atmospheres cubic meters/day kilometer kilograms atmospheres (absolute) kilograms/metric ton square meters square centimeters metric tons (1000 kilograms) meters •Actual conversion, not a multiplier 815 ------- TABLE 199 CLASSIFICATION BY SUBCATEGORY Product or Operation Description Applicable or Most Appropriate Subcategory Abrasive Cleaning Alkaline Cleaning Aluminizing Armor Plate Axles Billets Billet Casting Black Plate Bloom Casting Channels Electric Resistance Weld Pipe Removal of oxides via treat- ment with abrasives Degreasing of steel in an alkaline bath Hot Dip Steels of special metallurgi- cal composition for use as armor Rolled, forged, and/or rough- turned, usually in one heating Intermediate shape between blooms and a wide variety of other finished and semi- finished products Continuous conversion of molten steel directly into billets Uncoated, cold rolled coils or sheets, usually temper rolled also Continuous conversion of molten steel directly into blooms See Structural Shapes See Pipe and Tube Subcategory Discussion No regulation required, single operation gener- ates no wastewaters Prior to a hot coating, see Hot Coating. For specialty steel, see Continuous Alkaline Cleaning No present regulation may be similar to Galvanizing Hot Forming-Flat-Plate Hot Forming-Section Hot Forming-Section Continuous Casting Cold Rolling-Direct Application; Combina- tion; or Recirculation Continuous Casting Pipe and Tube (Cold Worked) 816 ------- ,te» ate * .?0< & -• tsv^ t? t:^ ^66 ! 1 «& n ,t 00S ------- a °U*, a COD,.' ?-s, >eet ns 91 A §Ur ------- Direct Reduction Fence Posts Forgings Frogs Hot Coating Cleaning Operations Galvanizing-Post Coating Operating Gun Forgings Hoops Iron from Direct Reduction Units I-Beaas Molten Lead Annealing Nails & Staples Nut Rods Pilings Pipe & Tube Pickling Rails & Rail Joints Iron making via an alternate technique which replaces blast furnace operations See Structural Shapes Hot working of metal by hammering or pressing Crossover sections allowing rails to intersect each other Alkaline cleaning and acid pickling Hot rinse or chemical treat- ment (dichromate dip) See Forgings Narrow flat rolled product joined to form a continuous loop Iron making via an alternate technique which differs from conventional blast furnaces See Structural Shapes Hot dip, rinse and clean (acid pickle) Fasteners made from wire or small rods, sometimes coated before shipment Hot rolled shapes from which nuts and bolts are formed See Sheet Pilings Acid Pickling Hot rolled shapes used for laying tracks of various types No present regulation Not covered by this regulation Hot Forming-Section Hot Coating (Galvanizing or Terne) Hot Coating Hot Forming-Flat-Hot Strip & Sheet No present regulation No present regulation. Flows may be similar to Pickling and constituents may be similar to Pickling and Terne Forming is a dry opera- tion; for Coating - See Hot Coating subcategories or electroplating Hot Forming-Section Acid Pickling Hot Forming-Section 817 ------- Pickling for Cold Rolling Rings Rounds Sheet Pilings Slab Casting Spiegeleisen Spikes & Chains Submerged Arc (Pipe) Weld Mill Structural Shapes Tie Plates Well Casings & Couplings Wheels, Forged Wheels, Forged and Rolled Acid Pickling Hot rolled product cut from an ingot or round, center punched out, and rolled into a continuous ring Billets of circular cross- section, used in forming seamless pipe and tube, some axles and bars, and some forged products A special structural shape hot rolled from blooms into a variety of configurations Continuous or batch conversion of molten steel directly into slabs A ferroalloy containing 16-28% Mn, and less than 6.5% carbon Hot formed shapes made from rods or small bars in a variety of sizes 24" to 36", cold formed Standard hot rolled sections, such as I-beams, channels, angles, beams, tees, and zees Hot rolled shapes used for connecting other sections Special strength pipe and tube products for oil, gas and water wells See Forgings Forged wheel blanks further processed by hot rolling to produce a flange and tread Acid Pickling Hot Forming-Section Hot Forming-Section Hot Forming-Section Continuous Casting and Pressure Slab Molding Blast Furnace-Ferro- Manganese Hot Forming-Section Pipe & Tube (Cold worked) Hot Forming-Section Hot Forming-Section Pipe & Tube Hot Forming-Section 818 ------- Wire & Wire Products made by drawing rods Drawing is a dry opera- Products through a series of dies to tion; for other wire- greatly reduce diameters. making processes, see Product may be pickled and/or Pickling, Hot Coating coated prior to shipment or electroplating wire pickling and coating Subcategories Wire Pickling Acid pickling Acid Pickling or Wire Pickling and Coating for specialty steel 819 -------

 EPA 440/1-76/048-
 Group I, Phase II
  . / - -,- '7''.-t ,.)
-------
              DEVELOPMENT DOCUMENT
                      for
                 INTERIM FINAL
        EFFLUENT LIMITATIONS GUIDELINES
                      and
   PROPOSED NEW SOURCE PERFORMANCE STANDARDS
                    for the
FORMING, FINISHING AND SPECIALTY STEEL SEGMENTS
                    Of the
          IRON AND STEEL MANUFACTURING
             POINT SOURCE CATEGORY
                    Volume 2
                Russell E. Train
                 Administrator

          Andrew W. Briedenbach, Ph.D.
       Assistant Administrator for Water
            and Hazardous Materials
                 Ernst P. Hall
 Acting Director, Effluent Guidelines Division

            Edward L. Dulaney, P.E.
                Project Officer

           Patricia E. Williams, P.E.
                Project Officer

                John G. Williams
           Assistant Project Officer

                  March, 1976
          Effluent Guidelines Division
    Office of Water and Hazardous Materials
      U.S. Environmental Protection Agency
            Washington, D.C.    20460
-------
                         SECTION VIII

         COST, ENERGY, AND NON-WATER QUALITY ASPECTS
 INTRODUCTION

 This  section will discuss the incremental costs  incurred  in
 applying  the  different   levels    of   pollution    control
 technology.    The    analysis   will also   describe   energy
 requirements, nonwater  quality  aspects   (including   sludge
 disposal,  by-product recovery, etc.),  and their  techniques,
 magnitude, and costs  for  each level  of  technology.

 It must be remembered that some of the  technology beyond the
 reference level  is  already  in  use.   Also many  possible
 combinations  or permutations  of various treatment  methods
 are possible.  Thus,  not  all plants  will be  required  to add
 all  of  the  treatment   capabilities,  or   incur all of the
 incremental costs indicated to  bring   the   reference  level
 facilities into  compliance with the  effluent limitations.

 Costs

 The  water  pollution control  costs for the plants  visited
 during the study are  presented in latles   109 through  128.
 The  treatment   systems,  gross effluent loads, and reduction
 benefits were described in  Section  VII.    The   costs were
 estimated from data supplied by the  plants.   The1 results are
 summarized as follows:
') Process
Plant   Cost per unit weight of product
                          (1)
      $/kkg     $/ton     Product
  M.  Hot  Forming
A-2
B-2
C-2
D-2
E-2
F-2
G-2
H-2
1-2
J-2
K-2
L-2
M-2
N-2
0. 203
0.286
0.482
0.445
0.644
1.69
0.730
0. 161
1.81
0.809
1. 19
(NA)
0.604
0.925
0.184
0.26
0.437
0.404
0.584
1.53
0.662
0.146
1.64
0.734
1.08
(NA)
0.548
0.839
                                                    Hot
                                                    Rolled
                                                    Product
                                     455
-------
M.  Hot-Forming
    (primary)
N. Hot-Forming
    (section)
O. Hot-Forming
   (flat)
P. Pipe and Tubes
Ave
E
H
K
R
M
D
Q
C
H
K
0
R
0
Q
E
F
D
E-2
GG-2
HH-2
II-2
JJ-2
KK-2

0.284
—
0.203
-
-
None
0 -
0.417
—
1.894
0.739
-
—
0.052
0.491
-
None
0.927
(NA)
(NA)
0.378
0.397
0.093
0.696
0.258
_
0.184
—
—
None
-
0.378
.
1.718
0.670
—
_
0.047
0.445
—
None
0.841
(NA)
(NA)
0.343
0.360
0.084




Steel
Rolled





Steel
Rolled



Steel
Rolled

Pipe
and
Tubes


                    Ave

Q. Pickling-Sulfuric
   Acid-Batch Cone. 1-2
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                    P-2
                    Q-2
                    R-2

                    Ave

   Sulfuric Acid Batch
   Pickling          R
   Batch Rinse
1-2
1-2
P-2
Q-2
R-2
S-2
0.264

0. 122
0. 115
(NA)
(NA)
0.0507
0.679
                    0.407
1.80
0.353
1.98
0.319
0.373
1.63
0.320
1.80
0.289
0.338
                    0.875
0.0239

0.0111
0. 104
(NA)
(NA)
0.046
0.616
                              Pickled
                              Product
                                                  Pickled
                                                  Product
                              456
-------
    Continuous
 Ave

 T-2
 R.  Pickling-
    Hydrochloric Acid-
    Batch Cone.       U-2
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   Batch Rinse
   Continuous
   Cone.
   Continuous
   Rinse
S. Cold Rolling
 Ave

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 V-2

 Ave
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 W-2
 X-2
 Y-2
 Z-2
 AA-2
 BB-2

 Ave
1-2
W-2
X-2
Y-2
Z-2
AA-2
EB-2

Ave

0.777
0.427
0.0709

1.98
0.0342

(NA)
(NA)
(-0.662)
(NA)
1.28
(NA)
0. 105

0.354
(NA)
(NA)
(NA)
0.0673
0. 136
0.400

0.798
0. 169
0.645
0.258
0.389
0.194
0.705
0.387
0.0643
0.226
1.80
0.0311
0.916
(NA)
(NA)
(-0.600)
(NA)
1.16
(NA)
0.0953
0.628
0.321
(NA)
(NA)
(NA)
0.0610
0.123
0.363
0.217
0.724
0. 153
0.585
0.234
0.353
                                                  Pickled
                                                  Product
                              Pickled
                              Product
                                                  Pickled
                                                  Product
                                                  Pickled
                                                  Product
                                                  Pickled
                                                  Product
X-2
BB-2
DD-2
EE-2
FF-2
Ave
D
I
P
0.798
0. 169
0.645
0.258
0.389

_
—
_
0.724
0. 153
0.585
0.234
0.353
0.410
_
_
_

Cold
Rolled
Product





                              457
-------
T. Hot Coatings-
   Galvanizing
1-2
MM-2
NN-2

Ave
0.368
0.908
0.498
U. Hot Coatings-
   Terne Plate
W. Combination ,
   (Continuous)
    (Batch pipe &
     tube)
   Combination Acid Pickling
   (Other batch)
X. Kolene  Scale
   Removal
   Hydride Scale
   Removal

Y. Wire Coating &
   Pickling
Z. Continuous  Alkaline
   Cleaning
0.334
0.824
0.452

0.537
                                                  Coated
                                                  Product
OO-2
PP-2
Pickling
A
D
I
0
Pickling
U
(NA)
(NA)

2.547
0.388
0.598
4.043

19.800
(NA)
(NA)

2.315
0.353
0.544
3.675

18.00
Coated
Product

Steel
Pickled


Steel
Pickled
C
F
L
L
C
Q
L
K
L
O
ie
I
0.949
4.663
0.822
0.011
0.031
1.247
0.005
3.896
0.066
1.486
4.239
1.486
0.010
0.028
1.134
0.006
3.542
0.060
Steel
Pickled
Steel
Cleaned
Steel
Cleaned
Wire
Processed
Steel
Cleaned
NOTE:
 (1)  NA   or  (-)   means   not  available from company supplied
data.
 (2) Appearance of  a negative   cost  indicates  a  profitable
operation.

FULL   RANGE  O_F TECHNOLOGY .IN USE OR AVAILABLE TO THE STEEL
INDUSTRY
                             458
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The full range of technology in  use  or  available  to  the
steel  industry  today  is presented in Tables 66 to 87.   In
addition  to  presenting  the  range  of  treatment  methods
available, these tables also describe for each method:

1.  Resulting effluent levels for critical constituents
2.  Status and reliability
3.  Problems and limitations
4.  Implementation time
5.  Land requirements
6.  Environmental impacts other than water
7.  Solid waste generation

BASIS OF COST ESTIMATES

Costs associated with the full range of treatment technology
including  investment,  capital  depreciation, operating and
maintenance, and energy and power  are  presented  on  water
effluent   cost  tables  corresponding  to  the  appropriate
category technology Tables 129 to 150.

Costs were developed as follows:

1.  National annual production rate data was  collected  and
tabulated   along   with   the  number  of  plants  in  each
subcategory.   From  this,  an  "average"  size  plant   was
established.

2.  Flow  rates  were  established   based   on   the   data
accumulated during the survey portion of this study and from
knowledge  of  what  flow  reductions could be obtained with
minor modifications.  The flow is here expressed in 1/kkg or
gal./ton of product.

3.  Then a treatment process model diagram was developed for
each subcategory.  This model was based on knowledge of  the
manner  in  which  most plants in a given subcategory handle
their wastes, and on the flow rates established by 1  and  2
above.

4.  Finally, a quasi-detailed cost estimate was made on  the
developed flow diagram.

Total  annual  costs in August, 1971 dollars were calculated
on  total  operating   costs    (including   all   chemicals,
maintenance,  labor,  energy,  and  power)  and  the capital
recovery costs.  Capital recovery costs were then subdivided
into straightline ten-year  depreciation  and  the  cost  of
capital at a 1% annual interest rate for ten years.
                           525
-------
The  capital  recovery  factor  (CRF)   is  normally  used in
industry to help allocate the  initial  investment  and  the
interest to the total operating cost of a facility.  The CRF
is equal to i plus i divided by a -1, where a is equal to (1
*  i)  to the power n.  The CRF is multiplied by the initial
investment to obtain the annual capital recovery.  That  is:
(CRF)  (P)   =  ACR.   The  annual  depreciation  is found by
dividing the initial investment by the  depreciation  period
(n = 10 years).  That is:  P/10 = annual depreciation.  Then
the  annual cost of capital has been assumed to be the total
annual capital recovery minus the annual depreciation.  That
is:  ACR - P/10 = annual cost of capital.

Construction  costs  are  dependent  upon   many   different
variable  conditions,  and  in order to determine definitive
costs the following parameters are established as the  basis
of  cost  estimates.   In  addition,  the  cost estimates as
developed reflect only average costs.

a.  The treatment facilities are contained within a "battery
limit" site location and are  erected  on  a  "green  field"
site.  Site clearance costs such as existing plant equipment
relocation, etc., are not included in cost estimates.

b.  Equipment costs are based on specific water  flow  rates
requiring  treatment.   A  change  in  water flow rates will
affect costs.

c.  The treatment facilities are located in close  proximity
to  the  steelmaking process area.  Piping and other utility
costs for interconnecting utility runs between the treatment
facilities battery limits and process  equipment  areas  are
not  included in cost estimates.

d.   Sales and use taxes or freight charges are not  included
in cost estimates.

e.   Land  acquisition  costs  are  not   included   in   cost
estimates.

f.   Expansion  of  existing  supporting  utilities  such  as
sewage,  river  water  pumping  stations,  increased  boiler
capacity are not included in cost estimates.

g.   Potable water, fire lines, and sewage lines  to   service
treatment facilities  are not included in cost estimates.

h.   Limited  instrumentation  has  been  included   for   pH
control,  but  no automatic samplers, temperature indicators.
                            526
-------
flow  meters,  recorders,  etc.,  are   included   in   cost
estimates.

i.  The site conditions are based on:

(1)  No hardpan or rock excavation, blasting, etc.
(2)  No pilings or spread footing foundations for
    poor soil conditions.
(3)  No well pointing.
(H)  No dams, channels, or site drainage required.
(5)  No cut and fill or grading of site.
(6)  No seeding or planting of grasses and only minor
    site grubbing and small shrubs clearance; no
    tree removal.

j.  Control buildings are prefabricated buildings, not brick
or block type.

k.  No painting, pipe insulation, and steam or electric heat
tracing are included.

1.  No special guardrails, buildings, lab  test  facilities,
signs, docks are included.

Other factors that affect costs but cannot be evaluated:

a.  Geographic location in United States.
b.  Metropolitan or rural areas.
c.  Labor rates, local union rules, regulations, and
    restrictions.
d.  Manpower requirements.
e.  Type of contract.
f.  Weather conditions or season.
g.  Transportation of men, materials, and equipment.
h.  Building cede requirements.
i.  Safety requirements.
j.  General business conditions.

The  cost  estimates  do  reflect an on-site "battery limit"
treatment plant with electrical substation and equipment for
powering the  facilities,  all  necessary  pumps,  treatment
plant  interconnecting  feed  pipe lines, chemical treatment
facilities,  foundations,  structural  steel,  and   control
house.   Access  roadways  within  battery  limits  area are
included in estimates based upon  3.8  cm   (1.5  in.)  thick
bituminous  wearing  course and 10 cm  (4 in.) thick sub-base
with sealer, binder, and  gravel  surfacing.   A  nine  gage
chain  link  fence with three strand barb wire and one truck
gate was included for fencing in treatment facilities area.
                                527
-------
The cost estimates  also  include  a  15%  contingency,  10%
contractor's  overhead  and  profit, and engineering fees of
15%.

The costs as developed above were  scaled  to  the  size  of
facilities   appropriate   in   alloy  and  stainless  steel
operations for those categories in which similar  wastewater
treatments  would be utilized.  Capital costs were scaled on
the basis of the ratios of the wastewater flow rates  raised
to  the  0.6  power.   The  "six-tenths" rule is an accepted
relationship in chemical process  cost  estimation  and  its
validity  was  tested and found to be acceptable using steel
industry wastewater treatment plant cost  data.   Operating,
maintenance and other similar costs were scaled on the basis
of the direct ratios of wastewater flow rates.

REFERENCE  LEVEL  AND  INTERMEDIATE  TECHNOLOGY, ENERGY, AND
NON- WATER IMPACT

The reference levels of treatment, the energy  reguirements,
and  non-water  quality aspects associated with intermediate
levels of treatment are discussed below by subcategories.

Basic Oxygen Furnace  (Wet Air Pollution Controls)

1.  Base Level of Treatment:  Agueous discharge from primary
scrubber to thickener with  water  used  on  a  once-through
basis.    Thickener  underflow  filtered  by  rotary  vacuum
filters  and  filter  cake  recycled  to  sinter  plant   or
landfilled for disposal.  Filtrate recycled to thickener.

2.  Additional Energy Requirements:  To bring the quality of
the  effluent  of the water treatment system utilized in the
fume collection of the EOF  (wet) steel manufacturing process
up to the anticipated standard for 1977,  additional  energy
will  be  necessary.  The additional energy consumed will be
0.63 kwh/kkg  (0.58  kwh/ton)  of  steel  made.   The  annual
operating cost for this additional consumption of power will
be approximately  $6,766.00.

3.  Non-Water Quality Aspects

a.   Air  Pollution:   The  air pollution problem of primary
significance in the   EOF   (wet)  method  .of  steelmaking  is
particulate  emissions.   Although the furnace exhaust  fumes
will  be  passed  through  a   scrubber   or   electrostatic
precipitator,  some   particulate matter will be emitted into
the atmosphere.   This is inherent in the production  process
and is not derived  from the wastewater treatment system.
                             528
-------
                                   TABLE 129

                        WATER EFFLUENT TREATMENT COSTS
                                STEEL INDUSTRY
          Basic Oxygen Furnace  (Wet Air Pollution Control Methods)

Treatment or Control Technologies
Identified under Item III of the
Scope of Work:
Investment
Annual Costs:
Capital
Depreciation
Operation & Maintenance
Sludge Disposal
Energy & Power
Chemical
TOTAL
Effluent Quality:
Raw
Effluent Constituents Waste
Parameters-units Load
Flow, sal/ton 872
Suspended Solids, TOR/! 2,700
Fluoride, me/1 10
pH 6-9
BPCTCA
A <—
$901,709 18
38,773
90,171 1
24,597
74,443
16,110
70
$244,094 74
B
,643
801
,864
506

362
,562
,095
RESULTING EFFLUENT
872 872
80
10
6-9
40
10
6-9
C
301,318
12,957
30,131
8,219

6,404
978
58,689
LEVELS
50
50
50(1)
6-9
BATEA
' ' D '
250,280
10,761
25,028
6,827
558
5,679
3,328
52,181
50
25
20
6-9
1 E
247,785
10,655
24,779
6,904

2,417
16
44,771
50
10
5
6-9
 (1)   Value that  can be  obtained using BPCTCA treatment  technology.
                                     529
-------
b.   Solid  waste  Disposal:    There should be no problem in
disposing  of  the  solid  waste  generated  by   the   fume
collection   system  for  the  EOF  (wet)   process  for  the
manufacture of steel.  It can be internally consumed in  the
sinter  process  plant,  where  available,   or  otherwise by
landfill.

Vacuum Degassing
1.   Base  Level   of   Treatment:    Once-through   system.
Treatment involves a scale removal classifier.

2.   Additional  Energy Requirements:  Additional power will
be necessary when bringing the quality of the effluent  from
the  water  treatment  system  utilized  in  the  barometric
condensers for  the  vacuum  degassing  process  up  to  the
anticipated   standard  for  1977.   The  additional  energy
utilized will be 11.4 kwh/kkg (10.3 kwh per  ton)  of  steel
produced.  For the typical 472 kkg/day (520 tons/day) vacuum
degassing  facility,  the  additional power required will be
224 kw   (300  hp).   The  annual  operating  cost  for  this
additional   power   consumption   will   be   approximately
$22,500.00.

3.  Non-Water Quality Aspects

a.  Air Pollution:  Won-condensable gases are vented to  the
atmosphere  during  degassing.   This  is  inherent  to  the
production process, however.

b.  Solid Waste Disposal:  The  solid  waste  that  will  be
generated  by  the  creation  of  a vacuum for the degassing
process  should present no problem.  It can be landfilled  or
consumed in the sinter plant.

Continuous Casting and Pressure Slab Molding

The  carbon  steel  costs  were based on a water use of 4200
gallons  per ton and a daily production of  1070  tons.   The
plant  survey  data  here  indicate an average production of
about 600 tons per day and a water use of 1,000 gallons  per
ton.  Although the flow rates during casting are higher, the
proportions should be valid as follows for scaling purposes:

         Carbon steel:   4200 X 1070  1440 = 3120 gpm
         Alloy  steel:    1000 X  600  1440 =   417 gpm

Capital  costs were thus scaled on the basis of  the ratio of
flow rates to the six-tenths power.
                             530
-------
                              TABLE 130

                   WATER EFFLUENT TREATMENT COSTS
                           STEEL INDUSTRY
                         Vacuum Degassing
Treatment or Control Technologies
Identified under Item III of the
Scope of Work:
Investment
Annual Costs:
Capital
Depreciation
Operation & Maintenance
Sludge Disposal
Energy & Power
Chemical
TOTAL
Effluent Quality:
Raw
Effluent Constituents Waste
Parameters-units Load
Flow, gal/ton 560
Suspended Solids, mg/1
Lead, me/1
Manganese, mg/1
Nitrate, mg/1 (1)
Zinc, me/1 (2)
PH
200
3
20
80
30
5-10
BPCTCA
A B
$259,774 423,797
11,170 18,224
25,977 42,379
9,092 14,832
36
22,500

$ 46,275 97,935
RESULTING EFFLUENT
560 25
100 50
2.5 2.0(3)
15 10(3)
80 175(3)
20 15(3) .
6-9 6-9
BATEA
C ' D
307,170 60,008
13,208 2,581
30,717 6,000
10,750 2,100
31
29,250 2,250
753
84,709 12,931
LEVELS
25 25
25 10
0.5 0.3
5 3
45 45
5 3
6-9 6-9

 (1)   If nitrogen gas is used to purge system, nitrate concentrations  can be
      very high.  If inert gases are used, nitrates are negligible.
 (2)   Zinc concentration depends on type of scrap used in steelmaking  process.
 (3)   Value expected of typical treatment plant utilizing BPCTCA technology.
                                   531
-------
                                   TABLE  131
                        WATER EFFLUENT TREATMENT COSTS
                                STEEL INDUSTRY
                  Continuous  Casting  £ Pressure  Slab Molding
Treatment or Control Technologies
Identified under Item III of the
Scope of Work:
Investment
Annual Costs:
  Capital
  Depreciation
  Operation & Maintenance
  Sludge Disposal
  Energy & Power
  Chemical
TOTAL
Effluent Quality:
                        Raw
  Effluent Constituents Waste
  Parameters-units      Load
 Flow,  gal/ton.
1000
BPCTCA
A
$16,653 594,245
715 25.553
Ir665 59r424
9.290
BATEA
B '
29.751
1.279
2r975
465
2.000 98
4.955
1.206

4.380 99.320
5.925
 RESULTING  EFFLUENT  LEVELS
1000	125	125
 Oil & Grease.  me:/l
  15
  15
15
10
 Suspended Solids,  mg/1  125
                         6-9
             100
            6-9
            50
           6-9
          10
         6-9
                                    532
-------
Operating and maintenance and other costs were scaled on the
basis of the ratio of flow rates.

1.  Base Level of Treatment: Recycle system utilizing  scale
    pit  settling,  oil  skimming,  flat  bed filtration and
    cooling towers.

2.  Additional Energy Requirements:  Additional  power  will
    not  be  required  to  meet  proposed standards for 1977
    since the base level is the BPCTCA treatment model.

3.  Non-Water Quality Aspects

    a.   Air Pollution:  Non-condensable gases and fumes are
         generated during continuous casting operations  but
         to a relatively minor extent.

    b.   Solid Waste Disposal:  The  solid  waste  generated
         can be consumed internally in the sinter plant.

Hot Forming - Primary

Reference  Level  of Treatment.  Once-through system.  Scale
pit with oil catching baffles for suspended solids and gross
oil removal.

Additional Energy Requirements.  To meet EPA 1977  standards
for  wastewater  discharge  to  public waters, modifications
will be required to the wastewater  treatment  system.   The
additional   power  consumed  will  be  2.67  kwh/kkg   (2.42
kwh/ton) processed.  For the typical  3,628  kkg/day   (1,000
ton/day)  facility,  the  power required will be 403 kw  (540
horsepower).  The annual cost to operate this equipment will
be $40,500.

Non-Water Quality Aspects.

1.  Air Pollution:  None
2.  Solid Waste Disposal:  The sludge will be collected and
    recycled to melting operations.

Hot Forming - Section

Reference Level of Treatment.  Once-through  system.   Scale
pit with oil catching baffles for suspended solids and gross
oil removal.

Additional  Energy Requirements.  To meet EPA 1977 standards
for wastewater discharge  to  public  waters,  modifications
will  be  required  to the wastewater treatment system.  The
                              533
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                                   535
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                                          TABLE  133

                                 WATER EFFLUENT TREATMENT COSTS
                                         STEEL INDUSTRY

                                      HOT FORMING - SECTION
Treatment of Control Technoloqies
 Identified under Item III of the
 Scope of Work:              A

Investment                $216,510

Annual Costs:

  Capital                    9,310

  Depreciation              21,651

  Operation & Maintenance    7, 578

  Sludge Disposal         	

  Energy & Power          	

  Oil Disposal            	

  Chemical Costs

TOTAL
Effluent Quality:

  Effluent Constituents
  Parameters - Units

  Flow, gal./ton	
 6,029
                         BPCTCA
                                               BATEA
            B          C          D         E    |  I    F         G

          $13,529    $662,880  $383,940  $650,855  $1,420,275  $441^18
              582
            1,353
              473
            ,28,503    16,509    27,987

            66,289  	38,394    65,085

            _23,200    13,438    22,780

                       5,400
                                  61,072    18,97

                                 142,027    44.11

                                  49,710    15,44
              900
            8,894
            22,500
             9,375
7,500
22,500    22.50
$38,539   $12,202    $140,492   $83.116   $123,_352     $275,309  $101,02
6,029
Resulting Effluent Levels

2,626       2,626     2,626
         2,626
  Suspended Solids, mg/1   100-200   100-150   100-200      50-75

  Oil and Grease, mg/1      50-100    20-50     20-70	    20-40

  pj	     6-9	     6-9    	6^9	Gr3__
                                              10
                                             10
                                              10
                                             10
                                            6-9
                                           6-9
  BPT  -  $1.Ob3/ton
  BAT  -  $l.ll/ton

Different from XI in Level C.  Total flow is pumped either to RFL or CL.
                                             536
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additional  power  consumed  will  be  8.14  kwh/kkq   (7.38
kwh/ton)   processed.  For the typical 1,179.1 kkq/day (1,300
ton/day)  facility, the power required will be  400  kw  (537
horsepower).  The annual cost to operate this equipment will
be $40,275.

Non-Water Quality Aspects.

1.  Air Pollution:  None
2.  Solid Waste Disposal:  The sludge will be collected  and
    recycled to melting operations.

Hot Forming - Flat - Plate

Reference  Level  of Treatment.  Once-through system.  Scale
pit with oil catching baffles for suspended solids and gross
oil removal.

Additional Energy Requirements.  To meet EPA 1977  standards
for  wastewater  discharge  to  public waters, modifications
will be required to the wastewater  treatment  system.   The
additional  power  consumed  will  be  13.22  kwh/kkg (11.99
kwh/ton)  processed.  For the typical  1,814  kkg/day  (2,000
ton/day)    facility,  the power required will be 999 kw (6340
horsepower).  The annual cost to operate this equipment will
be $100,500.

Non-Water  Quality Aspects.

1.  Air Pollution:  None
2.  Solid  Waste Disposal:  The sludge will be collected and
    recycled to melting operations.

Hot Forming - Flat  - Hot Strip and Sheet

Reference  Level of Treatment.  Once-through  system.   Scale
pit with oil catching baffles for suspended solids and gross
oil removal.

Additional  Energy Requirements.  To meet EPA 1977 standards
for wastewater discharge  to  public  waters,  modifications
will  be   required  to the wastewater treatment system.  The
additional  power  consumed  will  be  16.36  kwh/kkg   (14.84
kwh/ton)   processed.   For  the typical 3,447 kkg/day  (3,800
ton/day) facility, the  power  required  will  be  2,349  kw
 (3,150   horsepower).   The  annual  cost  to  operate  this
equipment  will be $236,250.

Non-Water  Quality Aspects.
                              538
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                                                            542
-------
1.  Air Pollution:  None
2.  Solid Waste Disposal:  The sludge will be collected and
    recycled to melting operations.

Pipe and Tubes - Integrated

Reference Level of Treatment.  Once-through  -  contact  and
noncontact  wastewaters.   Scale  pit  with  oil skimmer for
removal of heavy solids and oil.

Additional  Energy  Requirements.   To  meet  the  EPA  1977
standards  for  discharge  of wastewater into public waters,
modifications will be required to the  wastewater  treatment
system.  The additional power consumed will be 11.83 kwh/kkg
(10.74 kwh/ton) processed.  For the typical 363 kkg/day (400
ton/day)   facility,  the  power required will be 179 kw (240
horsepower)•  The annual cost to operate this equipment will
be $18,000.

Non-Water Quality Aspects.

1.  Air Pollution:  None
2.  Solid Waste Disposal:  The sludge  will  be  clamshelled
    and landfilled, or recycled to melting operations.

Pipe and Tubes - Isolated

Reference  Level  of  Treatment.  Once-through - contact and
noncontact wastewaters.  Scale  pit  with  oil  skimmer  for
removal of heavy solids and oil.

Additional Energy Requirements.

To  meet  the EPA 1977 standards for discharge of wastewater
into public waters, modifications will be  required  to  the
wastewater  treatment system.  The additional power consumed
will be 7.87 kwh/kkg   (7.14  kwh/ton)  processed.   For  the
typical  363  kkg/day   (400  ton/day)  facility,  the  power
required will be 119 kw  (160 horsepower).  The  annual  cost
to operate this equipment will be $12,000.

Non-Water Quality Aspects.

1.  Air Pollution:  None
2.  Solid Waste Disposal:  The sludge  will  be  clamshelled
    and landfilled, or recycled to melting operations.

Pickling - Batch Sulfuric Acid - Concentrates and Rinses
                               543
-------
                                      TABLE 135-1-INTEGRATED

                                 WATER EFFLUENT TREATMENT COSTS
                                         STEEL INDUSTRY

                                         PIPE AND TUBES
Treatment of Control Technologies
 Identified under Item III of the
 Scope of Work:              A

Investment                $182,658

Annual Costs:

  Capital                    7,854

  Depreciation              18,266

  Operation & Maintenance    6,393

  Sludge Disposal            1,217

  Energy & Power          	

  Oil Disposal            	

  Chemical Costs          	

TOTAL                      $33,730
                           BPCTCA
1 B
$10,765
462
1,077
377
C D
$272,330 $102,330
11,710 4,400
27,233 10,233
9,531 3,581
E 1
$178,210
7,665
17,821
6,235
1,875

11,250 3,750
3,000
1,587

$3,505
$61,599 $21,964
$34,720
                                               BATEA
                                                        16,666     2,98(

                                                        38,760     6,93(

                                                        13,566     2,42!
                                                        11,250     1,871
                                                       $80,242   $14,21
Effluent Quality:

  Effluent Constituents
  Parameters - Units

  Flow, gal./ton	

  Suspended Solids, mg/1

  Oil and Grease, mg/1

  PH	

  BPT  -  $0.976/ton
  BAT  -  $0.757/ton
  4,209
  50-100
   6-9
4,209
 100-200   100-150
20-50
 6-9
Other - 0.114/ton
Resulting Effluent Levels

4,209       1,002     1,002
          50-75
20-40
 6-9
            50-100
20-50
 6-9
             10
  10
6-9
                    *Seamless Only
A-B-C - 4,209 g/t
D - R - 3,207 g/t  (pumping all inclusive of 1,002 to filter)
E - Filter - 1,002 g/t
F - CT - 1,002 g/t
G - R - 1,002 g/t
                                          544
                     1,002
             10
  10
6-9
-------
                                TABLE 135-2 - ISOLATED

                            WATER EFFLUENT TREATMENT COSTS
                                    STEEL INDUSTRY

                                    PIPE AND TUBES
Treatment of Control Technologies
 Identified under Item III of the
 Scope of Work:
Investment

Annual Costs:

  Capital

  Depreciation

  Operation & Maintenance

  Sludge Disposal

  Energy & Power

  Oil Disposal

TOTAL
   A

$182,658



   7,854

  18,266

   6,393

   1.217
I   B

 $10,765



     462

   1,077

     377
                         BPCTCA
   C

$43,640



  1,876

  4,364

  1,527
                                     BATEA
   5    I   I    EI

$102,330      $69,305
   4,400
  10,233
   3,581
                                      3,750
  2,980
  6,930
  2,425
                                        1,875
 $33,730
  $3,505
 $7,767
 $21,964
$14,210
Effluent Quality:

  Effluent Constituents
  Parameters - Units

  Flow, gal. /ton _

  Suspended Solids, mg/1

  Oil and Grease, mg/1
  BPT  -  $0.266/ton
  BAT  -  $0.114/ton

C - Ponds - 4,209 g/t
D - R 3,207 g/t
E - R 1,002 g/t
  4,209
 100-200
  50-100
                                 6-9
      Resulting Effluent Levels

  4,209      4,209      1,002
 100-150
  20-50
              6-9
 50-75
 20-40
              6-9
   50
   15
             6-9
                                          545
-------
Reference  Level  of  Treatment.   Contract hauling of spent
pickle liquor off-site for disposal or treatment.
Additional Energy Requirements.  To meet EPA 1
for  was tester  discharge  to  public waters,
will be reguired to the wastewater  treatment
additional  power  consumed  will  be  36.16
kwh/ton)  processed.   For  the  typical  227
ton/day)  facility,  the  power required will
horsepower).  The annual cost to operate this
be $3U,420.
                   977  standards
                    modif ications
                    system.   The
                   kwh/kkg (32.83
                    kkg/day  (250
                   be 312 kw (U59
                   equipment will
Non-Water Quality Aspects.

1.  Air Pollution:  None
2.  Solid Waste Disposal:
    and landfilled.
The sludge  will  be  clamshelled
Water  uses  and  flow  rates are siirilar between the carbon
steel and stainless and alloy steel operations.  Costs  were
thus assumed to be equivalent.

Pickling - Batch Sulfuric Acid - Rinse
Reference  Level  of  Treatment.
rates.  No additional treatment.
        Minimize rinse water flow
Additional Energy Requirements.  To meet EPA 1977  standards
for  wastewater  discharge  to  public waters, modifications
will be required to the wastewater  treatment  system.   The
additional   power  consumed  will  be  1.98  kwh/kkg   (1.80
kwh/ton)  processed.   For  the  typical  227  kkg/day   (250
ton/day) facility, 18.7 kw  (25 horsepower) .  The annual  cost
to operate this equipment will be $1,875.

Non-Water Quality Aspects.

1.  Air Pollution:  None
2.  Solid Waste Disposal:  The sludge will be clamshelled
    and landfilled.

Pickling -   Continuous  Sulfuric  Acid  -  Concentrates  and
Rinses - Neutralization

Reference  Level  of  Treatment.  Minimize  rinse water  flow
rates.  No additional treatment.

Additional Energy Requirements.  To meet  EPA  1977  standards
for  wastewater  discharge  to  public waters, modifications
                                 546
-------
                               TABLE  136
                    WATER EFFLUENT TREATMENT COSTS
                            STEEL INDUSTRY

                PICKLING - H^S04 - BATCH - CONG. & RINSES
Treatment of Control Technologies           BPCTCA
 Identified under Item III of the           BATEA
 Scope of Work:                    A       |   B    I      C

Investment                       $36,224   $636,300   	

Annual Costs:

  Capital                          1,558     27,361   	

  Depreciation                     3,622     63,630   	

  Operation & Maintenance          1,268     22,271   	

  Crystal Disposal              	      7,800   	

  Energy & Power                   1,500     34,420   	

  SPL Disposal                    81,250   	   	

TOTAL                            $89,198   $155,482   	
  LESS CREDIT:
    Acid Recovery                             8,549
    Contract Hauling                         81,250

                                            $65,683

Effluent Quality:

  Effluent Constituents
  Parameters - Units                   Resulting Effluent Levels

                  Cone.              25
  Flow, gal./ton, Rinse	200        0	
                          Cone.  300-600
  Suspended Solids,  mg/1. Rinse  200-300

                        Cone.      2-5%
  Dissolved Iron,  mg/1. Rinse   6000-7000

      Cone.                        <1
  pH, Rinse	2-5
  Cone. - Disposed by continuous hauling - no discharge to stream.

  A:  Cont. hauling SPL;  disc,  rinse untreated.
  B:  Cascade rinse and use as PL makeup; recover H2S04 and FeSO4'7H20
      in evaporative recovery system.
                                  547
-------
                               TABLE 137


                    WATER EFFLUENT TREATMENT COSTS
                            STEEL INDUSTRY

   PICKLING - H2S04 - CONTINUOUS - CONC.  & RINSES - NEUTRALIZATION
Treatment of Control Technologies
Identified under Item III of the BPCTCA BATEA
Scope of Work:
Investment
Annual Costs:
Capital
Depreciation
Operation & Maintenance
Sludge Disposal
Energy & Power
SPL Disposal
Chemical Costs
TOTAL
LESS CREDIT for
Contract Hauling Costs
NET ANNUAL COST
Ac AR 1 B 1 1 C 1
$212,975 $455,828 $629,906 $136,200
9,157 19,600 27,085 5,857
21,298 45,583 62,991 13,620
7,454 15,954 22,047 4,767
224.640
7.500 15,000 7,875 2,700
468,000
(Replacement Cost)
5.055 158.770 19,320
$513,409 $101.192 $503,408 $46,264
468,000
$35,408
Effluent Quality:

  Effluent Constituents
  Parameters - Units

  Flow, gal./ton	

  Suspended Solids, mg/1

  Dissolved Iron, mg/1

  PH	
   25
Resulting Effluent Levels

      225         250
                                       50
300-600

  2-8%
   <1
   250-500
     5-25

     4-7
 50
25
  1.0
                                        0.2
6-9
                                      6-9
A:  Concentrates disposed by hauling - no discharge to stream;
    rinses treated via lime neut.  No settling.
B:  Neutralize cone, and rinses together; aerate; one-day lagoon.

C:  Countercurrent rinse to reduce flows; rest stays same; lagoon
    holds five days.
                                   548
-------
                               TABLE 137-1

                    WATER EFFLUENT TREATMENT COSTS
                            STEEL INDUSTRY
     PICKLING - H2SO4 - CONTINUOUS - CONC. & RINSES - ACID RECOVERY
Treatment of Control Technologies       BPCTCA
 Identified under Item III of the       BATEA
 Scope of Work:                 A      IB|
Investment                  $212,975   $1,870,975
Annual Costs:
  Capital                      9,157       80,451   	
  Depreciation                21,298      187,098   	
  Operation & Maintenance      7,454       65,484   	
  Crystal Disposal          	       44,928   	
  Energy & Power               7,500      122,700   	
  SPL Disposal               468,000   	-   	
  Replacement Parts         	       19,320   	
TOTAL                       $513,409     $519,981   	
  LESS CREDITS:
    Acid Recovery                          49,242
    Contract Hauling                      468,000
NET ANNUAL COST                            $2,739
Effluent Quality:
  Effluent Constituents
  Parameters - Units                 Resulting Effluent Levels
Flow, gal.
Suspended
mg/1,
Dissolved
mg/1,
Cone.
pH, Rinse
/ton.
Solids
Iron,

Cone.
Rinse
, Cone .
Rinse
Cone.
Rinse

25
225
300-600
250-500
2-8%
1800-3600
<1
2-5
0
0
-
-
:
A:  Concentrates disposed by hauling - no discharge to stream; rinses
    discharged untreated.
B:  Cascade rinsing to minimize flow; recover 113804 and FeSO4-7H2O in
    evap. recovery system.
                                   549
-------
will be required to the wastewater  treatment  system.   The
additional   power  consumed  will  be  1.72  kwh/kkg  (1.56
kwh/ton)  processed.  For the typical  1,088  kkg/day  (1,200
ton/day)   facility,  the  power  required will be 78 kw  (105
horsepower).  The annual cost to operate this equipment will
be $7,875.

Non-Water Quality Aspects.

1.  Air Pollution:  None
2.  Solid Waste Disposal:  Sludges will be  clamshelled  and
    land filled.

Pickling  -  Continuous  Sulfuric  Acid  -  Concentrates and
Rinses - Acid Beeovery

Reference Level of  Treatment.  Minimize  rinse  water  flow
rates.  No additional treatment.

Additional  Energy  Requirements. To meet EPA 1977 standards
for wastewater discharge  to  public  waters,  modifications
will  be  required  to the wastewater treatment system.  The
additional  power  consumed  will  be  26.91  kwh/kkg  (24.4
kwh/ton)   processed.   For  the typical 1,088 kkg/day  (1,200
ton/day)  facility, the  power  required  will  be  1,220  kw
 (1,636   horsepower).   The  annual  cost  to  operate  this
equipment will be $122,700.

Non-Water Quality Aspects.

 1.  Air Pollution:  None
 2.  Solid Waste Disposal:  The sludge  will  be  clamshelled
    and landfilled,

Pickling - Hydrochloric Acid - Concentrated - Alternate ^

Reference  Level  of  Treatment.   Deep  well  disposal,  or
 contract  hauling  of  spent  pickle  liquor  off-site   for
disposal or treatment.

Additional  Energy Requirements.  To meet EPA 1977 standards
 for wastewater discharge  to  public  waters,  modifications
 will  be  required  to the wastewater treatment system.  The
 additional  power  consumed  will  be  0.66  kwh/kkg    (0.60
 kwh/ton)  processed.   For  the typical 2,721 kkg/day  (3,000
 ton/day)  facility, the power required will  be  75  kw   (100
 horsepower).  The  annual  cost to operate this equipment  will
 be $7,500.

 Non-Water Quality  Aspects.
                              550
-------
1.  Air Pollution:  None
2.  Solid Waste Disposal:  The sludge will be clamshelled
    and landfilled.

Pickling - Hydrochloric Acid - Rinse - Alternate J

Reference   Level   of    Treatment.     Equalization    and
neutralization  of  free  acidity before direct discharge to
receiving stream.

Additional Energy Requirements.  To meet EPA 1977  standards
for  wastewater  discharge  to  public waters, modifications
will be required to the wastewater  treatment  system.   The
additional   power  consumed  will  be  1.31  kwh/kkg  (1.19
kwh/ton)  processed.  For the typical  2,721  kkg/day  (3,000
ton/day)   facility,  the  power required will be 149 kw  (200
horsepower).  The annual cost to operate this equipment will
be $15,000.

Non-Water Quality Aspects.

1.  Air Pollution:  None
2.  Solid Waste Disposal:  The sludge will be clamshelled
    and landfilled.

Pickling - Hydrochloric Acid - Concentrates and Rinses

Alternate II

Reference  Level  of  Treatment.   Deep  well  disposal,,  or
contract   hauling  of  spent  pickle  liquor  off-site  for
disposal or treatment; neutralization of free acidity before
direct discharge to receiving stream.

Additional Energy Requirements.  To meet EPA 1977  standards
for  wastewater  discharge  to  public waters, modifications
will be required to the wastewater  treatment  system.   The
additional   power  consumed  will  be  1.64  kwh/kkg  (1.49
kwh/ton)  processed.  For the typical  2.721  kkg/day  (3,000
ton/day)   facility,  the  power required will be 164 kw  (250
horsepower).  The annual cost to operate this equipment will
be $18,750.

Non-Water Quality Aspects.

1.  Air Pollution:  None
2.  solid Waste Disposal:  The sludge will be clamshelled
    and landfilled.

Cold Rolling - Recirculation
                               551
-------
                                   TABLE 138
                         WATER EFFLUENT TREATMENT COSTS
                                 STEEL INDUSTRY

                PICKLING - HYDROCHLORIC ACID - RINSES - ALTERNATE I
Treatment or Control Technologies
 Identified under Item III of the             BPCTCA       BATEA
 Scope of Work:                      A       I~B
Investment                       $ 373,391   $ 583.136   $ 235,900

Annual Costs:

  Capital                           16,056      25,075      10,144

  Depreciation                      37,339      58,314   	23,590

  Operation & Maintenance           13,069      20,410       8,257

  Sludge Disposal                	       6,521   	

  Energy & Power                     5,625      15.000       2,720

  Chemical Costs                    18,270      19,418   	

  Replacement Parts              	   	      33,480


TOTAL                            $  90,359   $ 144,738   $  78,191


Effluent Quality:

  Effluent Constituents
  Parameters  -  units                     Resulting Effluent Levels

  Flow, gal./ton	              200 (:L)     200(1)        50(1)

  Suspended Solids, mg/1           200-400   	50      	25

  Oil and Grease, mg/1              20-30        10(2)       10(2)

 ---Dissolved Iron, mg/1             100-240   	i. Q    	i. Q

  pH	           5-6         6-9         6-9
 (1) If the plant has a wet fume hood scrubber system over  the pickle  tanks,
    an additional load of 50 gals./ton applies and is added  to  the  flow shown.

 (2) This load allowed only when these wastes are treated in  combination with
    cold rolling mill wastes.
                                      552
-------
                                    TABLE  139
                         WATER EFFLUENT TREATMENT COSTS
                                 STEEL INDUSTRY                   *

            PICKLING  -  HYDROCHLORIC  ACID  -  CONCENTRATES  -  ALTERNATE  I
Treatment or Control Technologies
 Identified under Item III of the
 Scope of Work:
Investment

Annual Costs:

  Capital

  Depreciation

  Operation & Maintenance

  Sludge Disposal

  Energy & Power

  Disposal Costs

  Chemical Costs

  Less Credit for Recovered
  Acid and Iron Salts

TOTAL
,e BPCTCA
A | B |
$ 402,093 $9,057,448
17,290 389,470
40,209 905,745
14,073 317,011
BATEA
1 C 1
$ 64,464
2,771
6,445
2,256

3,750 7,500
1,500
1,044,000
11,045
(-2,624,530)
$1,119,322   $(-993,.759)  $  12,972
Effluent Quality:

  Effluent Constituents
  Parameters  -  units

  Flow, gal./ton	

  Suspended Solids, mg/1

  Oil and Grease, mg/1

  Dissolved Iron, mg/1

  PH	
  200-400
    8-12%
           Resulting Effluent Levels

       20       200          30
                 50
                             25
                 10*
                             10*
1.0
1.0
                6-9
            6-9
*This load allowed only when these wastes are treated in combination with
 cold rolling mill wastes.
                                       553
-------
                                     TABLE 140
                         WATER EFFLUENT TREATMENT COSTS
                                 STEEL INDUSTRY

       PICKLING - HYDROCHLORIC ACID - CONCENTRATES & RINSES - ALTERNATE II
Treatment or Control Technologies
 Identified under Item III of the
 Scope of Work:
Investment

Annual Costs:

  Capital

  Depreciation

  Operation & Maintenance
                   Sludge
  Disposal Costs:  Acid

  Energy & Power

  Replacement Costs

  Chemical Costs

  Less Credit for Recovered
  Acid and Iron Salts

TOTAL
e BPCTCA
A
S 752,
32,
75,
26,
1,044,
15,
353
351
235
332
000
000
1 B
5 874
37
87
30
152
18
1
,607
,460
,611
,000
,750

18,
270
396
,918

                           BATEA
                         $ 235,900
                            10,144

                            23,590

                             8,257
                             2,720

                            33,480
$1,211,188   $  723,346   $  78,191
Effluent Quality:

  Effluent Constituents
  Parameters  -  units

  Flow, gal./ton	

  Suspended Solids, mg/1

  Oil and Grease, mg/1

  Dissolved Iron, mg/1

  PH	
           Resulting Effluent Levels
       220
          (1)
                230
 (1)
           80
 (1)
   200-400
    8-12%
                 50
           25
                 15
                   (2)
                             10
              (2)
1.0
1.0
                6-9
            6-9
 (1) If the plant has a wet fume hood scrubber system over the pickle tanks,
    an additional load of 50 gals./ton applies and is added to the flow shown.

 (2) This load allowed only when these wastes are treated in combination with
    cold rolling mill wastes.
                                     554
-------
                                   TABLE 141
                         WATER EFFLUENT TREATMENT COSTS
                                 STEEL INDUSTRY

                          COLD ROLLING - RECIRCULATION
Treatment or Control Technologies
 Identified under Item III of the
 Scope of Work:
Investment

Annual Costs:

  Capital

  Depreciation

  Operation & Maintenance

  Sludge Disposal

  Energy & Power

  Chemical Costs

TOTAL
BPCTCA
BATEA
A
$ 186,877
8,035
18,688
6,541
1,958
525

$ 35,747
1 B
S 267,
11,
26,
9,
1.
9,
2,
$ 61,
1
588
501
759
365
392
750
590
357
Effluent Quality:

  Effluent Constituents
  Parameters  -  units

  Flow, gal./ton	

  Suspended Solids, rog/1

  Oil and Grease, mg/1

  Dissolved Iron, mg/1

  PH	
 25
200
600
6-9
Resulting Effluent Levels

      25      	

      25
             10
     6-9
*This load allowed only when these wastes are treated in combination with
 pickling rinses.
                                     555
-------
Reference Level  of  Treatment.   Recirculation  of  rolling
solutions  on  all  rolling  stands.  Oil skimmer in recycle
sump.    Blending   of   rolling   solution   blowdown   and
miscellaneous    (tramp   oils)   wastewaters.   Treatment  of
mixture with oil separator/settler.

Additional Energy Requirements.  To meet EPA 1977  standards
tot  wastewater  discharge  to  public waters, modifications
will be reguired to the wastewater  treatment  system.   The
additional   power  consumed  will  be  0.86  kwh/kkg  (0.78
kwh/ton)  processed.  For the typical  2,721  kkg/day  (3,000
ton/day)   facility,  the  power  required will be 97 kw  (130
horsepower).  The annual cost to operate this equipment will
be $9,750.

Non-Water Quality Aspects.

1.  Air Pollution:  None
2.  Solid Waste  Disposal:  The sludge will be clamshelled
    and landfilled.

Cold Rolling - Combination

Reference Level  of  Treatment.   Recirculation  of  rolling
solutions  on  as  many  stands  as possible, with remaining
stands oncethrough.  Oil skimmer in recycle sump.   Blending
of  rolling solution blowdown and miscellaneous  (tramp oils)
wastewaters.     Treatment    of    mixture     with     oil
separator/settler.

Additional  Energy Requirements.  To meet EPA 1977 standards
for wastewater discharge  to  public  waters,  modifications
will  be  required  to the wastewater treatment system.  The
additional  power  consumed  will  be  10.53  kwh/kkg   (9.55
kwh/ton)   processed.  For the typical 1,360.5 kkg/day (1,500
ton/day)   facility, the power reguired will be  597  kw   (800
horsepower).  The annual cost to operate this equipment  will
be $60,000.

Non-Water Quality Aspects.

1.  Air  Pollution:  None
2.   Solid Waste  Disposal:  The sludge will be clamshelled
     and  landfilled.

Cold Rolling - Direct Application

Reference  Level of  Treatment.   All   stands   use   rolling
solutions  once-through.   Oil  skimmer  in  recycle  sump.
Blending of rolling  solution  blowdown  and  miscellaneous
                                556
-------
                                    TAfcLE 142
                         WATER EFFLUENT TREATMENT COSTS
                                 STEEL INDUSTRY

                           COLD ROLLING - COMBINATION
Treatment or Control Technologies
 Identified under Item III of the
 Scope of Work:
              BPCTCA
              BATEA
Investment

Annual Costs:

  Capital

  Depreciation

  Operation £ Maintenance

  Sludge Disposal

  Energy & Power

  Chemical Costs

TOTAL
$ 242,245   $1,055,013
   10,416

   24,225

    8,479

   15,670
    3.000
 45^366
105,501

 36,925

 11,143

 60.000

 20,732
                                    61,790   $  279,667
Effluent Quality:

  Effluent Constituents
  Parameters  -  units

  Flow, gal./ton	

  Suspended Solids,  ing/1

  Oil and Grease, mg/1

  Dissolved Iron, mg/1

  PH	
          Resulting Effluent Levels

   400          400
   120
  25
   360
  10
                  1*
   6-9
 6-9
*This load allowed only when these wastes are treated in combination with
 pickling rinses.
                                   557
-------
                                    TABLE  143
                         WATER EFFLUENT TREATMENT COSTS
                                 STEEL INDUSTRY

                        COLD ROLLING - DIRECT APPLICATION
Treatment or Control Technologies
 Identified under Item III of the
 Scope of Work:
              BPCTCA
              BATEA
Investment

Annual Costs:

  Capital

  Depreciation

  Operation & Maintenance

  Sludge Disposal

  Energy & Power

  Chemical Costs

TOTAL
$ 269,856   $1.083.235
   11,603

   26,986

    9,445

   19,500

    3,750
      46.579
     108.323
      37.913
      13,920

      60,000

      25,792
$  71,284   $  292,527
Effluent Quality:

  Effluent Constituents
  Parameters  -  units

  Flow, gal./ton	

  Suspended Solids, mg/1

  Oil and Grease, mg/1

  Dissolved Iron, mg/1

  PH	
   1000
     80
Resulting Effluent Levels

      1000     	

        25
    200
    6-9
                  10
       6-9
*This load allowed only when these wastes are treated in combination with
 pickling rinses.
                                      558
-------
(tramp  oils)  wastewaters.   Treatment  of mixture with oil
separator/settler.

Additional Energy Requirements.  To meet EPA 1977  standards
for  wastewater  discharge  to  public waters, modifications
will be required to the wastewater  treatment  system.   The
additional  power  consumed  will  be  15.79  kwh/kkg (14.32
kwh/ton)  processed.  For  the  typical  907  kkg/day  (1,000
ton/day)   facility,  the  power required will be 597 kw (800
horsepower).  The annual cost to operate this equipment will
be $60,000.

Non-Water Quality Aspects.

1.  Air Pollution:  None
2.  Solid Waste Disposal:  The sludge will be clamshelled
    and landfilled.

Hot Coatings - Galvanizing

Reference Level of Treatment.   No  treatment  of  effluent.
Tight control of dragout in process.

Additional  Energy Requirements.  To meet EPA 1977 standards
for wastewater discharge  to  public  waters,  modifications
will  be  required  to the wastewater treatment system.  The
additional power consumed in galvanizing operations will  be
3.67  kwh/kkg (3.33 kwh/ton) processed.  For the typical 635
kkg/day (700 ton/day) facility, the power required  will  be
97  kw  (130  horsepower).   The annual cost to operate this
equipment will be $9,750.

Non-Water Quality Aspects.

1.  Air Pollution:  None'
2.  Solid Waste Disposal:  The sludge  will  be  clamshelled
and landfilled.

Hot Coatings - Terne

Reference  Level  of  Treatment.  No  treatment of effluent.
Tight control of dragout in process.

Additional Energy Requirements. To meet EPA  1977  standards
for  wastewater  discharge  to  public waters, modifications
will be required to the wastewater  treatment  system.   The
additional   power  consumed  will  be  3.36  kwh/kkg   (3.05
kwh/ton)   processed.   For  the  typical  635  kkg/day  (700
ton/day)   facility,  the  power  required will be 89 kw (120
                                559
-------
                                   TABLE 144
                         WATER EFFLUENT TREATMENT COSTS
                                 STEEL INDUSTRY

                           HOT COATINGS - GALVANIZING
Treatment or Control Technologies
 Identified under Item III of the
 Scope of Work:                      A
         BPCTCA
            BATEA
Investment                       $	0

Annual Costs:

  Capital                        	0

  Depreciation                   	0

  Operation & Maintenance        	0

  Sludge- Disposal                	0

  Energy & Power                 	0

  Oil Disposal                   	0

  Chemical Costs                 	0

TOTAL                            $	0

Effluent Quality:

  Effluent Constituents
  Parameters  -  units

  Flow, gal./ton  (With No Scrubber)   600
  (With Fume Scrubber)           	1200

  Suspended Solids, mg/1          120-200

  Oil and Grease, mg/1             25-75

  Chromium, Total, mg/1            12-16

  Chromium, Cr+6, mg/1             10-12

  Zinc, mg/1	          75-140
  $ 585.333   $ 225.995   $ 193,336
     25,169

     58,533

     20,436
      7,500
  9,718
  8,314
 22,599

  7.909
  2,250

  2,548

 16,092
  $ 111,688   $  61,116   $ ' 38,421
193,333

  6.767

    257

  3,750
Resulting Effluent Levels
        600
       1200
     50-100
     15-30
      5-10
      4-6
  PJL
                                    2-6
     15-75

      3-5
 600
1200
  50
  15
   0.02
 100
 250
  25
  10
               0.1
   0.02
                                                            6-9
             6-9
                                      560
-------
                                    TABLE 143
                         WATER EFFLUENT TREATMENT COSTS
                                 STEEL INDUSTRY

                              HOT COATINGS - TERNE
Treatment or Control Technologies
 Identified under Item III of the
 Scope of Work:
                 BPCTCA
                      BATEA
                        D
Investment

Annual Costs:

  Capital

  Depreciation

  Operation & Maintenance

  Sludge Disposal

  Energy & Power

  Oil Disposal

  Chemical Costs

TOTAL

Effluent Quality:

  Effluent Constituents
  Parameters  -  units

  Flow, gal./ton (With No Scrubber)
  (With Fume Scrubber)

  Suspended Solids, mg/1

  Oil and Grease, mg/1

  Lead, mg/1	
                                             $ 585.333   $ 208,538   $ 193,336
                                                25,169

                                                58,533

                                                20,486
                                                 7,500
                          8,967
                         20,854

                          7,299
                          1,500

                          2,548

                         12,124
                        8,314
                       19,333

                        6,767
                                                                           257
                        3,750
                                             $ 111,688   $  53,292   $'  38,421
                                           Resulting Effluent Levels
  Tin, mg/1

  PH	
r) 600
1200
120-200
600
1200
50-100
600
1200
50
 25-75

1.2-2.0

 10-30

  2-6
                                                15-30
                                              0.75-1.5
5-15

3-5
             15
              0.5
                                                                         100
                                                                         250
                                                                          25
10
0.25
                         6-9
                       6-9
                                      561
-------
                               TABLE 146-1

                    WATER EFFLUENT TREATMENT COSTS
                            STEEL INDUSTRY

              MISCELLANEOUS RUNOFFS - COAL STORAGE PILES
Treatment of Control Technologies
 Identified under Item III of the
 Scope of Work:              BPCTCA
                   BATEA
Investment

Annual Costs:

  Capital

  Depreciation

  Operation & Maintenance

  Sludge Disposal

  Energy & Power

  Oil Disposal

  Chemical Costs

TOTAL
                            I
    A    I
        0
I   B
$343,540
              14,772

              34,354

              12,024
               3,000
               1,220

             $65,370
  C     I
$256,790
               11,042

               25,679

                8,987
                              507
                5,250
                2,000

              $53,465
Effluent Quality:

  Effluent Constituents
  Parameters - Units

  Flow, gal./day*	

  Suspended Solids, mg/1

  Oil and Grease, mg/1

  PH	
          Resulting Effluent Levels

1,600,000    320,000     320,000

 20-2000     20-200
  5-100
  5-10
  5-100
  6-9
                  25
     10
  6-9
*Based on 2.5 inches of rainfall in a 24-hour period on a coal  storage
 pile serving a 5000 ton/day iron-making blast furnace shop.
                                    562
-------
                               TABLE 146-2

                    WATER EFFLUENT TREATMENT COSTS
                            STEEL INDUSTRY

              MISCELLANEOUS RUNOFFS - STONE STORAGE PILES
Treatment of Control Technologies
 Identified under Item III of the
 Scope of Work:              BPCTCA
                  BATEA
Investment

Annual Costs:

  Capital

  Depreciation

  Operation & Maintenance

  Sludge Disposal

  Energy & Power

  Oil Disposal

  Chemical Costs

TOTAL
                               A
      0
I   B
$201,687
             8,672

            20,169
             7,059
             2,475
             1,080

           $39,455
$162,000
                6,966

               16,200
                5,670
                            134
                4,275
                1,770

              $35,015
Effluent Quality:

  Effluent Constituents
  Parameters - Units

  Flow, gal./day*	

  Suspended Solids, mg/1

  Oil and Grease, mg/1

  PH	
        Resulting Effluent Levels

560,000    112,000     112,000

20-2000    20-200
 5-100
 5-10
  5-100
  6-9
                  25
     10
  6-9
*Based on 2.5 inches of rainfall in a 24-hour period on a stone storage
 pile serving a 5000 ton/day iron-making blast furnace shop.
                                  563
-------
                               TABLE  146-3

                    WATER EFFLUENT TREATMENT COSTS
                            STEEL INDUSTRY

               MISCELLANEOUS RUNOFFS - ORE STORAGE PILES
Treatment of Control Technologies
 Identified under Item III of the
 Scope of Work:              BPCTCA
                  BATEA
Investment

Annual Costs:

  Capital

  Depreciation

  Operation & Maintenance

  Sludge Disposal

  Energy & Power

  Oil Disposal

  Chemical Costs

TOTAL
  A    I
      0
I   B
$258,225
            11,103

            25,823

             9,038
             2,775
             1,200

           $49,939
  C     I
$204,640
                8,800

               20,464

                7,162
                            353
                4,725
                1,985

              $43,489
Effluent Quality:

  Effluent Constituents
  Parameters - Units

  Flow, gal./day*	

  Suspended Solids, mg/1

  Oil and Grease, mg/1

  PH	
        Resulting Effluent Levels

226,500     45,300     45,300
20-2000
 5-100
 5-10
  20-200
   5-100
   6-9
    25
    10
 6-9
*Based on 2.5 inches of rainfall in a 24-hour period on an ore storage
 pile serving a 5000 ton/day iron-making blast furnace shop.
                                   564
-------
                          TABLE 146-4

               WATER EFFLUENT TREATMENT COSTS
                       STEEL INDUSTRY

        MISCELLANEOUS RUNOFFS - CASTING AND SLAGGING
Treatment of Control Technologies
 Identified under Item III of the

 Scope of Wor :      REFERENCE LEVEL, BPCTCA & BATEA
                               I   A*   I

Investment                      $51,716         	

Annual Costs:

  Capital                         2,223         	

  Depreciation                    5,172         	

  Operation & Maintenance         1,810         	

  Sludge Disposal              	-         	

  Energy & Power               	-         	

  Oil Disposal                 	-         	

  Chemical Costs
TOTAL                            $9,205
Effluent Quality:

  Effluent Constituents
  Parameters - Units           Resulting Effluent Levels '

  Flow, gal./day*	           Q            	

  Suspended Solids, mg/1       	0            	

  Oil and Grease, mg/1         	0             	

  PH	                      	-
*Costs shown are based on excavation of slag pits suitable
 for handling all slag generated by a 5000 ton/day iron-
 making blast furnace shop.

                           565
-------
horsepower).  The annual coust  to  operate  this  equipment
will be $9,000.

Non-Water Quality Aspects.
1.  Air Pollution:  None
2.  Solid Waste Disposal:  The sludge  will
    and landifilled.
                                            be   clamshelled
Specialty Steel Pickling Cleaning and Coating Operations

For  these categories costs were based upon a plant designed
to treat the combined wastewaters from a mill with a 750 gpm
flow.  Costs were then scaled to the  size  appropriate  for
each subcategory on the basis of the following:

                         Production  Flow  Ratio of  Capital Cost
                         (tons/day)   (gpm)   Flows      Factor
Combination Acid Pickling:
  Continuous                 1384     750    1.00
  Batch and Pipe Tube          21      15    0.02
  Other Batch                 144      30    0.04
Kolene Scale Removal           29      15    0.020
Hydride Scale Removal          60      75    0.10
Continuous Alkaline Cleaning  144      45    0.06
Wire Coating and Pickling     547     500    0.67
                                                         1.00
                                                         0.096
                                                         0.145
                                                         0.096
                                                         0.251
                                                         0.185
                                                         0.784
Combination Acid Pickling, Scale Removal, Continuous
Alkaline Cleaning, and Wire Pickling and Coating

Reference   Level   of  Treatment;   Once-through  use  with
treatment  by  neutralization  and  solids   separated   via
clarifier  and  vacuum  filter.   Polymer  added  to improve
settling and dewatering.

Additional Energy Requirements:  Additional power  will  not
be  required  to meet proposed standards for 1977, since the
reference level is the BPCTCA treatment model.

Non-Water Quality Aspects ;

1.  Air Pollution:  No air pollution problems are foreseen.
 2.   Solid  Waste  Disposal:    The
 neutralization can be  landfilled.
                                      sludge   produced


ADVANCED TECHNOLOGY, ENERGY, AND NON-WATER IMPACT
by
                               566
-------
                                TABLE  147-1

                      WATER EFFLUENT TREATMENT COSTS
                              STEEL INDUSTRY
               Combination Acid Pickling  - Continuous
Treatment or Control Technologies  BPCTCA
Identified under Item  III of the   BATEA
Scope of Work:                 'A'

Investment                   $1,465,210

Annual Costs:

  Capital                        63,004
  Depreciation                  146,521
  Operation & Maintenance        135,084
  Sludge Disposal                 22,133
  Energy & Power                   7,000
  Chemical                      146,753
TOTAL                         $520,495 	

Effluent Quality:
                      Raw
  Effluent Constituents Waste
  Parameters-units      Load       RESULTING  EFFLUENT LEVELS

Flow,  gal/ton	1,000	1,000	

Suspended Solids, mg/1  _250	25	

Oil S Grease, mg/1	5	10	

Piss.  Chromium,  mg/1   25	0 . 5	

Piss.  Nickel, mg/1     15	0. 25	

Piss.  Iron, mg/1	100	1	

Fluoride,  mg/1	100	15	

pH	      4          6-9
                                 567
-------
                                 TABLE 147-2
                       WATER  EFFLUENT TREATMENT COSTS   -
                              STEEL INDUSTRY
          Combination Acid Pickling - Batch Pipe  £ Tube
Treatment  or Control Technologies   BPCTCA
Identified under Item III  of the    BATEA
Scope of Work:                  i
Investment
Annual  Costs:
  Capital
  Depreciation
  Operation  & Maintenance
  Sludge Disposal
  Energy & Power
  Chemical
TOTAL
Effluent Quality:
                       Raw
  Effluent Constituents Waste
  Parameters-units      Load
 1      A
$140.118
    6,025
  14,012
   1,627
      266
       84
    1,768
 $23,782
    RESULTING EFFLUENT LEVELS
Flow, pa~l/-|-on
Snsppnded Solids, mg/1
TH s s - nhroirri i mi , mg/ 1
Hiss. Nickel, mg/1
Diss. IronT mg/1
Fluoride, mg/1
PH
Oil £ Grease, mg/1
700
5
150
75
1100
500
2
5
700
25
0.5
0. 25
1
15
6-9
10
                                568
-------
                                 TABLE 147-3

                       WATER  EFFLUENT TREATMENT COSTS
                              STEEL INDUSTRY
               Combination  Acid Pickling  - Other  Batch
Treatment or Control Technologies   BPCTCA
Identified under Item III of the    BATEA
Scope of Work:                  r    A—'

Investment                     $212,455

Annual Costs:

  Capital                          9,135
  Depreciation                    21,246
  Operation  & Maintenance          3,243
  Sludge Disposal              	530
  Energy &  Power               	168
  Chemical                         3,523
TOTAL                           $37,845 	

Effluent Quality:
                       Raw
  Effluent Constituents Waste
  Parameters-units      Load        RESULTING EFFLUENT LEVELS
Flow, gal/ton
Suspended Solids, ms/l
Diss. Chromium, me/1
Diss. Nickel, mg/1
Diss. Iron, mg/1
Fluoride, mg/1
Oil g Grease, mg/1
DH
200
100
25
20
150
250
I
2
200
25
0.5
0.25
1
15
10
6-9
                                 569
-------
                                 TABLE 148-1
                       WATER EFFLUENT TREATMENT COSTS
                              STEEL INDUSTRY
                        Scale Removal -Kolene
                                  A
                              $140,QUO
                                 6,025
                                114,012
Treatment or Control Technologies
Identified under Item III of the  BPCTCA
Scope of Work:                   BATEA
Investment
Annual Costs:
  Capital
  Depreciation
  Operation & Maintenance
  Sludge Disposal
  Energy & Power
  Chemical
TOTAL
Effluent Quality:
                                 1,627
                                    266
                                 1.768
                               $23,782
                       Raw
  Effluent Constituents  Waste
  Parameters-units      Load
                       500
                                  RESULTING EFFLUENT LEVELS
                                  500	
Suspended Solids, mg/1  300
                                   25
Piss.  Chromium, mg/1  2.100
                                  0.5
Hex. Chromium, mg/1   1.700
                                 0.05
Diss. Iron, me/l
                        0.5
                       13 +
1.0
                                6-9
                                   570
-------
                                 TABLE 148-2
                       WATER EFFLUENT TREATMENT COSTS
                              STEEL INDUSTRY
                       Scale  Removal - Hydride
                                  A
                              $367,768
                                15,811
                                36,777
Treatment  or Control Technologies
Identified under Item III  of  the  BPCTCA
Scope of Work:                   BATEA
Investment
Annual  Costs:
  Capital
  Depreciation
  Operation & Maintenance
  Sludge Disposal
  Energy & Power
  Chemical
TOTAL
Effluent Quality:
                                  8,084
                                 1,321
                                    419
                                  8,782
                                71,197
                       Raw
  Effluent Constituents Waste
  Parameters-units      Load
 Flow, gal/ton
                       1,200
  RESULTING EFFLUENT  LEVELS
1,200	
SusTgended Solids, mg/1
                          375
   25
 Cyanide,  mg/1
_PH	
                           1.0
                           12
 0.25
6-9
                                   571
-------
                                 TABLE 149
                       WATER EFFLUENT TREATMENT COSTS
                               STEEL INDUSTRY
                      Wire  Pickling  and  Coating
Treatment or Control Technologies
Identified under Item III of the    BPCTCA
Scope of Work:
Investment
Annual Costs:
  Capital
  Depreciation
  Operation  & Maintenance
  Sludge Disposal
  Energy & Power
  Chemical
TOTAL
Effluent Quality:
                       Raw
  Effluent Constituents Waste
  Parameters-units      Load
         BATEA
      1,1^8,725
         49,395
        114,873
         57,537
           9,402
           2,979
         62,502
        296,688
 Flow,  gal/ton
1,000
  RESULTING EFFLUENT LEVELS
1,000
 Suspended Solids,  mg/1
  450
   25
 Cyanide,  mg/1
   30
 0.25
Piss. Nickel, mg/1
   35
 0.25
 Piss. Iron, mg/1
   25
  1.0
 Piss. Copper, mg/1
   10
 0.25
 Diss. Chromium, mg/1
   15
  0.5
 Fluoride, mg/1
 pH
   35
   15
         6-9
                              572
-------
                                 TABLE  150

                       WATER  EFFLUENT TREATMENT COSTS
                               STEEL INDUSTRY
                     Continuous Alkaline  Cleaning
Treatment or Control Technologies  BPCTCA
Identified under Item III of the _.BATEA_
Scope of Work:                  r    A   n

Investment                     $271,061

Annual  Costs:

  Capital                        11,656
  'Depreciation                    27,106
  Operation & Maintenance          4,861
  Sludge Disposal              	795
  Energy &  Power               	252
  Chemical                          5,281
TOTAL                           $1+9,957	

Effluent Quality:
                       Raw
  Effluent  Constituents Waste
  Parameters-units      Load       RESULTING EFFLUENT LEVELS

Flow, gal/ton	50	50
Suspended Solids, ing/1
Oil £
Diss .
Diss .
Diss .
PH
Grease, mg/1
Iron, mp/1
Cr, mg/1
Nickel, mg/1

560
1
60-
20
10
10 +
25
10
1
0.5
0.25
6-9
                                573
-------
The   energy  requirements  and  non-water  quality  aspects
associated with the advanced treatment technology  for  each
subcategory are discussed below.

Basic Oxygen Furnace Operation

Wet Systems

1.   Additional  Power  Requirements:   Additional equipment
will be required to improve the waste water  system  to  the
anticipated    1983   standard.    The   additional   energy
consumption will be 0.53 kwh/kkg  (0.48  kwh/ton)  of  steel
produced.   The annual operating cost for the consumption of
this extra power will be approximately $5,679.00.

2.  Non-Water Quality Aspects

    a.   Air Pollution:  The additional waste  water  equip-
         ment  required  will  not affect the quality of the
         exhaust gases  released  to  the  atmosphere.   The
         particulate emissions will be the same as they were
         for 1977.
    b.   Solid Waste Disposal:  Same as 1977
Vacuum Degassing

1.  Additional Power Requirements:  To improve  the  quality
    of  the  waste  water  treatment  system effluent to the
    anticipated  1983  standard,  will  require   additional
    equipment.   The  additional power requirement is 291 kw
     (390 hp) .  This equates to 15.9 kwh/kkg  (14.4  kwh/ton)
    of  steel produced.  The cost to operate this additional
    equipment will be $29,250.00.

2.  Non-Water Quality Aspects

    a.  Air  Pollution:  Same as 1977
    b.  Solid Waste Disposal:  Same as 1977

Continuous Casting Operation

1.  Additional  Power  Requirements:   Additional  equipment
will   be    required  to   improve  the  water  to  meet  the
anticipated   1983   standard.    The   additional    energy
consumption  will  be  0.53 kwh/ kkg  (0.48 kwh/ton) of steel
produced.  The additional  power requirements will be 12.0 kw
 (166  hp)   for  the  typical   544  kkg/day    (600   ton/day)
continuous   casting facility.  The annual operating cost due
to the addition of this equipment will be $1,206.
                              574
-------
2.  Non-Water Quality Aspects

    a.   Air Pollution:  Same as 1977
    b.   Solid Waste Disposal:  Same as 1977

Hot Forming - Primary

Additional Energy Requirements.  To meet EPA 1983  standards
for  wastewater  discharge  to  public waters, modifications
will be required to the wastewater  treatment  system.   The
additional   power  consumed  will  te  0.74  kwh/kkg  (0.67
kwh/ton) processed.  For the typical  3,628  kkg/day  (4,000
ton/day)  facility,  the  power required will be 112 kw (150
horsepower).  The annual cost to operate this equipment will
be $11,250.

Non-Water Quality Aspects.

1.  Air Pollution:  None
2.  Solid Waste Disposal:  The sludge will be collected and
    recycled to melting operations.

Hot Forming - Section

Additional Energy Requirements.  To meet EPA 1983  standards
for  wastewater  discharge  to  public waters, modifications
will be required to the wastewater  treatment  system.   The
additional   power  consumed  will  be  9.10  kwh/kkg  (8.25
kwh/ton) processed.  For the typical  1,179  kkg/day  (1,300
ton/day)  facility,  the  power required will be 447 kw (600
horsepower).  The annual cost to operate this equipment will
be $45,000.

Non-Water Quality Aspects.

1.  Air Pollution:  None
2.  Solid Waste Disposal:  The sludge will be collected and
    recycled to melting operations.

Hot Forming - Flat - Plate

Additional Energy Reguirements.  To meet EPA 1983  standards
for  wasteviater  discharge  to  public waters, modifications
will be required to the wastewater  treatment  system.   The
additional   power  consumed  will  be  8.88  kwh/kkg  (8.05
kwh/ton) processed.  For the typical  1,814  kkg/day  (2,000
ton/day)  facility,  the  power required will be 671 kw (900
horsepower).  The annual cost to operate this equipment will
be $67,500.
                            575
-------
Non-Water Quality Aspects.

1.  Air Pollution:  None
2.  Solid Waste Disposal:  The sludge will be collected and
    recycled to melting operations.

Hot Forming - Flat  - Hot Strip and Sheet

Additional Energy Requirements.  To meet EPA 1983  standards
for  wastewater  discharge  to  public waters, modifications
will be reguired to the wastewater  treatment  system.   The
additional   power  consumed  will  be  7.79  kwh/kkg  (7.07
kwh/ton) processed.  For the typical  3,447  kkg/day  (3,800
ton/day)  facility,  the  power  required  will  be 1,119 kw
(1,500  horsepower).   The  annual  cost  to  operate   this
equipment will be $112,500.

Non-Water Quality Aspects.

1.  Air Pollution:  None
2.  Solid Waste Disposal:  The sludge will be collected and
    recycled to melting operations.

Pipe and Tubes - Integrated

Additional  Energy Reguirements.  To meet EPA 1983 standards
for wastewater discharge  to  public  waters,  modifications
will  be  required  to the wastewater treatment system.  The
additional power consumed will be 8.6 kwh/kkg (7.8  kwh/ton)
processed.   For  the  typical  363  kkg/day  (400  ton/day)
facility,  the  power  required  will   be    130   kw    (175
horsepower).  The annual cost to operate this equipment will
be $13,125.

Non-Water Quality Aspects.

1.  Air Pollution:  None
2.  Solid Waste Disposal:  The sludge will be clamshelled
    and landfilled, or recycled to melting operations.

Pipe and Tubes -  Isolated

Additional Energy Requirements.  To meet EPA  1983  standards
for  wastewater   discharge   to  public waters, modifications
will be required  to the wastewater  treatment  system.   The
additional   power  consumed  will  be   1.26  kwh/kkg   (1.14
kwh/ton)  processed.   For   the  typical  363  kkg/day   (400
ton/day)  facility,  the  power  required  will be 19 kw  (25
horsepower).  The  annual  cost to operate this equipment will
be $1,875.
                              576
-------
Non-Water Quality Aspects.

1.  Air Pollution:  None
2.  Solid Waste Disposal:  The sludge  will  be  clamshelled
    and landfilled, or recycled to melting operations.

Pickling - Batch Sulfuric Acid - Concentrated

Additional  Energy Requirements.  To meet EPA 1983 standards
for wastewater discharge  to  public  waters,  modifications
will  be  required  to the wastewater treatment system.  The
additional power  consumed  will  be  33.33  kwh/kkg   (30.23
kwh/ton)  processed.   For  the  typical  227  kkg/day  (250
ton/day) facility, the power required will be  315  kw  (422
horsepower).  The annual cost to operate this equipment will
be $31,666.

Non-Water Quality Aspects.

1.  Air Pollution:  None
2.  solid Waste Disposal:  The sludge will be clamshelled
    and landfilled.

Pickling - Batch Sulfuric Acid - Rinse

Additional Energy Requirements.  To meet EPA 1983  standards
for  wastewater  discharge  to  public waters, modifications
will be required to the wastewater  treatment  system.   The
additional   power  consumed  will  te  2.90  kwh/kkg  (2.63
kwh/ton)  processed.   For  the  typical  227  kkg/day  (250
ton/day)  facility, the power required will be 27.4 kw (36.7
horsepower).  The annual cost to operate this equipment will
be $2,754.

Non-Water Quality Aspects.

1.  Air Pollution:  None
2.  solid Waste Disposal:  The sludge will be clamshelled
    and landfilled.

Pickling -  Continuous  Sulfuric  Acid  -  Concentrates  and
Rinses - Neutralization

Additional  Energy Requirements.  To meet EPA 1983 standards
for wastewater discharge  to  public  waters,  modifications
will  be  required  to the wastewater treatment system.  The
additional  power  consumed  will  be  0.60  kwh/kkg   (0.54
kwh/ton)  processed.   For the typical 1,088 kkg/kday  (1,200
ton/day) facility, the power required will be  27  kw  (36.7
                              577
-------
horsepower).  The annual cost to operate this equipment will
be $2,700.

Non-Water Quality Aspects.

1.  Air Pollution:  None
2.  Solid Waste Disposal:  Sludges will be  clamshelled  and
    landfilled.

Pickling - Hydrochloric Acid - Concentrated - Alternate I

Additional  Energy  Requirements. To meet EPA 1983 standards
for wastewater discharge  to  public  waters,  modifications
will  be  required  to the wastewater treatment system.  The
additional  power  consumed  will  be  0.13  kwh/kkg   (0.12
kwh/ton)   processed.   For  the typical 2,721 kkg/day  (3,000
ton/day)  facility, the power required will be  14.9  kw  (20
horsepower).  The annual cost to operate this equipment will
be $1,500.

Non-Water Quality Aspects.

1.  Air pollution:  None
2.  Solid Waste Disposal:  The sludge will be clamshelled
    and landfilled.

Pickling - Hydrochloric Acid - Rinse - Alternate I

Additional  Energy Requirements.  To meet EPA 1983 standards
for wastewater discharge  to  public  waters,  modifications
will  be  required  to the wastewater treatment system.  The
additional  power  consumed  will  be  0.24  kwh/kkg   (0.22
kwh/ton)   processed.   For  the typical 2,721 kkg/day  (3,000
ton/day)   facility, the power required  will  be  27  kw  (36
horsepower).  The annual cost to operate this equipment will
be $2,720.

Non-Water Quality Aspects.

1.  Air Pollution:  None
2.  Solid Waste Disposal:  The sludge will be clamshelled
    and landfilled.

Pickling  -  Hydrochloric Acid -  Concentrates  and  Rinses
Alternate II

Additional  Energy Requirements.  To meet EPA 1983 standards
for wastewater discharge  to  public  waters,  modifications
will  be  required  to the wastewater treatment system.  The
additional  power  consumed  will  be  0.24  kwh/kkg    (0.22
                               578
-------
kwh/ton)   processed.   For  the typical 2,721 kkg/day (3,000
ton/day)  facility, the power required  will  be  27  kw  (36
horsepower).  The annual cost to operate this equipment will
be $2,720.

Npn-Water Quality Aspects.

1.  Air Pollution:  None
2.  Solid Waste Disposal:  The sludge will be clamshelled
    and landfilled.

Hot Coatings - Galvanizing and Terne Plating

Additional Energy Requirements.  To meet EPA 1983  standards
for  wastewater  discharge  to  public waters, modifications
will be required to the wastewater  treatment  system.   The
additional   power  consumed  will  be  1.UO  kwh/kkg  (1.27
kwh/ton)   processed.   For  the  typical  635  kkg/day   (700
ton/day)   facility,  the  power  required  will be 37 kw (50
horsepower).  The annual cost to operate this equipment will
be $3,750.

Non-Water Quality Aspects.

1.  Air Pollution:  None
2.  Solid Waste Disposal:  The sludge will be clamshelled
    and landfilled.

Specialty Steel Co mbi ft at ion Acid  Pickling,  Scale  Removal,
Continuous Alkaline Cleaning, and Wire Pickling and Coating
Additional  Energy  Reguirements;  Additional power will not
be required to meet standards for 1983, since the base level
is the BATEA treatment model.

Non-Water Quality Aspects;

1.  Air Pollution:  No air pollution problems are foreseen.

2.   Solid  Waste  Disposal:    The   sludge   produced   by
neutralization can be landfilled.
                              579
-------
                         SECTION IX

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

The effluent limitations which must be achieved by  July  1,
1977  are to specify the effluent quality attainable through
the application of the Best Practicable  Control  Technology
Currently  Available.   Best  Practicable control Technology
Currently Available is generally based upon the  average  of
the  best  existing  performance by plants of various sizes,
ages, and unit processes within the industrial  subcategory.
This  average  is  not  based  upon  a broad range of plants
within the steel industry, but based upon performance levels
achieved  by  plants  purported  by  the  industry   or   by
regulatory  agencies  to be equipped with the best treatment
facilities.  Experience demonstrated that in some  instances
these  facilities  were  exemplary  only in the control of a
portion  of  the  waste  parameters   present.    In   those
industrial  categories  where  present control and treatment
practices  are  uniformly  inadequate,  a  higher  level  of
control  than  any currently in place may be required if the
technology to achieve such higher level can  be  practicably
applied by July 1, 1977.

Considerations must also be given to:

1.  The size and age of equipment and facilities involved

2.  The processes employed

3.  Non-water quality environmental impact (including energy
requirements)

4.  The engineering aspects of the  application  of  various
types of control techniques

5.  Process changes

6.  The total cost of application of technology in  relation
to  the effluent reduction benefits to be achieved from such
application

Also,  Best   Practicable   Control   Technology   Currently
Available  emphasizes  treatment  facilities at the end of a
manufacturing process, but includes the control technologies
                                 581
-------
within the process itself when the latter are considered  to
be normal practice within an industry.

A  further  consideration  is  the  degree  of  economic and
engineering reliability which must be  established  for  the
technology  to  be  "currently  available."   As a result of
demonstration projects, pilot plants and general user  there
must  exist  a  high degree of confidence in the engineering
and economic practicability of the technology at the time of
commencement of construction or installation of the  control
facilities.

IDENTIFICATION   OF   BEST  PRACTICABLE  CONTROL  TECHNOLOGY
CURRENTLY AVAILABLE - BPCTCA - BY SUBCATEGORY

G.  Basic Oxygen Furnace - Wet Air Pollution Control Methods
- thickener with polymer addition to  the  feed  and  vacuum
filtration  of  the thickener underflow.  550 gal/ton of the
thickener overflow is recycled, while  50  gal/ton  of  this
recycle flow is discharged.

K.  Vacuum Degassing - sedimentation with recycle of  solids
to  sinter;  recycle  and  cooling of 535 gal/ton of process
waters over cooling towers and discharge of  25  gal/ton  of
blowdown.

L.  Continuous  Casting  and   Pressure   Slab   Molding
sedimentation  with  continuous  dragout  and  oil skimming,
recycle flow over a cooling  tower  and  filtration  of  the
entire recycle flow.  Slowdown is 125 gal/ton.

M.   Hot  Forming-Primary  - primary scale pit, oil skimmer,
followed by recycle of 489 gpt  (692 gpt for alloy)  back  to
the  flume  for  flushing.   This is followed by a clarifier
with a vacuum filter on the underflow, and a deep bed filter
on the overflow.  At this point 845 gpt  (1220 gpt for alloy)
is discharged for BPT.

N.  Hot Forming-Section - primary scale pit  (assumed  to  be
part  of  the  operation,  rather  than  a pollution control
expense) , followed by an oil skimmer followed by recycle  to
the  flume  of  3,405  gpt  of  scale pit effluent, with the
remainder  (2626 gpt) going to a clarifier and  the  overflow
from the clarifier filtered prior to discharge.

O.  Hot Forming-Flat-Plate - primary scale pit, oil skimmer,
with 1,500 gpt  (3,513  gpt  for  alloy)  of  the  scale  pit
effluent  recycled  to  the  flume.   The  remainder   (4,000
gpt(9,366  for  alloy))  goes  through   a  clarifier,   with
                             582
-------
chemical treatment, with vacuum filtration of the underflow,
and the overflow filtered and discharged.

    Hot  Strip  and  Sheet - primary scale pit, oil skimmer,
with recycle of 3,835 gpt of the scale pit effluent  to  the
flume for flushing.  The remainder of the scale pit effluent
is  clarified,  with  the  underflow  vacuum  filtered.  The
overflow (4,180 gpt) is pressure filtered and discharged.

P.  Pipe and Tubes - following the primary  scale  pit,  the
integrated  plant  BPT  treatment  model  consists of an oil
skimmer and a clarifier,  with 3,207 gpt  of  the  clarifier
effluent  recycled to the flume.  The remaining 1,002 gpt is
filtered and discharged.  For BATr this flow is  cooled  via
cooling   tower   and  totally  recycled,  resulting  in  no
discharge.  The isolated plant model  is  identical  to  the
integrated  one  except  that  ponds replace the clarifiers,
filters, and cooling tower in the  integrated  plant  model.
The effluent limitations for BPT and BAT are the same as for
the integrated plants.

Q.  Pickling-Sulfuric Acid-Batch and Continuous Concentrates
acid recovery unit  or  neutralization  for  those  who  are
neutralizing as of December 1, 1975.

    Pickling-Sulfuric  Acid-Batch  and  Continuous  Rinses -
counter-current rinsing, with the rinsewater used to  dilute
the  concentrated  acid (after acid recovery) to make up the
pickle bath; neutralization for those who are doing so as of
December 1, 1975.

R.  Pickling-Hydrochloric Acid Batch and Continuous - Batch:
    Concentrates - segregated collection of acid wastes  and
equalization,   segregated  collection  of  caustic  wastes,
neutralization by waste blending,  lime  treatment,  mixing,
aeration, polymer addition, one day settling.

    Rinses  -  equalization  with  acid  and caustic wastes,
neutralization by chemical addition,  mixing  aeration,  one
day settling.

    Fume  Hood  Scrubber  -  equalization, neutralization by
chemical addition, mixing, aeration, one day settling.

Continuous:
    Concentrates  -  neutralization  by  chemicals,   mixing
aeration, one day settling.
                               583
-------
    Absorber    Vent    Scrubber    -   Acid   regeneration,
neutralization  by  chemicals  (lime),  aeration,  one   day
settling.

    Rinses  -  neutralization  by  chemicals (lime) , mixing,
aeration, polymer addition, one day settling.

    Fume Hood Scrubber - neutralization by chemicals (lime),
mixing, aeration, polymer addition, one day settling.

S.  Cold Rolling-Recirculation - oil skimming,  equalization,
chemical treatment and flocculation, air flotation,   surface
skimming, settling lagoon with 2-5 day retention.

    Cold  Rolling-Combination  - oil skimming,  equalization,
chemical treatment and flocculation, air flotation,   surface
skimming, settling lagoon with 2-5 day retention.

    Cold   Rolling-Direct   Application   -   oil  skimming,
equalization,  chemical  treatment  and  flocculation,   air
flotation,  surface  skimming,  settling lagoon with 2-5 day
retention.

T.  Hot  Coat  -  Galvanizing   -   segregated   collection,
equalization,  neutralization  by  waste  blending,   mixing,
hexavalent  chrome  reduction,  neutralization  by  chemical
addition, polymer addition.

U.  Hot Coat-Terne -  segregated  collection,  equalization,
neutralization  by waste blending, mixing settling lagoon (1
day) , oil skimming.

V.  Mi seellaneous  Runoff s-Casti nq  and  Slagging  -   water
conservation to prevent runoff.

W.  Combination   Acid-Batch   and    Continous    -    lime
neutralization  and  clarification  with flocculant addition
and vacuum filtration of underflow.

X.  scale Removal - Kolene and Hydride -  for  kolene  waste
waters,  acidification  and reduction with sulfur dioxide of
hexavalent chromium;  for  hydride  waste  waters,  chemical
oxidation  of cyanides; the specific pretreatment step to be
followed  by  lime  neutralization  and  clarification  with
flocculant addition and vacuum filtration of the underflow.

Y.  Wire Pickling and  Coating  -  lime  neutralization  and
clarification with flocculant addition and vacuum filtration
of the underflow.  Alkaline chlorination for cyanide removal
as a pretreatment, if necessary.
                             584
-------
Z.  Continuous  Alkaline  Cleaning  -   neutralization   and
clarification with flocculant addition and vacuum filtration
of the underflow.

In  establishing  the subject guidelines, it should be noted
that the resulting limitations or standards  are  applicable
to  aqueous  waste  discharge  only, exclusive of noncontact
cooling  waters.   In  the  section  of  this  report  which
discusses  control and treatment technology for the iron and
steelmaking industry as a whole, a qualitative reference has
been given regarding "the environmental  impact  other  than
water" for the subcategories investigated.

The effluent guidelines established herein take into account
only  those  aqueous  constituents  considered  to  be major
pollutants in each of the  subcategories  investigated.   In
general,  the  critical  parameters  were  selected for each
subcategory on the basis of those waste  constituents  known
to  be  generated in the specific manufacturing process, and
also known to  be  present  in  sufficient  quantity  to  be
inimical  to  the  environment.  Certain general parameters,
such as suspended solids, naturally include  the  oxides  of
iron and silica, however, these latter specific constituents
were  not  included  as  critical parameters, since adequate
removal of the general -parameter (suspended solids) in  turn
provides   for   adequate   removal  of  the  more  specific
parameters indicated.  This does not hold true when  certain
of  the  parameters  are in the dissolved state; however, in
the  case  of  iron  oxides  generated  in  the   iron   and
steelmaking  processes, they are for the most part insoluble
in the  relatively  neutral  effluents  in  which  they  are
contained.    The   absence   of   apparent  less  important
parameters  from  the  guidelines   in   no   way   endorses
unrestricted discharge of same.

The  recommended  effluent limitations guidelines for BPCTCA
resulting from this study are summarized in  Tables  151  to
173.   These  tables  also  list  the  control and treatment
technology applicable or  normally  utilized  to  reach  the
constituent  levels  indicated.   Figures 128 to 150 present
the BPCTCA treatment  models.   These  effluent  limitations
contained  herein are by no means the absolute lowest values
attainable (except where no discharge of process  wastewater
pollutant  is  recommended)  by the indicated technology, but
moreover  they  represent  values  which  can   be   readily
controlled around on a day by day basis.

It should be noted that these effluent limitations represent
values  not to be exceeded by any 30 continuous day average.
The maximum daily effluent  loads  per  unit  of  production
                           585
-------





































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should  not  exceed  these  values  by a factor of more than
three.  In the absence of sufficient performance  data  from
the  industry  to  establish  these factors on a statistical
basis, the factor of three was chosen  in  consideration  of
the  operating  variations  allowed  for in selecting the 30
continuous day average limitations.

RATIONALE FOR SELECTION OF BPCTCA

The following paragraphs summarize  the  factors  that  were
considered in selecting the categorization, water use rates,
level   of  treatment  technology,  effluent  concentrations
attainable by the technology, and hence in the establishment
of the effluent limitations for BPCTCA.

Size  and  Age   of   Facilities   and   Land   Avai labi li ty
Considerations

As  discussed  in  Section  IV,  the  age  and size of steel
industry  facilities  has  little  direct  bearing  in   the
quantity  or quality of wastewater generated.  Thus, the ELG
for a given subcategory of waste source applies  equally  to
all plants regardless of size or age.  Land availability for
installation  of  add-on  treatment facilities can influence
the type of technology utilized to meet the ELG's.  This  is
one  of  the considerations which can account for a range in
the costs that might be incurred.

Consideration of Processes Employed

All plants in a given subcategory use the  same  or  similar
production  methods, giving similar discharges.  There is no
evidence that operation of any current process or subprocess
will substantially affect capabilities to implement the best
practicable control technology currently available.  At such
time  that  new  processes   appear   imminent   for   broad
application,  the  ELGs should be amended to cover these new
sources.  No changes in process employed are  envisioned  as
necessary  for  implementation of this technology for plants
in any subcategory.  The treatment technologies  to  achieve
BPCTCA  are  end-of  process methods which can be added onto
the existing treatment facilities.

Consideration of Non-Water Quality Environmental Impact

Impact gf Limitations on Air Quality.  The increased use  of
recycle systems has the potential for increasing the loss of
volatile  substances to the atmosphere.  Recycle systems are
so effective in reducing wastewater volumes, and hence waste
loads, to and from treatment systems, and  in  reducing  the
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size  and  cost  of  such treatment systems that a trade-off
must be accepted.  Recycle  systems  requiring  the  use  of
cooling  towers have contributed significantly to reductions
of effluent loads, while contributing only minimally to  air
pollution  problems.  Careful operation of these systems can
avoid or minimize air pollution problems.

There  are  no  air  pollution  problems  which  have   been
identified  as resulting from the application of the control
and treatment technologies described herein.   The  handling
and  storage of spent nitric-hydrofluoric pickling solutions
must be done with care to avoid fumes  of  nitrogen  oxides.
One plant uses floating plastic balls on the surface of open
tanks to avoid this problem.

Impact    of    Limitations   on   Solid   Waste   Problems.
Consideration has also been given to the solid waste aspects
of water pollution controls.   The processes for treating the
wastewaters from this industry produce considerable  volumes
of sludges.  Much of this material is inert iron oxide which
can  be  reused  profitably  in  melting  operations.  Other
sludges  not  suitable  for  reuse  must  be   disposed   in
landfills, since they are mainly chemical precipitates which
could    be   little   reduced   by   incineration.    Being
precipitates, they are by nature  relatively  insoluble  and
nonhazardous substances requiring minimal custodial care.

The   solid  waste  problem  of  most  significance  is  the
generation of sludge from neutralization of spent  solutions
and   rinsewaters.    The  sludge  produced  from  the  lime
neutralization of sulfuric acid spent pickling solutions  is
voluminous,  equal  in  volume  to the original solution and
remains plastic  indefinitely.   Air  oxidation  to  produce
ferric  hydroxide  rather than ferrous hydroxide reduces the
sludge volume and the material is somewhat drier.  Oxidation
to magnetic iron oxide  can  reduce  the  volume  of  sludge
dramatically   and  produce  a  dry  material.   The  sludge
resulting  from  the  neutralization  of   spent   solutions
containing   nitric   acid   contains  mostly  ferric  iron,
resulting in lower volumes and drier materials.

In order to ensure long-term protection of  the  environment
from harmful constituents, special consideration of disposal
sites should be made.  All landfill sites should be selected
so  as to prevent horizontal and vertical migration of these
contaminants to ground or surface waters.   In  cases  where
geologic conditions may not reasonably ensure this, adequate
mechanical  precautions   (e.g., impervious liners) should be
taken to ensure long-term protection to the environment.   A
program   of  routine  periodic  sampling  and  analysis  of
                            627
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                                                     t,  6
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                                                                  i.
641
-------
leachates is advisable.  Where appropriate,  the location  of
solid   hazardous   materials   disposal   sites  should  be
permanently recorded in  the  appropriate  office  of  legal
jurisdiction.

Impact of Limitations on Energy Reguirements.   The effect of
water  pollution control measures on energy requirements has
also been determined.  The additional energy required in the
form of electric power to achieve the  effluent  limitations
for  BPCTCA  and  BATEA  amounts to less than 3% of the 51.6
billion kwh of electrical energy used by the steel  industry
in   1972.   Energy  requirements  in  the  specialty  steel
segments for various levels of treatment have been estimated
and generally do not exceed 2 percent of the 606  kw-hr  per
kkg  (550  kw-hr  per  ton)   of  electric  power required in
electric furnaces producing stainless steel.

The enhancement to  water  quality  management  provided  by
these   effluent  limitations  substantially  outweighs  the
impact on air, solid waste,  and energy requirements.

Consideration of the Engineering Aspects of the  Application
of Various Types of Control Techniques

The  level  of  technology  selected as the basis for BPCTCA
limitations is considered to  be  practicable  in  that  the
concepts are proven and are currently in place and in use by
the  various steel mills as more fully described below.  The
level  of  technology  selected  as  the  basis  for  BPCTCA
limitations  is  considered  to  be  practicable in that the
concepts  are  proven  and  are  currently   available   for
implementation  and  may  be readily applied as "add-ons" to
existing treatment facilities.

Identification of the Best Practicable Control Technology
Currently Available - BPCTCA

Discussion By Subcategories;

The  rationale  used  for  developing  the  BPCTCA  effluent
limitations  guidelines  is summarized below for each of the
Subcategories.   All  effluent  limitations  guidelines  are
presented  on  a  "gross"  basis  since  for  the most part,
removals   are    relatively    independent    of    initial
concentrations  of contaminants.  The ELG^ are in kilograms
of pollutant per metric ton  of  product  or  in  pounds  of
pollutant  per  1,000  pounds  of product and in these terms
only.  The ELG's are not  a  limitation  on  flow,  type  of
technology to be utilized, or concentrations to be achieved.
These  items are listed only to show the basis for the ELG's
                            642
-------
and may be varied as the discharger desires so long  as  the
ELG loads per unit of production are met.

Basic Oxygen Furnace Operation

The  only direct contact process water used in the EOF plant
is the water used for cooling and scrubbing the furnace off-
gases.  One method used is the wet gas cleaning system which
uses a venturi scrubber and a gas quencher.  The use of  wet
air  pollution  control  is  rare in the alloy and stainless
steel industry.  The water use at one plant producing  alloy
steel  in  a EOF was 870 gals/ton.  The water was used once-
through and the only treatment  provided  was  clarification
where  the  EOF  waste water was combined with blast furnace
gaswasher water.

The technology identified as used in the alloy and stainless
steel industry was judged to be inadequate.  The  water  use
rate  lies  within  the  range  found  in  the  carbon steel
industry  (130-1020  gal/ton)  and  there  is  no  reason  to
believe  that  the  technology  in use there is not directly
transferable, since the characteristics of the waste  waters
and  the  nature  of  the processes are similar.  The BPCTCA
limitations have thus been established on the  basis  of  an
effluent  suspended  solids  concentration  of 50 mg/1 at an
effluent volume of 209 1/kkg (50  gals/ton).   The  blowdown
rate of 5.9 percent is being achieved in at least one carbon
steel plant and at least two such plants are achieving lower
effluent  concentrations of suspended solids.  The pH of the
scrubber water effluent from the alloy  steel  EOF  averaged
7.4,  so  that  no  difficulty  with  a pH 6-9 limitation is
foreseen.

Vacuum Degassing Subcategory

The direct contact process water  used  in  specialty  steel
vacuum degassing is the cooling water used for the steam-jet
barometric  condensers.   Although  most  systems  use steam
ejectors to draw the vacuum, dry mechanical pumps  are  also
used.   The  vacuum  degassing systems surveyed in the alloy
and stainless steel industry used  water  once-through  with
little  effective  treatment,  completely  recirculated  -£he
water with no discharge, or use mechanical pumps.

It was judged to be unduly  restrictive  to  impose  a  zero
effluent discharge limitation for BPT because all plants may
not  be  able to completely recirculate the water or convert
to mechanical pumps.  The water use rate determined for  the
once-through  system (3021 1/kkg) lies in the range found in
the carbon steel industry plants  surveys   (813-3750  1/kkg)
                        643
-------
and there is no reason to believe that the technology in use
there    is    not    directly   transferable,   since   the
characteristics of the waste waters and the  nature  of  the
processes  are  similar.   The  BPCTCA limitations have thus
been established on  the  basis  of  an  effluent  suspended
solids concentration at 50 mg/1 at an effluent volume of 101
1/kkg  (25  gals/ton).   The blowdown rate of 3.4 percent is
being achieved in at least one carbon steel  plant  and,  of
course,  in  the  completely  recirculated  system mentioned
above.  At least one carbon steel plant is  achieving  lower
effluent  suspended  solids concentrations and the pH of the
once-through alloy steel systems averaged  6.5  (within  the
specified 6-9 range) .

Continuous Casting and Pressure Slab Molding Subcategory

Continuous  casting  and pressure slab molding are processes
by which primary steel shapes are cast or molded from molten
steel instead of being rolled from ingots.   The  molds  are
cooled   by  indirect  water  circulation.   The  continuous
casting spray cooling water system is direct contact cooling
of the cast product.  As the cast product (slab,  bloom,  or
billet)  emerges  from  the  mold,  the water sprays further
solidify and cool the cast  product.   The  principal  waste
contaminant  in  this  contact  cooling  water  is suspended
solids and, additionally,  oil  from  machinery  lubrication
finds  its  way  into  this  water  effluent.  Pressure slab
molding results in the generation of wastewaters.  containing
suspended solids and oil.

The  current  control  and treatment technology in the alloy
and stainless steel industry consists  of  clarification  of
the waste water with varying degrees of recirculation of the
water  to  the process use.  One plant surveyed recirculated
the water completely with only periodic batch-type  blowdown
of the system.

No  system  in  current use in the alloy and stainless steel
industry was found to be adequate and/or necessarily  usable
at  all other plants; treatments were adequate, but complete
recirculation may not be always  feasible.   The  water  use
rates  of 2379-4173  1/kkg are lower than the minimum of 6172
1/kkg  found in the carbon steel  industry  plants  surveyed.
The  characteristics  of  the waste waters and the nature of
the processes are similar  to  those  in  the  carbon  steel
industry  and  hence  there is no reason to believe that the
technology  in  use  there  is  not  directly  transferable,
resulting  in  a  very  conservative  estimate of achievable
limitations.   The   BPCTCA  limitations   have   thus   been
established  on  the  basis  of  effluent  suspended  solids
                              644
-------
concentrations of 50 mg/1 and of 15 mg/1 oil and  grease  at
an   effluent  volume  of  522  1/kkg  (125  gal/ton).   The
resultant blowdown rates are easily achievable  as  compared
to  those  in either of the carbon steel plants surveyed and
both carbon steel plants were achieving lower concentrations
of both suspended solids and oil  and  grease.   All  plants
surveyed easily achieved an effluent pH between 6 and 9.

Hot Forming-Primary

The  carbon  steel  data base was examined and an average of
the best plants calculated.  The calculated  discharge  rate
was  based  upon the average of the best loadings, which for
this subcategory was the average of the loads at the  plants
surveyed.   In some cases, where the suspended solids or oil
concentrations in the effluent were less than 5 or  10  mg/1
respectively,   the   concentration   for  the  purposes  of
calculating an average load were taken to be 5 or 10.    This
variance  from  actual  data  was  justified on the basis of
analytical accuracy, in  that  although  we  know  that  the
suspended  solids  level was very low, the analytical method
is not totally reliable at less than 5 or 10 mg/1.  From the
calculated  loading,  a  flow  representing  an   achievable
concentration  level  such  as  10  mg/1 for TSS and oil was
calculated.   This  flow  was  used  for  the  cost  of  the
treatment  technology,  since  costs  are  largely  based on
hydraulic flows.

Plants E, H and D in the alloy and stainless steel  industry
plant  survey  had water uses averaging 1912 gal/ton.   Using
direct transfer of technology, the carbon  steel  guidelines
for this category were scaled up to reflect the higher water
use rate.

Hot Forming-Section

The   carbon   steel   data   base   was  examined  and  the
concentrations of pollutants were adjusted if they  averaged
below  the  accepted  minimum  for  that parameter.  In some
plants, more than one section operation had been sampled, so
that  although  7  plants  were  visited,  information   was
available  from  11  operating  lines.   The  loadings  were
calculated for  each  line.   One  plant,  H-2,  which  used
cyclones  for  settling  (TSS was 71 ppm) was discarded from
consideration because the  cyclones  did  not  prove  to  be
exemplary  for TSS or oil removal.  The plant had originally
been sampled to ascertain as to the quality of the treatment
provided by cyclones.  The average load from the  10  plants
which  were  determined to be exemplary was then calculated.
                           645
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Using achievable concentration levels, a discharge flow  for
BPT of 2626 gpt was derived.

The  section  rolling mills in the alloy and stainless steel
industry plant survey in  this  subcategory  had  water  use
rates  which  averaged  to  be slightly less than for carbon
steel.  Directly transferring the technology  results  in  a
conservative effluent limitation.

Hot Forming-Flat Plate

Only  one exemplary carbon plate mill, K-2, was studied.   No
other  plate  mills  with  good  waste  treatment  could  be
identified  since  other  plate  mills  either discharged to
central treatment facilities or had even less treatment.   It
had  a  150  gpt   discharge   rate,   and   the   pollutant
concentrations  for  oil  loading  calculations  had  to  be
adjusted upward to allow for analytical  methods.   The  BPT
loadings  for  TSS  also had to be adjusted upwards to allow
for  achievable  concentrations  in  the  treatment   plant.
Because  the  technology for this operation was so much more
sophisticated than for the other hot forming operations,  the
BPT technology was established at about  the  level  of  the
other hot forming operations and the limitations established
accordingly.   The  sole specialty steel plate mill surveyed
had a water usage rate twice the rate for the  carbon  steel
mill  and  was  judged  to  be  inadequate  from a treatment
standpoint.  Since the waste constituents are  similar,  the
technology  in  use  in  the  carbon segment was transferred
directly, although an allowance was made for the higher flow
rate in the specialty steel segment.

Hot Forming-Flat-Sheet and Strip

The data base was examined and concentrations  adjusted  for
analytical  methods.   The  average  load of the four carbon
steel plants studied was derived from the  loads,  and  this
average was used as the BPT limitation.  The specialty steel
hot  strip  mills  which were surveyed had water usage rates
which were slightly less than  those  in  the  carbon  steel
segment.    However,  none  of  the  specialty  plants  were
practicing recirculation.  Therefore, the technology used in
the carbon steel segment was directly  transferred  and  the
limitations were established as the same for both, resulting
in a conservative limitation for the specialty strip mills.

Pipe and Tube

Six  plants  were studied in the sutcategory, of which three
were electric resistance welding, two were butt weld and one
                              646
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a seamless plant.   One  of  the  ERW  plants  was  excluded
because  it  used  evaporation  as  part  of  the  treatment
technology, which  is  not  generally  applicable  to  steel
plants.  The average load from the five remaining plants was
then  determined,  and  the  technology  for  the cost model
selected.  Two of the plants achieved zero discharge through
total recycle, and this was subsequently  found  to  be  the
limitation  for  BAT.   The  BPT model was subdivided on the
basis of pipe and  tube  operations  integrated  with  other
steel  forming  operations,  and  those  which were isolated
plants.  The data base revealed  that  the  isolated  plants
generally  used  ponds for settling and cooling, rather than
clarifiers and cooling towers,  since  modeling  all  plants
based on use of clarifiers would tend to overstate the cost,
the  subcategory  was  subdivided  up  for  the  purposes of
calculating limitations and costs.

Sulfuric Acid-Batch

Examination of the data base revealed that six  plants  were
treating the pickling concentrated acid.  Five of these were
achieving  zero  discharge  via  sulfuric  acid recovery for
three and waste acid hauling for two.  The  remaining  plant
was  neutralizing  together  with  rinse water, settling and
discharging to the sewer.  Sufficient  data  indicated  that
BPT  limitations  could be established at zero discharge for
the sulfuric acid batch concentrated subcategory.

Six plants were studied that had sulfuric acid batch rinsing
operations.  Three facilities were achieving zero  discharge
by  treating  rinses  via the concentrate recovery unit, and
using the rinsewater  (after countercurrent use) as a diluent
in the concentrate makeup.  One  plant  had  essentially  no
treatment,  another treated along with the concentrated acid
via  settling  and  a  third  treated  rinse  wastewater  by
dilution  with  rod  mill  wastes.   These latter three were
deemed to be inadequate treatment methods.  Average of  best
(three  mills  practicing  zero  discharge)   dictated  a BPT
limitation of zero discharge.

Sulfuric Acid-Continuous

The data base  for  sulfuric  acid  continuous  pickling  is
composed  of six mills.  Considering deep well disposal as a
mechanism for zero discharge of concentrates, then four  out
of  the  six mills were capable of zero discharge  (three out
of the four were practicing deep well disposal).  Out of the
other two  mills  not  attaining  zero  discharge,  one  was
discharging  while  the  other was neutralizing.  Noting the
fundmental   differences   between   acid    recovery    and
                           647
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neutralization  technologies,   a provision was developed for
those   facilities   practicing   acid   neutralization   of
concentrates.

Of  the  six mills, only one mill achieved zero discharge of
the rinse wastewater.  The  others  were  practicing  either
joint treatment (4) or discharging to a sewer (1) .

Recognizing   the  difference  in  neutralization  and  acid
recovery, plants with neutralization facilities existing  at
the time of promulgation will be permitted a discharge of 25
gpt  for  concentrates and 200 gpt for rinses and 25 gpt for
fume hoods  for  BPT.   The  BPT  treatment  model  will  be
neutralization followed by a 1 day settling lagoon.

Sulfuric Acid Pickling - Specialty Steel

There  was  only  one  operation identified in the alloy and
stainless  steel  industry  plant  survey  that   could   be
separated  from  other  pickling and cleaning operations for
the  purposes  of  raw  waste  load  and   treatment   level
specification.   Since  the characteristics and flows of the
wastes  and  nature  of  available  treatments  are  similar
between  the  two  industry segments, it was decided to base
the BPCTCA limitations on those adopted for this subcategory
for carbon steel operations.  The specialty steel plant  was
achieving no discharge of process wastewater pollutants both
for rinses and concentrations.

Pickling  -  Hydrochloric  Acid  -  Batch  and  Continuous -
Concentrates

Batch Pickling Operations.  A  relatively  small  number  of
pickling  operations, predominantly rod and wire processors,
use hydrochloric acid in batch pickling systems.  Production
rates  on  these  units  are  about  half   of   those   for
corresponding  sulfuric  acid lines, so most batch operators
do not generate enough spent hydrochloric acid pickle liquor
to make acid recovery units practical.  Instead, the general
practice has been  contract  hauling  of  batches  of  spent
pickle  baths  to  treatment and ultimate disposal off-site,
where they may be blended with alkaline  wastes  from  other
industrial  sources.  Two plants of this type were surveyed,
and these were either neutralizing to a level acceptable  to
the  municipal  sanitary  authority,  or were using contract
hauling  services  to   dispose   of   spent   concentrates.
Technology  for  treatment  of spent concentrates from batch
hydrochloric acid pickling does exist.  In  most  instances,
it  is  more  practical  to treat spent concentrates jointly
with rinses in one unified treatment system.
                           648
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Continuous   Pickling    Operations.     Plants    utilizing
hydrochloric  acid  for continuous pickling, primarily sheet
and strip lines, are relatively  new  when  contrasted  with
continuous  sulfuric acid pickling lines.  As a result, they
practice more modern control and treatment  technology  than
their  sulfuric  acid  counterparts.   Emphasis is placed on
recovery  of  reusable  hydrochloric  acid  from  all  spent
pickling  concentrated solutions.  Typical lines run at high
production rates, on the order of 1,270 to 5,440 kkg   (1,400
to  6,000  tons)  per  day,  with an average production near
2,720 kkg (3,000 tons)  per day.  Many  plants  operate  more
than  one  line at a given location.  Spent concentrates are
generated at a typical rate of 42 to  65  1/kkg  (10  to  15
gal./ton).

The  three  continuous HCl regeneration systems surveyed are
using the same basic acid recovery process.  Spent  acid  is
evaporated  in  a  gas-fired roaster.  Iron oxide is removed
from the bottom of the roaster while HCl vapors pass  on  to
an  absorber  where  they  are converted into reusable acid.
The inert combustion products pass through the absorber to a
final water scrubber for removal of any residual  HCl  vapor
and  fine  particulates prior to venting to atmosphere.  The
vent scrubber discharge is the only liquid  waste  from  the
acid recovery system, averaging approximately 830 1/kkg (200
gal./ton)   in  flow  rate.   For  those  hydrochloric  acid
pickling  operations  not  practicing   acid   regeneration,
treatment  alternatives  for  spent concentrates ranged from
deep   well   disposal   to   carefully   controlled    lime
neutralization,  jointly  with  the more dilute acidic rinse
waters.  Of the seven  continuous  HCl  pickling  operations
surveyed,  three  were  regenerating  their spent acids, two
were practicing deep well disposal, one was  using  contract
hauling disposal services, and one was blending concentrates
and  rinse  waters  prior - to  treatment  via aeration, lime
neutralization,  polymer  addition,  clarification   via   a
thickener,  with  vacuum  filtration of thickener underflows
and discharge of a clear, neutral, iron-free effluent.

Pickling - Hydrochloric Acid - Batch and Continuous - Rinses

A total of  nine  hydrochloric  acid  pickling  plants  were
examined  for rinse water quality during the survey, and six
of these were large tonnage strip and sheet mills.   Of  the
nine  operations,  three  were  presently providing no rinse
water treatment; three attain some concentration  reductions
through  partial neutralization or dilution; two treat rinse
waters effectively using  conventional  lime  treatment  and
sedimentation/clarification;   and   the   remaining   plant
cascades dilute rinse waters toward  the  head  end  of  the
                            649
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pickling  line,  thereby  concentrating iron and acid levels
until the rinse waters resemble  dilute  (1-2%)   spent  acid
concentrated solutions.  At present, this plant injects this
waste  and  the  spent  concentrate to a deep well,  but this
mixture is amenable to acid recovery  by  systems  described
previously in the sections on Pickling - Hydrochloric Acid -
Concentrates.

Cold Rolling Subcategories

Re ci r c ul a t io n  Systems.   Four of the five mills sampled had
recirculation systems.  Spent rolling oils are pumped  to  a
separate  storage  tank  and  metered  into an oil separator
along with oily wastewater (spillage,  pump  leakage,  etc.)
from  the  oil  cellar and machine shop, associated with the
cold mill operation.  Discharges from  these  plants  ranged
from  67  1/kkg to 760 1/kkg (16 to 182 gal./ton) of product
rolled.  The volume of discharge per ton of  product  rolled
is highly dependent upon the width, thickness,, and type of a
product, the speed of the rolling mill, the condition of the
rolls  and  wipers,  and will vary considerably on different
days for the same mill, depending on the product rolled.  In
spite of the wide variation in flows shown above,  three  of
the  four plants achieved average discharge rates between 67
and 75 1/kkg (16 and 18 gal./ton), and 4 to 6  mg/1  of  oil
and  grease  was  readily  attained  in  the treatment plant
effluent, partly  due  to  the  dilution  effect  caused  by
treating   cold   rolling  mill  wastewaters  in  a  central
treatment plant along with wastewaters from other processes.
Two of the cold rolling mills at specialty  plants  achieved
no discharge of process waste water pollutants by completely
recirculating  the  oil  or  oil  emulsion.  The third plant
discharges at a rate of 57  gal/ton  but  with  unacceptable
levels   of  suspended  solids  and   oil  and  grease.   No
generally applicable treatment technology was identified  in
the  alloy and stainless steel industry plant surveys and it
was thus decided that the limitations for  this  subcategory
would   be   based  upon  the  BPCTCA  adopted  for  similar
operations in the carbon steel industry.

Combination Systems.  Although recent trends in cold rolling
practice  have  aimed  at  increased  use  of  recirculatTion
systems  wherever possibly, many plants must continue to run
one or more stands on a once-through basis.   This  need  is
dictated   by  special  customer  requirements,  control  of
dissolved solids, or the need to remove a previously applied
oily coating which may  be  incompatible  with  the  rolling
solutions   used.    Plants  using   such  a  combination  of
recirculation  and  direct   application   stands   generate
considerably  more wastewater than  recirculation alone.  For
                              650
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example, the one combination plant visited on two  different
occasions during this survey consisted of two different cold
rolling  lines  and a temper mill using various combinations
of recirculation and  direct  application,  with  wastewater
flows  averaging 1551 1/kkg (372 gal/ton) at the time of the
visits.  Data reported by this plant  for  a  representative
period of operations confirmed the above average, indicating
a  28-day  average  flow  of  1,530  1/kkg (367 gal./ton)  to
treatment.  For this reason, the BPCTCA ELGs for combination
cold rolling operations has been  based  on  flow  rates  of
1,668 1/kkg  (400 gal./ton) of steel produced.

Direct    Application   Systems.    A   few   cold   rolling
installations will continue to operate without recirculation
on any rolling stand,  providing  only  once-through  direct
application  of  rolling  solutions.   Although no plants of
this type were surveyed, a review of the  application  rates
utilized  by  the  recirculation  and  combination  types of
operation in the cold rolling subcategory indicate a typical
water  reguirement  of  approximately  4,170  1/kkg   (1,000
gal./ton)  of product rolled.  Thus this flow, together with
the treatment technology utilized on the other cold  rolling
wastewaters   (namely,   equalization,  chemical  treatment,
flocculation, dissolved air flotation, surface skimming  and
long-term  settling) form a basis for BPCTCA ELGs for direct
application plants.

Hot Coatings - Galvanizing operations

Four plants in the hot coatings  subcategory  were  visited.
Two  of  these  were rod and wire mills producing galvanized
wire, but one had no process wastewaters in contact with the
coated  product  and,  consequently,  no  raw   waste   load
attributable  to the coating step.  Waste loads from the rod
mill  and  the  pickling  operations  associated  with  this
production  line  are  covered under the hot forming section
and the pickling - hydrochloric acid subcategories.

The remaining three  mills  included  two  large  continuous
strip  galvanizing  operations  and   (including  one running
three coating  lines  side  by  side)   one  continuous  wire
galvanizing  operation.   Wastewater  flow  rates  for these
three lines ranged from 557 to 2,195 gal./ton for the  strip
galvanizing lines, to 4,600 gal./ton for the wire mill.   All
lines  included varying portions of noncontact cooling water
from furnace cooling and from  temperature  control  of  the
molten metal baths.

Hot Coatings - Terne Operations
                            651
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Two  plants operating terne plating lines were surveyed,  and
both of these were  practicing  tight  control  to  minimize
drag-out  of  solutions  from  process tanks.  Process water
flow rates ranged from 2,150 to  4,115  1/kkg  (516  to  987
gal./ton),  and  fume  hood  scrubber  waters contributed an
equivalent load at one of the plants.

Miscellaneous Runoffs-Storage Piles - Coal, Stone, and Ore

These three miscellaneous  runoffs  are  discussed  together
since at a minimum, all three runoffs would require the same
general type of treatment; namely collection, sedimentation,
and  pH  adjustment.   This is not meant to imply that these
runoffs  should  necessarily  be   collected   and   treated
together, although that possibility need not be specifically
excluded  either.   Nor  should  this  analysis  necessarily
preclude that the above treatment is all that is  needed  in
every  case.   For  coal  pile  runoffs  in  particular,  the
presence of other undesirable contaminants (as discussed  in
Section  V)  due  to  their  presence  in  the coal would be
heavily dependent on the area where the coal  is  mined  and
the particular mineral makeup of the soil in that area.

Miscellaneous Runoff s - Casting and Slagging

Ingot  Casting.   Ingot  casting  operations  employ minimal
amounts of water for mold spray cooling.  Water usage is  so
minimal  that  there  is  rarely  any  runoff  from the area
proper.  In addition, any excess spray water would generally
contain only suspended matter in the form  of  larger  scale
particles which would settle in the immediate spray area.  A
runoff  that might exist at a specific site due to excessive
spray water usage could best be resolved by tightening up on
spray water usage.

Specialty Steel Pickling, Cleaning and Coating
Suspended Solids

The removal of suspended solids from  the  treated  effluent
from  pickling and cleaning wastes generally is accomplished
by clarification.  The precipitated metal hydroxides act  as
flocculating  agents  and  the  addition of polyelectrolytes
acts to  agglomerate  the  flocculant  particles  into  more
readily  settlable  form by increasing their bulk densities.
Properly designed  and  operated  treatment  facilities  can
regularly  achieve  effluent suspended solids concentrations
of 25  mg/1.   Such  a  value  has  been  determined  to  be
attainable  as  a  result of the carbon steel study.  In the
                              652
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alloy  and  stainless  steel  industry  plant  survey,   the
treatment  facilities  at  Plants  A and O attained effluent
suspended solids concentrations averaging 20  and  21  mg/1,
respectively.   The limitation of 25 mg/1 thus appears to be
readily achievable.

Chromium

Chromium is optimally precipitated at pH 8.0.  The 0.50 mg/1
limitation is based upon that effluent  concentration  which
is  readily  achievable at high flow rates.  This limitation
is conservative in view of the fact that the treatment plant
effluents at Plants A and P never exceeded  this  value  and
averaged 0.32 and 0.10 mg/lr respectively.

Ch romi urn, He xa va1ent

Hexavalent chromium compounds are highly soluble compared to
the  trivalent  form.   Treatment  for  hexavalent  chromium
consists of reduction to the trivalent form  at  low  pH  by
sulfur  dioxide,  ferrous  sulfate, sodium metabisulfite, or
sodium hydrosulfite.  The pH is then raised to pH 8 with  an
alkaline  reagent, precipitating the reduced chromium as the
hydroxide.  Proper operation can reduce hexavalent  chromium
to  nearly  zero.   The  0.05  mg/1 limitation is based upon
analytically reproducible concentrations and is conservative
as judged from the less-than-detectatle concentrations found
in the treatment plant effluent at Plant P where  hexavalent
chromium reduction is regularly practiced.

Cyanide

Cyanides  are  oxidized  at  elevated  pH levels, usually by
chlorine, i.e., alkaline chlorination.  The initial reaction
is very  fast  and  produces  cyanates.   Maintenance  of  a
chlorine residual at a nearly neutral pH for an hour or more
oxidizes  the  cyanate  to  nitrogen  and carbon dioxide and
essentially  zero  cyanide  levels  can  be  achieved.   The
limitation  was conservatively based on 0.25 mg/1, as judged
from the treatment plant effluents at Plants O and  S  which
did not exceed 0.10 and 0.04 mg/1, respectively.

Nickel, Iron, and Fluoride

The  limitations  here  are  based upon one-half the maximum
and/or the average concentrations  found  in  the  treatment
plant   effluent  at  Plant  A.   This  is  a  well-operated
conventional  lime  neutralization  system  using  a  solids
contact  clarifier  and polyelectrolyte addition.  Nickel is
reduced here from about 15 mg/1 to an average of  0. 18  mg/1
                            653
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and  a maximum of 0.22 mg/1.   0.25 mg/1 is used as the basis
for the limitation.  Iron is  reduced from 80-105 mg/1 to  an
average  of  0.13 mg/1 and a  maximum of 1.4 mg/1.  Fluorides
are reduced from 150-320 mg/1 to an average of 14  mg/1  and
15  mg/1  was used as the basis.  The chosen limitations for
iron (1.0 mg/1) is also the limitation adopted as BPCTCA  in
the carbon steel industry pickling subcategories.

Copper

The  limitations  for this metal at 0.25 mg/1 are based upon
the development document for  the non-ferrous metals industry
as representing the  concentrations  readily  achievable  by
lime  neutralization  and  clarification  as demonstrated in
those industries.  This transfer of technology  approach  is
judged  to  be  the  best method of establishing limitations
here because much more attention and study has been  devoted
to  treatment  of  these  constituents in non-ferrous wastes
than has been the case in the steel industries.

BPCTCA for these  subcategories  has  been  based  upon  the
attainment  of  the  above  effluent  concentrations by lime
neutralization,       flocculation-clarification        with
polyelectrolyte  addition,  and  vacuum  filtration  of  the
clarifier underflow to reduce sludge volumes  for  landfill.
Waste  waters  containing cyanides are pretreated to oxidize
the cyanide by alkaline  chlorination  as  described  above.
Waste  waters  containing hexavalent chromium are pretreated
to reduce the chromium to the trivalent form with the use of
sulfur dioxide or othejr reducing agent as described above.

Combination Acid Pickling  (Continuous)

The flow volume for this  subcategory  are  based  upon  the
plant  survey  data  from  Plants  A,  D, E and I to include
rinsewater, spent liquor, and fume scrubber effluents.   The
rinsewater  volumes at Plant A were from 3394-3721 1/kkg and
at Plant D from 3962-4237 l/kkgr averaging 3803 1/kkg.   The
rinsewater volumes at Plant I equaled 7564 1/kkg of product,
but  no data were provided as to the tonnage pickled vs. the
product tonnage.  Assuming, for Plant I, that there are  two
picklings   per   unit   produced,   the  indicated  average
rinsewater volume is 3803  1/kkg   (912  gals/ton)  of  steel
pickled.  The  spent pickle liquor volume is based upon those
for Plants A,  I, and E which were, respectively, 96, 98, and
112 1/kkg, averaging 102 1/kkg  (24.5 gals/ton).  Considering
all  of  the   above  data,  an effluent volume of 4170 1/kkg
 (1000  gals/ton)  was  selected  as  representing  the  best
estimate for this subcategory.
                           654
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Combination Acid Pickling (Batch Pipe and Tube)

The  flow  volumes  for  this subcategory are based upon the
plant  survey  data.   The  rinsewater  volume  at  Plant  U
provided the only basis for estimation of rinsewater volumes
in  this subcategory and was equal to 677 gal/ton.  The fume
scrubber effluent volume was based  upon  that  at  Plant  F
which  equaled  60  1/kkg (14.3 gals/ton).  The spent pickle
liquor volume was based upon the average volume of 49 1/kkg,
the spent liquor volumes at Plants C, F, K and the remaining
plant were, respectively, 24, 60, 75 and 38 1/kkg.   On  the
basis  of  these  data,  the  waste  water  volume  for this
subcategory was determined to be 2919 1/kkg (700 gals/ton) .

Combination Acid Pickling (Other Batch)

The flow volumes here were based upon the plant survey data.
The fume scrubber and spent liquor volumes  were  determined
from  the  data  as  described  above  for the pipe and tube
subcategory.  Rinsewater  volumes  for  operations  in  this
subcategory  at Plants Cr F and L were respectively, 91, 279
and 140 gal/ton, averaging 170  gal/ton.   The  waste  water
volume   for   this   subcategory  was  thus  conservatively
estimated at 834 1/kkg (200 gals/ton).

Scale Removal

Kolene Scale Removal

The flow volumes for this subcategory were  based  upon  the
plant  survey data.   The waste water volumes were, 398, 494
and 108 gal/ton, averaging 333  gal/ton.   The  waste  water
volume   here  was  thus  established  at  2085  1/kkg   (500
gals/ton) .

Hydride

The flow volume for this  subcategory  was  based  upon  the
plant survey data at Plant L at 5004 1/kkg (1200 gals/ton).

Wire Coating and Pickling

The  flow  was  established  on the basis of an observed 10-
minute rinsing of a 227 kkg  (500 Ib) coil at Plant K at  the
rate  of  1.31/sec  (20 gpm), i.e., 3378 1/kkg (800 gals/ton)
and the flows at plants K and O  which  were  222  and  1828
gal/ton,  respectively,  for an average of 950 gal/ton.  The
limitations were established on the basis of 1000 gal/ton.

Continuous Alkaline Cleaning
                             655
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The flow volume here was based upon the  plant  survey  data
from Plant I at 209 1/kkg (50 gals/ton).

Consideration of Process Changes

No in-process changes will be required to achieve the BPCTCA
limitations,  although  recycle  water  quality  changes may
occur as a result of efforts to  reduce  effluent  discharge
rates.   Many plants are employing recycle, cascade uses, or
treatment and recycle as a means for  minimizing  water  use
and the volume of effluents discharged.  The limitations are
load  limitations  (unit  weight of pollutant discharged per
unit  weight  of  product)   only,   and   not   volume   or
concentration  limitations.  The limitations can be achieved
by  extensive  treatment  of  large   flows;   however,   an
evaluation  of  costs  indicates  that  the  limitations can
usually be achieved most economically by minimizing effluent
volumes.

Consideration of Costs Versus Effluent Reduction Benefits

In consideration of the costs  of  implementing  the  BPCTCA
limitations  relative  to  the  benefits  to be derived, the
limitations were set at values which  would  not  result  in
excessive capital or operating costs to the industry.

To  accomplish this economic evaluation,  it was necessary to
establish the treatment technologies that could  be  applied
to  each  subcategory  in  an  add-on  fashion, the effluent
qualities attainable with each technology,  and  the  costs.
In  order  to determine the added costs,  it was necessary to
define what treatment processes were already  in  place  and
currently  being  utilized  by  most  of the plants within a
given subcategory.  This was established  as  the  reference
level of treatment.

Treatment  systems were then envisioned which, as add-ons to
existing facilities, would achieve  significant  waste   load
reductions.   Capital  and operating costs for these systems
were then  developed  for  the  average  size  carbon  steel
facility.   The  average  size was determined by dividing the
total  industry  production  by  the  number  of   operating
facilities.   The capital costs were developed from a quasi-
detailed engineering estimate of the cost of the  components
of  each of the systems.  The annual operating cost for  each
of the facilities was  determined  by  summing  the  capital
recovery   (basis  ten  year  straight line depreciation) and
capital use   (basis  7%   interest)  charges,  operating  and
maintenance costs, chemical costs, and utility costs.
                             656
-------
Costs for the alloy steel segment were generally scaled down
from  those  for  carbon  steel,  using the "0.6" factor, as
explained in Section VIII.  Average  plant  size  for  alloy
steel  was  determined  by  selecting a representative plant
from  those  studied.   Where  there   was   no   comparable
subcategory  in  the  carbon steel segment, a quasi-detailed
engineering estimate was determined.

Cost effectiveness diagrams were then prepared to  show  the
pollution  reduction  benefits derived relative to the costs
incurred.  As expected, the diagrams show an increasing cost
for treatment per percent reduction obtained as the  percent
of  the  initial  pollutional load remaining decreased.  The
BPCTCA limitations were set at the point where the costs per
percent pollutant reduction took a sharp break upward toward
higher costs per percent of pollutant removed.   These  cost
effectiveness diagrams are presented in Section X.

The  initial  capital  investment  and  annual  expenditures
required of the carbon steel industry to achieve BPCTCA were
developed by multiplying the costs (capital or  annual)  for
the  average  size  facility  by  the  number  of facilities
operating for each subcategory.  These costs are  summarized
in  Table  197 in Section X.  Table 197 also shows the costs
for the specialty steel segment.

After selection was made of the treatment technology  to  be
designated  as  one  means to achieve the BPCTCA limitations
for each subcategory, a sketch of each treatment  model  was
prepared.   The  sketch  for  each  subcategory is presented
following the table presenting the  BPCTCA  limitations  for
the subcategory.

Multi-community Economic Impact

Comments  submitted  in  response  to  effluent  limitations
proposed on February 19, 1974 (39 F.R. 6481) , contended that
the proposed regulations might result  in  large  employment
reduction  in  the  multi-community  Mahoning  River  Valley
region of eastern Ohio.   Upon  the  promulgation  of  those
regulations  on June 28, 1974 (39 F.R. 24114), EPA concluded
that it lacked sufficient information to  support  different
requirements  for  point  sources  located  in  that region.
Following the promulgation  of  those  regulations,  and  in
accordance  with  the  preamble hereto, companies contending
that the effluent limitations guidelines  contained  therein
would cause curtailment of operations and heavy unemployment
in  the Mahoning Valley region were afforded the opportunity
of  presenting  detailed  technical,  cost   and   financial
information    to    support   that   contention.    Similar
                        657
-------
opportunities  to  present   additional   information   were
afforded   to  officials  of  state,  county  and  municipal
governments and regional planning and  economic  development
agencies.   The  data  supplied  by  the companies and other
commenters, and the evaluation thereof by EPA,  through  its
consultants,  have been utilized in the establishment of the
effluent limitations guidelines, as  set  forth  in  interim
final form, promulgated herein.

    EPA  retained  a  consulting  firm  to study the data in
order to determine whether conditions in the Mahoning  River
Valley  region  warrant the establishment of region-specific
effluent limitations.  The primary purpose of the study  was
to  assess  the  likelihood that major economic dislocations
would result in the region from plant  closings  if  region-
specific   factors   were  not  considered  in  establishing
effluent  limitations  guidelines  for  facilities   located
therein.  In order to make this assessment, it was necessary
to  determine  whether:   (1)  the  return on investment from
continued operation of these plants was sufficient to  allow
the  firms  to  make  the  sizeable investments required for
pollution controls, and,  (2) the  firms  would  be  able  to
raise   sufficient  capital  to  provide  pollution  control
equipment for these plants  in  the  context  of  the  total
capital requirements of the firms.

    On   August    1,  1974,  EPA  requested  that  companies
operating facilities in the region submit, by September  15,
1974,  data  concerning  estimates  of investment and annual
costs for pollution  control  equipment  required  for  non-
region   specific  effluent  limitations,  analyses  of  the
effects of such costs upon profitability, and rationale  for
concluding  whether the necessary capital could be invested.
In order to facilitate the submission of the data, which was
not accomplished by the September  15,  1974  deadline,  EPA
delivered a questionnaire to the companies in October, 1974.
The  information   solicited therein concerned plant physical
and operating characteristics, financial management  systems
and  policies,  historical  operating  and  financial  data,
pollution abatement cost  analyses,  and  methodologies  and
assumptions for ROI  (Return on Investment) projections.  The
gathering  and  evaluation  of the data required conferences
attended by EPA  and  its  consultants  and  the  companies,
visits  by  EPA and its consultants to the corporate offices
of the companies,  and inspections by EPA and its consultants
of the companies'  steelmaking  facilities  in  the  Mahoning
River Valley.

    Tentative  analysis   of  the available data leads to the
conclusion that conditions  in  the  Mahoning  River  Valley
                             658
-------
region   are   unique  with  respect  to  the  physical  and
geographical  characteristics  of  the  facilities   located
therein, and the importance of the facilities to the economy
of the region.  Tentative analysis of the available data and
the  consultant's evaluation thereof appears to support that
mandatory compliance with  effluent  limitations  guidelines
which  do  not  take into account these factors is likely to
result in severe economic dislocation  within  the  Mahoning
River Valley region.

    The  discussion  of  categorization  within the industry
contained in  (i)  supra, indicates  that  EPA  has  concluded
that  subcategorizaticn  of the industry is inappropriate on
the basis of size, per se, age, per se, or land availability
(location) , per  se.   The  type  of  manufacturing  process
employed  was  deemed  to  be the appropriate determinant of
subcategorization.

    Data  submitted  by  the  companies  operating  in   the
Mahoning  Valley  region  reveal  a  unique  combination  of
economically disadvantageous size, age and land availability
(location)  factors which  appear  to  warrant  consideration
pursuant  to  section  304 (b) (1) (B)   of  the  Federal  Water
Pollution Control Act, as amended, in determining  the  best
practicable  control technologies available to facilities in
the region.  The plants in the Mahoning River Valley  region
include  some  of the oldest steelmaking facilities still in
use in the United States.  The first  steel  plants  in  the
region  were  installed  near the turn of the century.  Four
blast furnaces and fourteen  open  hearth  furnaces  at  one
facility are in the range of 60-75 years in age.  In another
facility, the newest finishing mill is 40 years old with the
balance  of  finishing  equipment  more  than  50 years old.
Several antiquated units have  been  closed  over  the  past
several years.

    In  addition to similar economic disadvantages resulting
from age and size characteristics, facilities in the  region
appear  to share economic disadvantages caused by locational
characteristics.  These include the movement of markets away
from the region, constrained access to raw materials due  to
the unavailability of waterborne transportation and required
transhipment  by  rail, and space limitations which prohibit
major expansion of existing  facilities.   All  eight  steel
plants  operated  by the companies submitting data are built
on land surrounded by either the  river,  main  highways  or
residential or industrial buildings.

    As  a  result  of this combination of age, size and land
availability  (location) factors  common  to  plants  in  the
                             659
-------
region,  these facilities appear to be economically marginal
before the addition of pollution control  costs.    Tentative
analysis  of  available data and the consultant's evaluation
thereof indicates that the imposition of  pollution  control
costs   is  likely  to  substantially  degrade  the  already
marginal profitability of these plants.  Tentative  analysis
of  cash  flows  developed  from  company  data submissions,
calculated on a "stand-alone" basis  for  average  case  and
best case conditions appear to substantiate this conclusion.
The  cash .flows for all evaluated facilities are expected to
be negative on a stand alone basis under average conditions.
On this basis, the Mahoning Valley operations of one of  the
companies  submitting data is expected to realize a positive
cash flow only under infrequently  occurring  conditions  of
maximum  demand,  while  the operations of the two remaining
companies are expected to  have  negative  cash  flows  even
under the best conditions.

    The  likelihood  of  a  plant  closing  in  a particular
community as a result of the unwillingness or  inability  of
its  owners  to  invest  the sums necessary to meet effluent
limitations  does  not  justify  the  relaxation  of   those
limitations.   On  the  contrary, the legislative history of
the  Act  indicates  Congressional  awareness   that   plant
closings   may   result.    Similarly,  the  combination  of
disadvantageous age, size, and land availability  (location)
factors  which  apparently  results in the marginal economic
status of the Mahoning Valley plants does  not,  in  itself,
require the relaxation of standards which would otherwise be
applicable.   What  does  justify  a relaxation of otherwise
applicable  standards  is   the   requirement   in   section
304(b) (1) (B)   of  the  Act  that  the  assessment  of  best
practicable control  technology  currently  available  shall
include,  inter  alia,  consideration  of  the total cost of
application of technology to the effluent reduction benefits
to be achieved from such application.   The  total  cost  of
application  of  technology  includes external costs such as
potential unemployment, dislocation, and rural area economic
development sustained by the community, area, or region.  It
is this consideration of external costs in relation  to  the
effluent reduction benefits to be achieved which established
the  propriety of exempting point sources located within the
Mahoning Valley from required compliance with the nationwide
effluent  limitations  based  on   BPCTCA.    As   discussed
previously,  the  imposition of non-region specific effluent
limitations to facilities in the Mahoning Valley which share
region-specific economic  disadvantages  appears  likely  to
lead   to  plant  closing, the effect of which would be heavy
unemployment and severe economic dislocation in this  multi-
community region.
                             660
-------
    Steel  production  is  the  largest single factor in the
economy of the  Mahoning  River  Valley,  a  region  with  a
population  of approximately 550 thousand.   In terms of jobs
and  payroll,  the  steel  industry  employs  more   people,
approximately  15%  and  provides  more wages, approximately
20%, than  any  other  industry  in  the  region.    Of  more
significance than the percentages of employment and payroll,
however,  is  the  absolute  magnitude of the employment and
payroll statistics.  Steel industry operations in  the  two-
county  region account for 27,000 jobs and a taxable payroll
of $80 million.  In addition, according to a study conducted
for  a  local  economic  development  Agency  in  1972,  the
industry,  in  addition  to  its  own payroll, purchased $90
million in  goods  and  services  from  the  local  economy,
supporting  an  additional 3300 jobs with a total payroll of
about $31 million, and generated between 19% and 27% of  the
region's  201,500  non-farm jobs and a similar proportion of
the  $142  million  in   total   tax   revenues   of   local
jurisdications.

    The  relief  granted  from severe economic impact in the
Mahoning River Valley region,  which  impact  is  likely  to
occur  absent such relief, is the exemption of point sources
located within that region  from  the  effluent  limitations
based  on  best  practicable  control  technology  currently
available.  Nevertheless,  the  Agency  fully  expects  that
authorities granting permits, pursuant to section 402 of the
Federal  Water  Pollution Control Act, as amended, shall not
allow point sources in that region to  discharge  pollutants
in  any  greater amounts than are currently being discharged
by those sources.

    As to reguirements  which  will  be  applicable  in  the
future,  EPA  is  proposing  limitations which establish the
degree of effluent  reduction  accomplished  by  BAT,  under
section  301(b)(2) of the Act.  The proposed BAT limitations
for plants in the Mahoning Valley  are  identical  to  those
reguired  to be met by the balance of the industry.  Section
301(c)  authorizes  modifications  to  be  made   in   these
limitations  under  certain  circumstances, based in part on
economic conditions  applicable  to  individual  owners  and
operators.

    Modifications  under  301(c)  may not, of course, reduce
the level  of  treatment  below  that  required  by  BPT  or
applicable  state water quality standards.   Since the Agency
is not establishing  BPT  limits  for  the  Mahoning  Valley
plants,  a  special provision is proposed which will confine
any such 301(c) modifications for Mahoning Valley plants  to
                             661
-------
levels  comparable  to a region-specific BPT installed at an
economically feasible pace.
                            662
-------
                         SECTION X

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

The effluent limitations which must be achieved by  July  1,
1983  are  to  specify  the  degree  of  effluent  reduction
attainable through the application  of  the  best  available
technology    economically   achievable.    Best   available
technology  is  not  based  upon  an  average  of  the  best
performance  within  an  industrial  category,  but is to be
determined  by  identifying  the  very  best   control   and
treatment  technology  employed  by  a specific point source
within the industrial category or subcategory, or  where  it
is  readily  transferable from one industry to another, such
technology may be identified as BATEA technology.

With the exception of the  Hot  Coating  -  Galvanizing  and
Terne  subcategories  and  the absorber vent scrubber on the
hydrochloric acid subcategory, there are plants in all other
categories who are presently achieving  the  BATEA  effluent
limitation  guidelines  for  carbon  steel  plants.  This in
itself justifies the fact that technology is  available  and
demonstrates  that  the limitations can be achieved on a day
by day basis.

Consideration must also be given to:

1.  The size and age of equipment and facilities involved.

2.  The processes employed.

3.  Non-water quality environmental impact (including energy
requirements).

4.  The engineering aspects of the  application  of  various
types of control techniques.

5.  Process changes.

6.  The cost of achieving the effluent  reduction  resulting
from application of BATEA technology.

Best  available  technology  assess  the availability in all
cases of in-process changes or controls which can be applied
to reduce waste  loads,  as  well  as  additional  treatment
                              663
-------
techniques  which  can be applied at the end of a production
process.  Those plant  processes  and  control  technologies
which  at  the pilot plant, semi-works, or other level, have
demonstrated both  technological  performance  and  economic
viability  at  a  level  sufficient  to  reasonably  justify
investing in such facilities may be considered in  assessing
best available technology.

Best  available  technology is the highest degree of control
technology that has been achieved or has  been  demonstrated
to be capable of being designed for plant scale operation up
to  and  including  "no  discharge" of pollutants.  Although
economic factors are considered in the development, the cost
for this level of control is intended to be the  top-of-the-
line  current  technology  subject to limitations imposed by
economic and engineering feasibility.  However,  this  level
may  be characterized by some technical risk with respect to
performance  and  with  respect  to  certainty   of   costs.
Therefore,   the  BATEA  limitations  may  necessitate  some
industrially  sponsored  development  work  prior   to   its
application.

IDENTIFICATION OF THE BEST AVAILABLE TECHNOLOGY ECONOMICALLY
ACHIEVABLE - BATEA

Based  on  the information contained in Sections III through
VIII of this report, a determination has been made that  the
quality  of  effluent- attainable through the application of
the Best Available Technology Economically Achievable is  as
listed  in  Tables  174 through 196.  These tables set forth
the ELGs for the  following  process  subcategories  of  the
steel industry.

3.  Basic Oxygen Furnace  (Wet Air Pollution Control Methods)
- BPCTCA plus treatment of blowdown by lime precipitation of
fluorides, followed by sedimentation and neutralization.

K.  Vacuum  Degassing  -   BPCTCA   plus   additional   lime
treatment,  clarification  and  filtration,  and  biological
flenitrif ication, if necessary.

L.  Continuous Casting and Pressure Slab  Molding  -   BPCTCA
plus pressure filtration of the blowdown.

M.  Hot Forming-Primary - BPCTCA plus recycle  of  clarifier
effluent  to  the   sprays,  discharge  of 25 gpt  (40 gpt for
alloy) .
                            664
-------
N.  Hot Forming-Section  -  BPCTCA  plus  total  recycle  of
clarifier  effluent  through  cooling  tower  to the sprays,
resulting in zero discharge to navigable waters.

O.  Hot Forming-Flat-Plate - BPCTCA plus  discharge  of  150
gpt (350 gpt for alloy)  and remainder recycled after cooling
tower.

Hot  Strip  and  sheet - total recycle of clarifier effluent
through cooling tower  to  the  sprays,  resulting  in  zero
discharge to navigable waters.

P.  Pipe and Tubes - for integrated mills; total recycle  of
clarifier  effluent  through cooling tower resulting in zero
discharge to navigable waters.

For isolated mills;  total  recycle  of  clarifier  effluent
through  ponds  resulting  in  zero  discharge  to navigable
waters.

Q.  Pickling-Sulfuric Acid-Batch and Continuous - Batch  and
Continuous   Concentrates:   identical   to  that  for  best
practicable control technology currently available.

Batch and Continuous Rinses: for those facilities practicing
neutralization as of December 1, 1975; countercurrent rinses
and cascade use in fume hoods to achieve 25 gpt of fume hood
scrubber and rinse discharges.

For those facilities without neutralization as  of  December
1,  1975  - countercurrent rinsing to achieve zero discharge
to navigable waters.

R.  Pickling-Hydrochloric Acid-Batch and  Continuous  -  For
batch  concentrates: aeration, followed by a settling lagoon
with 2 to 5 day retention.

For  batch  rinses:  countercurrent  rinsing,  aeration  and
mixing followed by 2 to 5 day settling.

For  batch fume hood scrubbers: aeration and mixing followed
by 2 to 5 day settling.

For continuous concentrates: settling for 2 to 5 days.

For continuous  operations  with  absorber  vent  scrubbers:
recycle  to  the  acid  absorber vent scrubber, reuse, and a
settling lagoon with 2 to 5 day retention.
                               665
-------
For continuous rinses: countercurrent rinsing, aeration  and
mixing followed by 2 to 5 day settling.

For   continuous  operations  with  a  fume  hood  scrubber:
aeration and mixing followed by 2 to 5 day settling.

S.  Cold    Rolling-Recirculation,    Combination,    Direct
Application - identical to that for best practicable control
technology currently available.

T.  Hot Coat Galvanizing - Rinses:   countercurrent  rinses,
neutralization  by chemical addition, settling lagoon with 2
to 5 day retention.

Fume Hood Scrubber:  recycle, settling lagoon with  2  to  5
day retention.

U.  Hot  Coat-Terne  -   Rinses:    countercurrent   rinses,
neutralization by chemical addition, settling lagoon with 2-
5 day retention.

Fume  Hood  Scrubber:   recycle,  neutralization by chemical
addition, settling lagoon with 2 to 5 day retention.

V.  Miscellaneous  Runoffs  -  Stock   Piles   -   parameter
collection,   egualization,   neutralization   by   chemical
addition,  chemical  treatment  and  flocculation,   polymer
addition, settling lagoon with 2 to 5 day retention.

Casting  and Slagging - water conservation to prevent runoff
resulting in zero discharge to navigable waters.

W.  Combination Acid-Batch and continous - identical to that
for best practicable control technology currently available.

X.  Scale Removal - Kolene and Hydride - identical  to  that
for best practicable control technology currently available.

Y.  Wire Pickling and Coating - identical to that  for  best
practicable control technology currently available.

Z.  Alkaline  Cleaning  -  identical  to   that   for   best
practicable control technology currently available.

In  establishing  the subject guidelines, it  should be noted
that the resulting limitations or standards   are  applicable
to  aqueous  waste  discharges only, exclusive of noncontact
cooling  waters.   In  the   section  of  this  report  which
discusses  control and treatment  technology for the iron and
steelmaking industry  as a whole,  a qualitative reference has
                               666
-------
been given regarding "the environmental  impact  other  than
water" for the subcategories investigated.

The effluent guidelines established herein take into account
only  those  aqueous  constituents  considered  to  be major
pollutants in each of the  subcategories  investigated.   In
general,  the  critical  parameters  were  selected for each
subcategory on the basis of those waste  constituents  known
to  be  generated  in the specific manufacturing process and
also known to be present  in  sufficient  quantities  to  be
inimical  to  the  environment.   Certain general parameters
such as suspended solids naturally  include  the  oxides  of
iron   and   silica.    However,   these   latter   specific
constituents were not included as critical parameters, since
adequate  removal  of  the  general  parameters   (suspended
solids)  in  turn  provides for adequate removal of the more
specific parameters indicated.  This does not hold true when
certain of  the  parameters  are  in  the  dissolved  state;
however,  in  the  case of iron oxides generated in the iron
and steelmaking  processes,  they  are  for  the  most  part
insoluble  in the relatively neutral effluents in which they
are contained.  The absence  of  apparently  less  important
parameters   from   the   guidelines   in  no  way  endorses
unrestricted discharge of the same.

The  recommended  BATEA  effluent   limitations   guidelines
resulting  from  this  study are summarized in Tables 174 to
196.  These tables  also  list  the  control  and  treatment
technology  applicable  or  normally  utilized  to reach the
constituent levels indicated.  Figures 151  to  176  present
the  BATEA treatment models.  These effluent limitations set
herein  are  not  necessarily  the  absolute  lowest  values
attainable  (except where no discharge of process wastewater
pollutants  to  navigable  waters  is  recommended)   by  the
indicated technology, but rather they represent values which
can be readily controlled around on a day by day basis.

It should be noted that these effluent limitations represent
values  not to be exceeded by any 30 continuous day average.
The maximum daily effluent  loads  per  unit  of  production
should  not  exceed  these  values  by more than a factor of
three as discussed in Section IX.

RATIONALE FOR THE SELECTION OF BAT FA

The following paragraphs summarize  the  factors  that  were
considered in selecting the categorization, water use rates,
level   of  treatment  technology,  effluent  concentrations
attainable by the technology, and hence the establishment of
the effluent limitations for BATEA.
                             667
-------
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                      Figure 151-2


             MODEL COST EFFECTIVENESS DIAGRAM
                   BASIC OXYGEN FURNACE
     (WET AIR POLLUTION CONTROL METHODS)  SUBCATEGORY
    "*ANNUAL COSTS = BASED ON TEN YEAR CAPITAL RECOVERY
                  + INTEREST RATE 7%
                  + OPERATING COSTS INCLUDE LABOR, CHEMICALS
                         & UTILITIES
                  •*• MAINTENANCE COSTS BASED ON 3.5% OF CAPITAL
                         COSTS
    THIS  GRAPH CANNOT BE USED FOR INTERMEDIATE VALUES
  *C05T  BASED ON 2847 KKG/DAY {2808 TON/DAY)  BOF SHOP
473,830
429,059
376,878
318,189
244,094
D
(BATEA)
C
(BPCTCA)
B
                                                      (BASE LEVEL)
                      PERCENT REMOVED

                           670
-------
Size  and  Age   of   Facilities   and   Land   Availabili ty
Considerations

As  discussed  in  Section  IV,  the  age  and size of steel
industry  facilities  has  little  direct  bearing  on   the
quantity  or quality of wastewater generated.  Thus, the ELG
for a given sutcategory of waste source applies  equally  to
all plants regardless of size or age.  Land availability for
installation  of  add-on  treatment facilities can influence
the type of technology utilized to meet the ELGs.   This  is
one of the considerations which can account for a wide range
in the costs that might be incurred.

Cons ider at ion of Processes Employed

All  plants  in  a given subcategory use the same or similar
production methods, giving similar discharges.  There is  no
evidence that operation of any current process or subprocess
will substantially affect capabilities to implement the best
available  control  technology  economically achievable.  At
such time that  new  processes  appear  imminent  for  broad
application,  the  ELGs should be amended to cover these new
sources.  The treatment technologies to achieve BATEA assess
the availability of in-process controls as well  as  control
or  additional treatment techniques employed at the end of a
production process.

Consideration of Non-Water Quality Environmental Impact

Impact of Limitations on Air Quality.  The impact  of  BATEA
limitations  upon  the non-water elements of the environment
has been considered.  The increased use of  recycle  systems
have  the  potential for increasing the loss of volatiles to
the  atmosphere.   Recycle  systems  are  so  effective   in
reducing  wastewater  volumes,  and hence waste loads to and
from treatment systems, and in reducing the size and cost of
treatment  systems  that  a  trade-off  must  be   accepted.
Recycle  systems  requiring  the  use of cooling towers have
contributed significantly to reductions  of  effluent  loads
while contributing only minimally to air pollution problems.
Careful operation of such a system can avoid or minimize air
pollution  problems.   The  handling  and  storage  of spent
nitric-hydrofluoric pickling solutions  must  be  done  with
care  to  avoid  fumes  of  nitrogen oxides.  One plant uses
floating plastic balls on the surface of open tanks to avoid
this problem.

Impact   of   Limitations   on   Solid    Waste    Problems.
Consideration has also been given to the solid waste aspects
of water pollution controls.  The processes for treating the
                            671
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                           FIGURE 152-2

               MODEL COST  EFFECTIVENESS DIAGRAM
                 VACUUM DEGASSING SUBCATEGORY
* ANNUAL COST = BASED ON TEN  YEAR CAPITAL RECOVERY
             •f INTEREST RATE 7%
             + OPERATING COSTS INCLUDE LABOR, CHEMICALS &
                  UTILITIES
             + MAINTENANCE COSTS BASED ON 3.5% OF CAPITAL
                  COSTS
        THIS GRAPH CANNOT  BE USED FOR INTERMEDIATE VALUES
*COST BASED ON 472 KKG/DAY (520  TON/DAY)  VACUUM DEGASSING
     OPERATION
                                SUSPENDED SOLIDS
                                                        C
                                                        (BATEA)
                                                        B
                                                        (BPCTCA)
                                                        (BASE  LEVEL)
                                                    100
                      PERCENT REMOVED
                            674
-------
wastewaters  from this industry produce considerable volumes
of sludges.  Much of this material is inert iron oxide which
can be  reused  profitably  in  melting  operations.   Other
sludges  not  suitable  for  reuse  must  be  disposed of to
landfills, since most  of  them  are  chemical  precipitates
which  could  be  little  reduced  by  incineration.   Being
precipitates they are by  nature  relatively  insoluble  and
nonhazardous substances requiring minimal custodial care.

Impact  of Limitations Due to Hazardous Materials.  In order
to ensure  long-term  protection  of  the  environment  from
harmful  constituents,  special  consideration  of  disposal
sites should be made.  All landfill sites should be selected
so as to prevent horizontal and vertical migration of  these
contaminants  to  ground  or surface waters.  In cases where
geologic conditions may not reasonably ensure this, adequate
mechanical precautions  (e.g., impervious liners)   should  be
taken  to ensure long-term protection to the environment.  A
program  of  routine  periodic  sampling  and  analysis   of
leachates  is advisable.  Where appropriate, the location of
solid  hazardous  materials   disposal   sites   should   be
permanently  recorded  in  the  appropriate  office of legal
jurisdiction.

Impact of Limitations on Energy Requirements.  The effect of
water pollution control measures on energy requirements  has
also been determined.  The additional energy required in the
form  of  electric power to achieve the effluent limitations
proposed for BPCTCA and BATEA amounts to less than 2% of the
electrical energy used by the carbon steel industry in 1972.
Limitations proposed for BPCTCA and  BATEA  amount  to  less
than  1.5  to  3.7  percent  of the power required for alloy
production.

The enhancement to  water  quality  management  provided  by
these   effluent  limitations  substantially  outweighs  the
impact on air, solid waste, and energy requirements.

Consideration of the Engineering Aspects of the  Application
of Various Types of Control Techniques

The  BATEA  level of technology is considered to be the best
available and economically achievable in that  the  concepts
are  proven  and  available  for  implementation, and may be
readily applied through adaptation or as add-ons to proposed
BPCTCA treatment facilities.

Basic Oxygen Furnace Operation
                           675
-------
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                              Hjv
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677
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                          FIGURE 153-2

               MODEL COST EFFECTIVENESS DIAGRAM
         CONTINUOUS CASTING AND PRESSURE SLAB MOLDING
*ANNUAL COSTS = BASED ON TEN YEAR CAPITAL RECOVERY
              •f INTEREST RATE 7%
              •f OPERATING COSTS INCLUDE LABOR, CHEMICAL & UTILITIES
              + MAINTENANCE COSTS BASED ON 3.5% OF CAPITAL COSTS
THIS GR^-PH CANNOT BE USED FOR INTERMEDIATE VALUES
*COSTS BASED ON 544KKG/DAY (6CO TON/DAY) CONTINUOUS CASTING OPERATION
                                                       B
                                                        (BATEA)

                                                       A
                                                        (BPCTCA)
                                    60

                       Percent Removed
80
100
                             678
-------
The only direct contact process water used in the EOF  plant
is  the  water  used for cooling and scrubbing the off-gases
from the furnaces.  One method used is the wet gas  cleaning
system  which  uses  a  venturi scrubber and a gas quencher-
The use of wet air pollution controls is rare in  the  alloy
and  stainless  steel  industry.  The water use at one plant
producing alloy steel in a EOF was 870 gals/ton.  The  water
was  used  once-through  and the only treatment provided was
clarification where the BOF waste-water  was  combined  with
blast furnace gaswasher water.

The technology identified as used in the alloy and stainless
steel  industry  was judged to be inadequate.  The water use
rate lies  within  the  range  found  in  the  carbon  steel
industry  plant  surveys  (542-4250  1/kkg)  and there is no
reason to believe that the technology in use  there  is  not
directly  transferable,  since  the  characteristics  of the
waste waters and the nature of the  processes  are  similar.
The  BATEA  limitations  have  thus  been'established on the
basis of an effluent suspended solids  concentration  of  25
mg/1  at an effluent volume of 208 1/kkg  (50 gals/ton).  The
blowdown rate of 5.9 percent is being achieved in  at  least
one  carbon  steel  plant  and  at least two such plants are
achieving this effluent concentration of  suspended  solids.
The  pH  of the scrubber water effluent from the alloy steel
BOF averaged 7.4, so  that  no  difficulty  with  a  pH  6-9
limitation  is  foreseen.   The BATEA limitations for carbon
steel operations also specify a  limit  for  fluoride  based
upon an effluent concentration of 20 mg/1 attainable by lime
precipitation   and  sedimentation.   The  alloy  steel  BOF
surveyed indicated fluoride present in the raw  waste  at  a
concentration  at  10  mg/1  vs. 14 mg/1 found in the carbon
steel survey.  Similar treatment to  reduce  the  expectedly
high  concentrations  in  the  blowdown  are  thus similarly
attainable in alloy steel operations.

Vacuum Degassing Subcategory

The direct contast process water used in vacuum degassing is
the  cooling  water  used  for  the   steam-jet   barometric
condensers.   Although  most  systems  use steam ejectors to
draw the vacuum, dry mechanical pumps are  also  used.   The
vacuum  degassing  systems  surveyed used water once-through
with little effective treatment, completely recirculated the
water with no discharge, or used mechanical pumps.

It was judged to be unduly  restrictive  to  impose  a  zero
effluent  discharge limitation for BATEA, because all plants
may not be able  to  completely  recirculate  the  water  or
convert  to mechanical pumps.  The water use rate determined
                             679
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453^67
                                     FIGURE  154-2.
                           MODEL  COST  EFFECTIVENESS
                          HOT  FORMING)- PRIMARY  5UBCATEG|ORY

           ANNUAL COST- BASED  ON TEN YEAR  CAPITAL  RECOVERY
                          + INTEREST RATE. 7 %
                          + OPe.WATIN(a  COSTS  INCLUDE LABOR, CHEMICALS 4 UTILITIES
                          •(•OPERATING) AND  MAINTENANCE.  COSTS  BASED OKI 3.9%
                          OF CAPITAL  COSTS
           COST BASED  OM  3
-------
                          Figure  154-A
                Hot Forming - Primary - Specialty

             Annual Cost = Based  on Ten Year Capital Recovery
                         + Interest Rate 7%
                         + Operating Costs Include Labor,  Chemicals  &  Utilities
                         + Operating & Maintenance Costs based  on  3.5%
                           of Capital Costs
             Cost based on 2,144  kkg/day (2,364 tons/day)  of steel rolled.
             This graph cannot be used for intermediate values.
SIB 62
3\,->&3
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                                    683
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685
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                        F/GUGE ISS-'L
              MODEL COST SFFECT/VEKESS O/AG&AM
              HOT FQGMING- SECT/O/V SUBCATSGO/2Y
    ANNUAL COSTS = BASED ON JEN VEA& CAP/TAL
                  •+/NTE/ZEST /S.ATS  7%
                  / OP£i2A7(N<5  COSTS /NCLUDE LAQO&, CHEMICALS 4L/T/LITK
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                    O^ CAP/TAL COSTS
    COSTS BASED ON/l/79KKG/DAY0300TO^JS/DAY)of:-STEEL HOLt-ED
      THIS GRAPH CANNOT BE USED POR IMTEKMED/ATE VALUES
774,039
673,010
50,741
36,539
CBATEA^
                                                             IOO
                          686
-------
             Figure 155-A
   Hot Forming - Section - Specialty

Annual Cost = Based on Ten Year Capital Recovery
            + Interest Rate 7%
            + Operating Costs Include Labor, Chemicals & Utilities
            + Operating & Maintenance Costs based on 3.5%
              of Capital Costs
Cost based on 327 kkg/day (360 tons/day) of steel rolled.
This graph cannot be used for intermediate values.
                                                          too
                         687
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689
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                               FIGURE IS6-Z
                    MODEL COST EFFECTIVENESS
                    HOT FORM INS- FLAT- HOT STRIP AND SHEET
                              SUBCATESORY

         ANMUAL COSTS * BASED ON TEN YEAR CAPITAL RECOVERY
                      + INTEREST RATE 1%
                      + OPERATING COSTS INCLUDE LABOR,CHEMICALS 4 UTILITIES
                      + OPERATING AND MAINTENANCE COSTS BASED ON 3.s1> OF CAPITAL COSTS
         COST BASED ON 344-7 KKft/DAY (38OOTONS/DAY) OF STEEL ROLLED
              THIS GRAPH  CANNOT BE USED FOR INTERMEDIATE VALUES
1,970, 103-
 1,310,214-
789,817
 440,169 •
                                                                             <3 (BATEAU
                                                                         IOO
                                   690
-------
                             FIGURE 156-A

                MODEL COST EFFECTIVENESS  DIAGRAM
                HOT  FORMING - FLAT - HS & SHEET

ANNUAL COSTS « BASED ON  TEN YEAR CAPITAL  RECOVERY
             + INTEREST  RATE   7  %
             + OPERATING COSTS  INCLUDE LABOR,  CHEMICALS & UTILITIES
             + MAINTENANCE COSTS  INCLUDE  LABOR & MATERIALS
COSTS BASED ON 1851   KKG/DAY (2041  TONS/DAY)  PRODUCTION
THIS GRAPH CANNOT BE USED FOR INTERMEDIATE  VALUES
  1,404,120
  1,254,809
                          SUSPENDED SOLIDS
    274,487
     54,249

     32,011
  G
(BATEA)
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                                                                   (BPCTCA)
                                                                    D
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  A
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                                                                 100
                                 PERCENT REMOVED

                                  691
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693
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                           FIQURE  157-2
                   MODEL COST  EFFECTIVENESS DIAGRAM
                 HOT  FORMIWG,-FLAT-PLATE  SUBCATEQORV
        ANNUAL COSTS-BASED  ON  TEN VEAR  CAPITAL RECOVERV
                     t INTEREST RATE  7%
                     + OPE*«TIM^  COSTS INCLUDES LAEK5R ,CWftM4CAA.* t UTILITIES
                      •t-OPERATING, AMD  MAIMTCMAKJCE  COSTS  BASED OM
                       3.5?,  OP  CAPITAL COSTS
        COSTS  BASED OM  1814 KKQ/DAV  (3OOO TONS/DAV^ OP  STEEL ROLLED
        THIS GRAPH  CAM MOT  BE  USED FOR  INTERMEDIATE  VALUES
                                                                       (3 (BATEA')
fo4,07O
47,573
B
AfREFERENCE
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                         PERCENT REMOVED

                                   694
-------
             Figure 157-A
Hot Forming - Flat - Plate - Specialty

Annual Cost = Based on Ten Year Capital Recovery
            + Interest Rate 7%
            + Operating Costs Include Labor, Chemicals & Utilities
            + Operating & Maintenance Costs based on 3.5%
              of Capital Costs
Cost based on 479 kkg/day (528 tons/day) of steel rolled.
This graph cannot be used for intermediate values.
     C
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                                  695
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697
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                              FIGURE I5S-2.
                  MODEL COSTS EFFECTIVENESS DIAGRAM
                      PIPE AND TUBES SUBCATE.QORY
               INTEGRATED PLANTS (THOSE WITH NO LAND AVAILABLE.)

        ANN UAL COSTS = BASED ON  TEN YEAR  CAPITAL RECOVERY
                      + INTEREST RATE 7%
                      •t-OPERATING. COSTS INCLUDE LABOR, CHEMICALS £ UTILITIES
                      + OPERATING AND MAINTENANCE- COSTS  B466D
                       ON 3.5 7. OF CA^I TAl_ COSTS>

        COSTS BA5&O ON 3fe3 KKfi/DAY (400 TONS/DAY) PRODUCTION
        TWI5 GRAPH CANNOT BE-USfrD FOe INTB2.MEDIATE- VAl_u&<=>.
24937O
235,760
              q (BATEA
             FOR. SEAMLESS)

              F (SEAMLESS
              ONLV)
 169,728
 155,516
              E'(BPCTCA FOR
 120,798
 98.B34
 37.Z35
 33,730
                                                                   ALL EXCEPT
                                                                   SEAMLESS)
              A (RErERENCE.
              LEVEL)
                               i      r     i
                              4O          6O
                           PERCENT REMOVED
80
           IOO
                                698
-------
for the once-through system (3022 1/kkg)  lies in  the  range
found  in  the carbon steel industry plant surveys (813-3750
1/kkg)  and there is no reason to believe that the technology
in  use  there  is  not  directly  transferable,  since  the
characteristics  of  the  waste waters and the nature of the
processes are similar.  The BATEA limitations have thus been
established on the basis of  an  effluent  suspended  solids
concentration  of 25 mg/1 at an effluent volume of 1014 1/kkg
(25 gals/ton).  The blowdown rate of 3.H  percent  is  being
achieved  in at least one carbon steel plant and, of course,
in the completely recirculated system mentioned above.   The
pH  of  the  once-through  alloy  steel  system averaged 6.5
(within  the  specified  6-9  range) .   Limits   for   zinc,
manganese,  lead, and nitrate were also established for this
subcategory of the carbon steel  industry.   The  raw  waste
concentrations  of zinc, lead, and nitrate were not found to
be significant in the vacuum degassing effluents at Plants E
and G in  the  alloy  and  stainless  steel  industry  plant
survey;  maximum  concentrations  found were 0.37, Zero, and
17.6   mg/1,   respectively.    Fluoride    and    manganese
concentrations  were  found  at 35 mg/1 each at Plant E, but
were  negligible  at  Plant  G.    Accordingly   the   BATEA
limitations  for this subcategory of the alloy and stainless
steel industry include a limitation  for  manganese  on  the
basis  of  an  effluent  concentration  of  5  mg/1  and for
fluoride on the basis of 20 mg/1.  Manganese  and  suspended
solids removals are based upon the use of sand filtration as
in  the  carbon steel industry guidelines.  Fluoride removal
is  based  upon  the   use   of   lime   precipitation   and
sedimentation as for the BOF subcategory above.

Continuous Casting and Pressure Slab Molding Subcategory

Continuous  casting  and pressure slab molding are processes
by which primary steel shapes are cast or molded from molten
steel instead of being rolled from ingots.   The  molds  are
cooled  by  indirect  water  circulation.  The spray cooling
water system  is  a  direct  contact  cooling  of  the  cast
product.   As  the  cast product (slabs, blooms, or billets)
emerge from the molds, the water  sprays  further  cool  and
harden  a  thicker  skin on the cast product.  The principle
waste contaminant in this contact water is suspended  solids
and,  additionally, oil from machinery lubrication finds its
way into this water effluent.   Pressure slab molding,  in  a
manner  analogous  to  that  found in the case of continuous
casting, results in the generation of wastewaters containing
suspended solids and oil.

The current control and treatment technology  in  the  alloy
and  stainless  steel  industry consists of clarification of
                              699
-------
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701
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                         F/GUB.E   /5<=>-2
              MODEL COST EFFECTIVENESS D/AGQAM
                  P/PE $ TUBE'S SUBCATEGO/QY
     /SOLATED PLANTS (THOSE W/W LAND AVAILABLE FOR LARGE
 ANNUAL COSTS */3A5EO ON  TEN  VEA/2 CAP/TAL
                 + INTEREST GATE 7%
                 + OPERAT/NG  COSTS /NCLUDE LABOG ^CHEMICALS $ UTILITIES
                + OPERATING. A>NC>tA\WTE.NfrvNCE COSTS BAiSEta
                  ON 3. 5^0 C>FCAP|TO\_C.C»5TS
    COSTS BASED O^ 3C.-5 KX.Q/DKY (4OOTON3/D^Y) PRODUCTION
                              USEO'
81,17* -|	1-£
                                                                   (3AT£A)
66,966
                                                                  PREFERENCE
                                                                    LEVEL)
                                                               /OO
-------
the waste water with varying degrees of recirculation of the
water to the process use.  One plant  surveyed  recirculates
the  water completely with only periodic batch-type blowdown
of the systems.

No system in current use in the alloy  and  stainless  steel
industry  was found to be adequate and/or necessarily usable
at all other plants; treatments were adequate, but  complete
recirculation  may  not  always  be feasible.  The water use
rates of 2379-4173 1/kkg are lower than the minimum of  6172
1/kkg  found  in  the carbon steel industry plants surveyed.
The characteristics of the waste waters and  the  nature  of
the  processes  are  similar  to  those  in the carbon steel
industry and hence there is no reason to  believe  that  the
technology  in  use  there  is  not  directly  transferable,
resulting  in  a   conservative   estimate   of   achievable
limitations.    The   BATEA   limitations   have  thus  been
established  on  the  basis  of  effluent  suspended  solids
concentrations  of  10 mg/1 and of 10 mg/1 oil and grease at
an  effluent  volume  of  522  1/kkg   (125  gal/ton) .    The
resultant  blowdown  rates are easily achievable as compared
to those in either  carbon  steel  plant  surveyed  and  one
carbon    steel   plant   surveyed   was   achieving   lower
concentrations of both suspended solids and oil and  grease.
The  suspended  solids  and  oil  and  grease  removals were
established on the basis of using a flat bed  filter  system
as  in  use  at  this  one  carbon  steel plant.  All plants
surveyed easily achieved an effluent pH between 6 and 9.

Hot Forming-Primary •

The best plant in the subcategory was  used  in  calculating
the best available technology limitations.  In this case, it
was  plant  L-2.   However, because the water usage rate for
this plant was smaller than the average of the other plants,
an increase in the loading was made, based  on  water  usage
ratios.  Using direct transfer of technology, the guidelines
for this category were scaled up to reflect the higher water
use  rate  for  alloy operations to arrive at the guidelines
for specialty steel operations.

Hot Forming-Section

Of the ten process lines surveyed for this subcategory, four
were practicing either tight or total recycle.  Two of these
plants had effluent flows of 584  1/kkg   (140  gal/ton)  and
1,555  1/kkg   (373  gal/ton)  of  product.   The third plant
containing two process lines  had  zero  aqueous  discharge,
with  the only "blowdown" being the water content of the wet
sludges generated by the treatment processes.
                             703
-------
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                                  704
-------

                                                 5
                                           %
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705
-------
                           FIGURE ieO-Z
                MODEL COST ££TECr/VEAfESS  D/AGBAM
                PtCKL W<5 - 5ULFUAIC A C/D - GA TCH
      ANNUAL COSTS = BASSD ON JEN YEAR CAWTAL
                + INTEREST SATE 7%
                y- OPERATING COSTS INCLUOE LA8QRtCHEMKAI-S
                + OPERATING AND MAINTENANCE COSTS*BASED ON 3.5%

                  OF CAPITAL COSTS
      COSTS BASED ON Z27 KKG/DAY (ZSO TONS/DAY) OF STEEL PICKLED

      THIS GRAPH CAUNOT BE USED FOR INTERMEDIATE VALUES
            *TOTAL COSTS POR LEVEL B' INCLUDE CREDITS POR
              ACIO RECOVERY AND AL&O REFLECT SAVIMQS DUE
              TO E.LIMINATIOM OF OFF-SITE. DISPOSAL COSTS
              WHICH WERE INCLUDED IN LEVEL A. COSTS SHOWN
              FOR LEVEL B ARE ^ROSS COSTS, WITH MO CREDITS
I55.46Z
              DOLLARS SPENT FOR "COLLECTION SYSTEM AND
              HAULINQ WASTES  FOR OFF-SITE DISPOSAL IN
              LEVEL A. THIS MEANS OF DISPOSAL IS ABANDONED
              AND REPLACED BY A SYSTEM UTILIZING,  COUNTER
              CURRENT RIK1SIN& TO REDUCE  RINSE WATER
              FLOWS TO A VOLUME SUITABLE FOR USE AS
              MAKE-UP TO PICKLE TANKS. SPENT PICKLE
              LIQUORS  ARE REGENERATED IN A EVAPORATIVE
              RECOVERY UNIT, PRODUCING, H25O4 AND
                   I
                  20
 I     I      I      I      I

PERCENT REMOVED


      706
 I
ffO
                                                                   (BPCTCA i
                                                                     LEVEL)
                                                                    (BPCTCA 4
/oo
-------
One  plant  operating  two  bar  mills  was   recycling   so
effectively  that no aqueous discharges were required.  From
the data base, the best available technoloyg indicates  that
the water discharged for BPT should he passed over a cooling
tower  and  then recycled totally to the sprays resulting in
zero discharge to navigable waters.

The section rolling mills in the alloy and  stainless  steel
industry  plant  survey  in  this sutcategory had water uses
which averaged to be slightly less than  for  carbon  steel.
Directly   transferring   the   technology   results   in  a
conservative effluent limitation.

Hot Forming-Flat Plate

Limitations here are based on the present performance of the
best plant.  The limitations for alloy steel  are  based  on
those for carbon steel, with allowance made for higher water
usage.

Hot Forming-Flat, Hot Strip and Sheet

The  best plant in the subcategory was used for the basis of
BAT  determinations.   This   plant   was   achieving   zero
discharge.   The  specialty steel hot strip mills which were
surveyed had water usage rates which were slightly less than
those in the carbon steel segment.   However,  none  of  the
specialty  plants were practicing recirculation.  Therefore,
the technology used in the carbon steel segment was directly
transferred and the limitations were established as the same
for both, resulting in a  conservative  limitation  for  the
specialty strip mills.

Pipe and Tube

As indicated for BPT, one of the electric resistance welding
plants  was eliminated from the discharge flow determination
because it used evaporation to achieve  zero  discharge  and
this treatment technology is not generally applicable to all
steel  plants.   Two of the six plants sampled achieved zero
discharge through total recycle, thus  indicating  the  best
plants   in   the   subcategory.   The  BAT  technology  and
limitations are based, therefore, on total recycle resulting
in zero discharge to navigable  waters.   The  BAT  effluent
limitations  guidelines are for both isolated and integrated
mills.

Sulfuric Acid-Batch
                              707
-------























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709
-------
                  FIGURE IG-li-Z
         MODEL COST  EFFECTIVENESS DIAGRAM
      PICKLINQ  SULPURIC ACID- CONTINUOUS  SUBCATEQORV
            TREATMENT VIA NEUTRALIZATION

ANNUAL COSTS = BASED  ON TEKl VEAR CAPITAL RECOVERS
             -*• INTEREST RATE.  7%
              + OPERATING COSTS  INCLUDE  LABOR, CHEMICALS i UTILITIES
              ••• OPERATING ^ MAIKITENANCE COSTS B.ASED OKJ -3.5% OP
               CAPITAL COSTS
COSTS BASED OMIO88K KG/ DAY f 1100 TOKJS/DAY) OF STEEL PICKLED
   THIS GRAPH CAMNOT BE USED FOR INTER MEDIATE. VALUES

                                                     c (BATEA)
                                                    A (REFERENCE
                                                    B.    L
                                                     (BATEA)
      * TOTAL COSTS FOR LEVELS B' AND C1 REFLECT
        SAVINGS DUE TO ELIMINATION OF «4fe6,,OOO
        OP CONTRACT HAULINQ COSTS WHICH
        WERE IMCLUDED IN LEVEL A. COSTS
        SWOWN FOR LEVELS B AND C ARE
        COSTS WITH NO CRtDITS.
                             60
60
                                                  IOO
                    710
-------
Examination  of  the  data  base  indicated  that  the   BAT
technology and limitations are identical to those of BPT.

SuIfuric Acid-Continuous

For  plants  with  neutralization facilities existing at the
time of promulgation, the BAT limitations are based  on  the
use  of  countercurrent rinses and cascade use in fume hoods
to achieve flows of 25 gpt of concentrate and 25 gpt of fume
hood scrubber and rinse discharges.

For  those  plants  presently  without  neutralization,  BAT
limitations  are  set at zero discharge for both concentrate
and rinses.

Pickling-Hydrochloric Acid-Batch and Continuous-Concentrates
Concentrates

The most modern pickling installations in use today  utilize
hydrochloric   acid  continuous  pickling,  with  continuous
regeneration of spent  pickle  liquor  to  produce  reusable
hydrochloric   acid  and  sinterable  ferric  oxides.   Such
systems are  discussed  in  Section  IX,  where  the  BPCTCA
limitations  were  set  using such a system to recover spent
concentrated acid, discharging only the wastewaters from the
absorber vent scrubber.

A significant reduction in discharge flows from this  system
can  be  obtained  by  adding a recycle loop on the absorber
vent scrubbers, and treating the blowdown from  this  system
via  aeration,  lime  neutralization  and  sedimentation.  A
system such as this has not been tested; however, the key to
the system is keeping the water flows in  balance.   Systems
similar   to   this   are   in  use  in  the  sulfuric  acid
subcategories with considerable success.

Based on the above, the BATEA limits for pickling operations
utilizing HC1 regeneration have been  established  for  each
critical parameter as discussed below.

For   those   hydrochloric   acid  pickling  operations  not
practicing  acid  regeneration,  joint  treatment  of  spent
concentrates and rinse waters was recommended to achieve the
BPCTCA  limitations.   This  technology  is further advanced
through use of countercurrent rinsing to reduce  flows  from
that source to less than 209 1/kkg (50 gal./ton), which when
taken   together   with   the  wastewater  flow  from  spent
concentrates gives a total flow to the  treatment  plant  of
333 1/kkg (80 gal./ton of product) .  Although the only plant
surveyed  which was discharging flows approximately twice as
                             711
-------
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                   713
-------
               MODEL COST EFFGCT/VE/VESS O/AGRAM
                        SULFURIC AC/D - CONT/NUOU5-
                    T&EATMEMT V/A AC/D  RECOVERY
519,961

513,409
       ANNUAL COSTS*BASED ON TEN YEAR. CAPITAL &ECOVE&Y

                 V- INTEGERST GATE  7%

                 i-OPE/SATING COSTS /NCLVOE LA&O*, CHEMICALS ^ C/T/L/T/ES

                 + OPERATING AND MAINTENANCE- COSTS BA56D

                  ON 3.5%  OF CAPITAL COSTS

        COST*  BAftB.0 ON  lOftft HfcG /DAY ( I7OO TONS/DAY) OF- STEEL.

                 TWI5 GRAPH CANNOT BE U5K) FOR INTERMEDIATE-  VALUES.



             * TOTAL COSTS FOR l_£YEL B1 INCLUDE CREDITS FOR
               ACID  RECOVERY AMD ALSO REFLECT  SAVINGS DOE
               TO  ELIMINATION  OP  OFF-SITE DISPOSAL  COSTS
               WHICH WERE INCLUDED  IN LEVEL A. COSTS S.HOWKI
               FOR   LEVEL B ARE  5ROSS COSTS WITH NO CREDITS



                                                                       B (BPCTCA
                                                                         BATEAU
     IT
     3

     I
 2,739
-DOLLARS  SPENT FOR COLLECTION SYSTEM
 A.ND  HAULIN^  \WASTRS FOR  OFF-SITE
 DISPOSAL IN LEVEL A TMIS MEANS OF
 DISPOSAL is ABANDONED AND  REPLACED
 BY A SYSTEM  UTILIZING, COUNTER-CURRENT
 RlNSINCj TO REDUCE RINSE WATER FLOWS
 TO A VOLUME  SUITABLE FOR USE AS A
 MAKE-UP TO PICKUN^ TANKS. SPENT PICKLE
 LIQUORS ARE REGENERATED  IN AN
 EVAPORATIVE RECOVERY USIVT, PRODUCING
       AND
                         SUSPENDED  SOUDS AND DISSOLVED IRON
                   20         4O          6O
                          PERCENT REMOVED
                                        80
                                                        [A ('REFERENCE
                                                           LEVELS
/do
                                 714
-------
large as the recommended flows, two of the other plants,  one
using regeneration and the other deep  well  disposal,   were
successfully  concentrating rinse water flows to 50 gal./ton
or less.  In  fact,  the  plant  using  deep  well  disposal
methods  achieves  flow  rates of only 3.3 gal./ton of  spent
pickle liquor, plus 5.9 gal./ton  of  rinse  water  using  a
cascade  system, indicating how efficiently such rinse  water
conservation practice may be.

Pickling-Hydrochloric Acid-Rinse Waters

One of the  two  plants  providing  more  or  less  complete
treatment  of rinse waters in this subcategory has been used
as the basis for establishing all BATEA Effluent Limitations
Guidelines.  This  plant  provides  equalization,  blending,
lime  addition to pH 8.0, mixing, aeration in dual chambers,
polymer addition, clarification in either of  two  identical
thickeners  used  in  parallel  with  vacuum  filtration  of
underflows, and  final  settling  in  a  large  lagoon   with
discharge of overflow to a receiving stream.  An effluent of
extremely high quality results.  All parameters listed  below
are  effectively  removed  using  the  above  equipment  and
treatment technology.

Cold Rolling

The degree of effluent  load  reductions  achieved  via  the
treatment  and  control  technology  required  to attain the
BPCTCA limitations for recirculation, combination and direct
application cold rolling operations as described in  Section
IX   is   equivalent   to   the  best  available  technology
economically achievable at this time.  To achieve additional
reductions  would  require  expenditures  of   capital    and
operating  costs out of line with the benefits derived.  For
this reason, the BATEA  limitations  for  the  cold  rolling
operations  are identical with the BPCTCA limitations in all
cases.

Hot Coatings-Galvanizing Operations

Flow information relative to  the  four  plants  visited  is
discussed in Section IX, along with the BPCTCA limitations.

Hot Coatings-Terne Operation

Since   both   of  the  terne-plating  lines  surveyed   were
discharging  wastewaters  after  once-through  use   without
treatment,  but  rather  with  control  to minimize dragout,
BATEA limitations for all parameters were set at  levels  in
                            715
-------
38
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-------
           FIGURE
         COST
            MODEL  COST EFFECTIVENESS  P/AG,KAM
              PICKLING HYDROCHLORIC /9C//D -
             CONCENTRATED 5U&CflrEGOF?y - ALTERNATE _T
          COST-&ASED OH TEN Y&A& C.APITA.L
                + IN T&K.&S T «A T£- 7 %
                + OPERATING COSTS INCLUDE LA&OK, Cf-/EM/CALS $ UTILITIES
               + OPERATTINCSi ANt> tAA.\NTE.N KNCE COSTS
                      a .5% OF C-A^rroL. c.o«»-rs
          TUX'S
/,//9,322-•
                                                        -A
            TOTAL
                      5PSMT f=-OR.
                    A. 7W/S  MEANS- '
               DISPOSAL IS
AND REPLACED  WITH
AND IRON OX/Di
            WITH
                                      I
                             LEVEL &,
                                         INCLUDE  t=K.£DlTS FOK,
                I
       tOO     75
         h	 PERCENT  ADDED
            \
          SO
 I
O
         I
        SO
PERCENT REMOVED
/OO
                               718
-------
719
-------
                  F/6URE /G4-2
    PICKLIMG-HYDROCHLORIC ACID-RINSE SUBCATEGORY ALTERNATE /

ANNUAL COSTS = BASSO OM TBM YBAR CAP/TAl- ff£COVeBY
3/3,288
                                TBM YBAR
                                    7%
                   + opea AT/MS COSTS
                   + OPERATING, AND MAINTENANCE COSTS BASED ON 3.5%
                    OF CAPITAL COSTS
     COST BASED OH Z7ZI KKG/DW(3OOOTOHSI DAY) OF STEEL PICKLED
       THIS GRAPH CAN NO T BE USED FOR INTERMEDIATE VALUES
               /OO

             PEI3CEMT ADOSD
                            720
-------
effluents  from  systems  similar  to  those used in the Hot
Coatings - Galvanizing subcategory.

Miscellaneous Runoffs-Storage Piles

Coal, Stone and Ore

These three miscellaneous runoffs were discussed in  general
terms   in  Section  IX,  but  no  BPCTCA  limitations  were
specified, indicating instead that such limitations will  be
deferred  until  such  time as BATEA limits apply.  The best
available technology economically achievable  is  considered
to  be perimeter collection, storage, chemical flocculation,
neutralization and sedimentation.   The  use  of  impervious
liners  or  other  means to preclude subsurface drainage has
not been included in the BATEA technology due to the absence
of demonstrated cost effectiveness.

Concentration limits on specific pollutants present  in  the
wastewater which are due to leaching from the stockpile must
be set on an individual basis wherever appropriate.

The  .stockpile  size and surface area is calculated from the
raw material usage,  storage  capacity,  bulk  density,  and
stockpile  height  parameters.   The  rainfall  value chosen
represents  the  greatest  mean  maximum  2U  hour  rainfall
generally  experienced  in  the  western, north central, and
northeastern part of the United States.  (Source:  The  1970
National   Atlas   of   the   United  States.)    The  runoff
coefficient  of  0.90  was  assumed   since   the   proposed
subsurface  and  surface  runoff  collection  systems should
collect  all  rainfall  except   that   accounted   for   by
evaporation.

It  should  be  particularly  obvious  that the system costs
based  upon  the  above  set  of  criteria  and  assumptions
represent  only  one  specific  case of the probable cost of
such a system.  A great variety of alternatives in size  and
cost  exist  for  this  basic  treatment concept and must be
determined  and  applied  on  a  site-by-site  basis.    The
particular system described above, although not rigorous for
all  applications,  does  provide a reasonable cost estimate
for the particular set of criteria and assumptions used.

The basic concept of collection and storage  is  justifiable
in  every  application.  Even though logistics and economics
may preclude the application of  provisions  for  impervious
sealing  of  the  stockpile  base  for existing piles, there
should generally be  no  restriction  to  prevent  perimeter
collection  of  a large part of the runoff.  Once collected.
                               721
-------
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                            722
-------
723
-------
                           F/GURE ICoS-2.
          MODEL  COST EFFECT/VENESS  DIAGRAM
                         P/CKLING - HYD&OCHLOR 1C  AC/D-
          CONCENTRATED/WDRINSE- £UBCATEGOGY-ALTERNATE!!
ANNUAL COST -BASED  ON  T&N VEAE  CAPITAL. QeCOVEEV
              + j/vreffe-ST  RATS  T7.
              + OPERATING COST INCLUDE LABOR,CHEMICAL* * UT/L/r/C-5
              i- OPERATING AND MA/MTBNANCE COSTS  B45E-O
                O/V/v3.57.  OP-  C4P3/TAL.  COSTS
      COSTS  BASED  ON 2.7Z KKG/&AV C3OOO  7-QM5/OAY)
                      OF 5TE£L  ^/CKLED
   THIS  GRAPH CANNOT SE USED r<3& //VTE/SMED/ATE  VALUES
                                                                  _l_ X?
        SPENT PICKLE LIQUOf? A(OD RINSE WATER TREATMENT COSTS ^BA5£
        INCLUDES DOLUfcBS •JENIT FOe COtLeCTlOKJ SY^TfeM A^>5P HAULIVJ&
                                                             OF
                l"5 ^BAWOMfcCJ AMD CtPLACtO BY KJ&UTEAUWTIOW 5Y5TEM
        Bfr(JIKJIs)|ioG \yfrM LfeVEL eTMUS ELIMINATING '(,044,000 OF LEVEL A COSTS
                                                                 _ . ft (COSTS
                                                                      CARRt
                                                                      FORWARD)
           PERCENT ADDED
             I
 o           50           /oo
•(*	PERCENT REMOVED
                                 724
-------
at least minimal  treatment  for  suspended  solids  and  pH
should be applied under BATEA wherever site or area specific
pollutants appear in excessive concentrations in the runoff.
The  treatment  of  these specific pollutants where they are
identical to critical parameters identified in  this  study,
should  follow  the  treatment  and  control  technology and
effluent guidelines  established  for  these  parameters  in
other subcategories.   In other cases, treatment and control
technology and limits will have to be formulated and applied
on a case-by-case basis.

Since  it  is  not  possible  to  present  a  uniform set of
parameters on which to design, size, and cost these systems,
some discussion of the variables involved and  their  impact
on  the completed system is in order.  They can be described
as follows:

Stockpile Surface Area.  This, of  course,  depends  heavily
upon the capacity of the ironmaking facility, its production
rate, the number of days stockpiled inventory, the height of
the   pile,  and  the  amount  of  sinter  charge  employed.
Although coal is converted to coke before  charging  to  the
blast furnace, the coal supply will generally keep pace with
blast  furnace  production  since coke produced is generally
used immediately in the blast furnace.

Rainfall.  Rainfall intensity, frequency, and  duration  can
vary  significantly  from  area to area in this country.  In
certain areas, the use of mean maximum 24 hour  rainfall  to
estimate the load on the system may be sufficient.  However,
in  other  areas, the use of figures for the 2 year, 5 year,
10 year, etc., 24 hour storms may be more  appropriate.   In
other  areas,  where  definite wet seasons occur, the system
design may have to be based upon maximum consecutive days of
rainfall in the area.  Each  case  will  depend  on  weather
conditions  specific  to  the  area  and  will  have  to  be
determined on that basis.

Runoff Coefficients.  Again, case-by-case estimates  may  be
needed.   Runoff  coefficients are generally average numbers
reflecting runoff throughout the storm  cycle.   During  the
peak   of   an   intensive,   long  duration  rainfall,  the
coefficient may approach 100%.  However, during brief rains,
at the start of rainfall,  and  after  rainfall  has  ended,
these   coefficients   may   be   considerably  lower.   The
coefficient  in  all   cases   will   require   conservative
estimation to avoid underdesign of the system.

Treatment  Alternatives.  As mentioned previously, the basic
treatment system  for  will  require  sedimentation  and  pH
                             725
-------
1
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-------
adjustment,  with more specific treatment processes employed
under BATEA where additional constituents appear.   However,
this  does  not  preclude the possibility of using treatment
facilities associated with other subcategory  facilities  in
the  mill.   With the right combination of rainfall load and
storage capacity, flow may be effectively metered  to  allow
such a possibility.

In  addition, in some areas of the country where evaporation
exceeds rainfall, it may be possible to  collect  and  store
the  runoff  during  wet  periods, and later spray evaporate
runoff during dry periods and thus achieve zero discharge.

Another  factor  that  may  affect  the  size  of  treatment
facilities  will  be  land  area  available  for  storage of
runoff.  Where land is at a premium, pond area will have  to
be  minimized  and treatment capacity maximized.  Where land
availability is not restrictive, the opposite may be true.

The 2.5 inch 24 hour rainfall used as the basis  for  runoff
collection  and  treatment  facilities  for storage piles is
based upon mean annual maximum 24 hours rainfall data in the
USGS National Atlas,  This data map indicates that the  vast
majority  of  steel industry production is centered in areas
of the country having a mean annual maximum 24 hour rainfall
equal to 2.5 inches or less.

Although it is realized that maximum rainfall data is highly
site specific, and in many cases should be  based  upon  10,
25, etc. years storms, no other source of data was available
that  could  provide a general estimate covering most of the
areas of the country where steel production is located.

Specialty Steel Pickling and Coating Operations

It has been determined on the  basis  of  a  review  of  the
available   technology,   the  engineering  aspects  of  the
application   of   various   control   techniques,    energy
requirements,  and  the  costs of application in relation to
the effluent reduction benefits  to  be  achieved  that  the
BATEA limitations for the specialty steel pickling, cleaning
and  coating subcategories should be the same as the same as
the BPCTCA limitations:

Cons ideration of Process! Changes

No process changes are envisioned for implementation of this
technology for plants in  any  subcategory.   The  treatment
technologies to achieve BATEA assess the availability of in-
                             729
-------
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731
-------
                              FIGURE
             MOD&L COST  tFFfcCTlVEKJfcSS
             COLD eOLLIUG-COMBIVJATlOM
AKJKJUA.L CO«5TS » BAStD OU TEKJ Yfc\e  CAPITAL
                 + IMT6B65T  RATE: T/u
                 •»• OPEPATlUG COST^ WCLUDE L*vt>OR>
                 * OPERATIKIG ^MAlMTEWAKJC-E. COSTS BASED OK) 3,5%
                  CAPITAU COSTS
COSTS BASED OW »3
-------
process  controls as well as control or additional treatment
techniques employed at the end of a production process.

Consideration of Costs of Achieving the  Effluent  Reduction
Resulting from the Application of BATEA Technology

The  costs of implementing the BATEA limitations relative to
the benefits to be derived is pertinent, but is expected  to
be  higher  per  unit  reduction  in  waste load achieved as
higher guality effluents are produced.  The  overall  impact
of  capital and operating costs relative to the value of the
products  produced  and   gross   revenues   generated   was
considered in establishing the BATEA limitations.

The  technology evaluation, treatment facility, costing, and
calculation of overall capital and operating  costs  to  the
industry  as  described in Section IX and which provided the
basis for the development of the BPCTCA limitations was also
used  to  provide  the  basis  for  determining  the   BATEA
limitations,  the  costs,  and  the  acceptability  of those
costs.

The initial capital investment and total annual expenditures
required of the industry to achieve  BATEA  limitations  are
summarized in Table 197.

After the treatment technology to be designated as one means
to  achieve  the  BATEA limitations for each subcategory was
selected, a sketch of each  treatment  model  was  prepared.
The  sketch  for each subcategory is presented following the
tables presenting the BATEA limitations for the subcategory.

Cost Versus Effluent Reduction Benefits

Estimated total costs on a dollars per ton basis  have  been
included  for each sufccategory as a whole.  These costs have
been based on  the  wastewaters  emanating  from  a  typical
average   size   production   facility   for   each  of  the
subcategories investigated.  In arriving at  these  effluent
limitations  guidelines,  due  consideration  was  given  to
keeping the costs of implementing the new  technology  to  a
minimum.   Specifically, the effluent limitations guidelines
were kept at values which  would  not  result  in  excessive
capital or operating costs to the industry.  The capital and
annual  operating  costs  that  would  be  required  of  the
industry to achieve  BATEA  was  determined  by  a  six-step
process  for  each  of  the  subcategories.   It  was  first
determined what treatment processes were  already  in  place
and   currently  being  utilized  by  most  of  the  plants.
Secondly, a hypothetical  treatment  system  was  envisioned
                              733
-------
                                                 >S  e
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                    734
-------
735
-------
            MODEL CO«5T fcFFtCTlVfcKJfc^*,  DIAGRAM
            COLD EOLLIKX5-DIBECT APPLICAJIOK)
AUUU/U- COSTS • fcASfcO OU Tfc»0
              •t- IkJTfcBfc'ST  BATE
              + OP6BATIIOG
dOSTS
                                    CAPITAL
                                 IWCLUDfc
                                                            * UT\HTIES
                           OF
                              RO t5OCT\ON
                                                                          e>
                                                                          (BPCTCAi
                                                                           Av
                                                                           CKEf/TRENCE
                                                                            LEVEL)
                                                                       IOO
                                    736
-------
which,  as  an add-on to existing facilities would treat the
effluent sufficiently to  meet  BATEA  ELGs.   Thirdly,  the
average  plant  size  was  determined  by dividing the total
industry production by the number of  operation  facilities.
Fourth,  a  quasi-detailed engineering estimate was prepared
on the cost of the components and the total capital cost  of
the  add-on  facilities  for  the average plant.  Fifth, the
annual operating, maintenance, capital  recovery  (basis  10
years  straight line depreciation) and capital use (basis 1%
interest) charges were determined.   And  sixth,  the  costs
developed  for  the  average facility were multiplied by the
total number of facilities to arrive at  the  total  capital
and  annual costs to the industry for each subcategory.  The
results are summarized in Table 197 which also  shows  total
costs for the specialty steel segment.

Mahoning Valley

For  steel plants wihtin the Mahoning Valley which apply for
a Section 310(c) exemption, the modified  limitations  shall
not   be   less  stringent  than  the  industry-wide  BPCTCA
limitations for the following subcategories:

    Cold Rolling
    Hot Coating - Galvanizing
    Hot Coating - Terne
    Miscellaneous Runoffs - Storage Piles, Casting and  •
      Slagging
    Combination Acid Pickling
    Seale Remova1
    Wire Pickling and Coating
    Continuous Alkaline Cleaning

For steel plants within the Mahoning Valley which apply  for
a  Section  301(c) exemption, the modified limitations shall
not be less stringent than those set forth below.

Hot Forming-Primary-Mahoning Valley:

Effluent                         Effluent
Characteri st ic                   Limitations

                    Maximum for     Average of  daily
                    any one day     values for  thirty
                                    consecutive days
                    	     shall not exceed

          (Metric units)   kg/kkg of product

         (English units)   lb/1000 Ib of product
                              737
-------
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                                             In
                        738
-------
739
-------
           MODEL COST EFFECTIVENESS
                  HOT COATING - GALVANIZING-5UBCATEGORY

   ANNUAL COSTS = BASED ON TEN YEAR CAP/TAL RECOVERY
                + INTEREST RATE 7%
                i-OPERATING COSTS INCLUDE LABOR,CUEMICAL5 f'UTILITIES
                ^OPERATING AND MAINTENANCE COSTS BASED OA/3.5%
                  OF CAPITAL COSTS
   COSTS BASED ON 635MG/DAY(7OOTONS/DAY) HOT COATING OPERATION
    THIS GRAPH CANNOT BE USED FOR INTERMEDIATE VALUES
VI
8
                          NO INCREASED COST'S.
                                            ARE A
                                   OF SETTS'R.
                                        A
                                       (REFERENCE
                                        LEVEL}
     o
I     I     I      I     I
PERCENT REMOVED
                                                         /OO
                           740
-------
Oil and Grease
TSS
PH
0.5391           0.1797
0.8238           0.2746
Within the range 6.0 to 9.0.
Hot Forming Section-Mahoning Valley:
Effluent
Characteristic
                    Maximum for
                    any one day
         Effluent
         Limitations

            Average of daily
            values for thirty
            consecutive days
            shall not exceed
          (Metric units)

         (English units)
Oil and Grease
TSS
PH
  kg/kkg of product

  lb/1000 Ib of product

0.7062           0.235U
2.2560           0.7520
Within the range 6.0 to 9.0.
Hot Forming-Flat-Sheet & Strip-Mahoning Valley:
Effluent
Characteristic
                    Maximum for
                    any one day
         Effluent
         Limitations

            Average of daily
            values for thirty
            consecutive days
            shall not exceed
         (Metric units)

        (English units)
Oil and Grease
TSS
PH
  kg/kkg of product

  lb/1000 Ib of product

0.7758           0.2856
1.7661           0.5887
Within the range 6.0 to 9.0.
Pipe and Tube-Ma honing Valley:
Effluent
Characteristic
                    Maximum for
                    any one day
         Effluent
         Limitations

            Average of daily
            values for thirty
            consecutive days
            shall not exceed
                            741
-------


























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                                         FIGURE  170-Z.
                              MODtL  CO5T  EFFECTIVENESS DIAGRAM
                                   HOT COATING-TERNE SUBCATEGORY
            ANNUAL COSTS * BASED  ON TEN YEAR CAPITAL  RECOVERY
                          + INTREST  RATE 77.
                          •••OPERATING COSTS  INCLUDE LABOR, CHEMICALS t UTILITIES
                          4- OPERATING £ MAINTENANCE COSTS BASED ON 3,5% OF
                            CAPITAL. COSTS
            COSTS BASED ON  €>35 KKG/DAY (700 TONS/DAY)  HOT COATING OPE.R.
            TUIS GRAPM CANNOT Be. USED FOR  INTERMEDIATE VALUES
2O34OO
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111,688
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                                                        NO INCREASED COSTS.
                                                        IMPROVEMENTS AREA
                                                        RESULTOF BETTER
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                                                                                   (REFERENCE
                                                                                     LCVEt)
                                    4O            60
                                    PERCENT  REMOVED
                                                                 80
                                                                                100
                                  744
-------
         (Metric units)    kcr/kkg of product

        (English units)    Ib/IOQO Ib of product

Oil and Grease          1.0527          0.3509
TSS                     4.2597          1.4199
pH                      Within the range 6.0 to 9.0.

Pickling-Sulfuric Acid-Mahoning Valley: Rinses

Effluent                         Effluent
Characteristic                   Limitations

                    Maximum for     Average of daily
                    any one day     values for thirty
                                    consecutive days
                    	     shall not exceed

         (Metric units)    kg/kkq of product

        (English units)    lb/1000 Ib of product

TSS*                    0.0705     0.0238
Dissolved Iron          0.0282     0.0094
Oil and Grease*         0.0282     0.0094
pH                      Within the range 6.0 to 9.0.

* This  applies  only  when  these  wastes  are  treated  in
combination with cold rolling wastes.

Concentrates:   There shall be no discharge of process waste
water pollutants to navigable waters.

Fume Hood Scrubbers:

Effluent                         Effluent
Characteristic                   Limitations

                    Maximum for     Average of daily
                    any one day     values for thirty
                                    consecutive days
                    	     shall not exceed

         (Metric units)    kg/kkg of product

        (English units)    lb/1000 Ib of product

TSS*                    0.0156     0.0052
Dissolved Iron          0.0063     0.0021
Oil and Grease*         0.0063     0.0021
                            745
-------
*  This  applies  only  when  these  wastes  are  treated in
combination with cold rolling wastes.
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               Figure 172-1-2
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              Figure 172-2-2
Combination  Add Pickling - Batch Pipe  & Tube

   Annual  Cost = Based on Ten Year Capital Recovery
              + Interest Rate 7%
              + Operating Costs Include Labor, Chemicals & Utilities
              + Operating & Maintenance Costs based on 3.5%
                of Capital Costs
   Cost based on 19 kkg/day (21 tons/day)  steel processed.
   This graph cannot be used for intermediate values.
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* This  applies  only  when  these  wastes  are  treated  in
combination with cold rolling wastes.

Pickling-Hydrochloric Acid-Mahoning Valley: Rinses

Effluent                         Effluent
Characteristic                   Limitations

                    Maximum for     Average of daily
                    any one day     values for thirty
                                    consecutive days
                    	     shall not exceed

         (Metric units)   kg/kkg of product

        (English units)   lb/1000 Ib of product

TSS*                    0.0627     0.0209
Dissolved Iron          0.0249     0.0083
Oil and Grease*         0.0249     0.0083
pH                      Within the range 6.0 to 9.0.

*  This  applies  only  when  these  wastes  are  treated in
combination with cold rolling wastes.

Concentrates:  There shall be no discharge of process  waste
water pollutants to navigable waters.

Fume Hood Scrubbers:.

Effluent                         Effluent
Characteristic                   Limitations

                    Maximum for     Average of daily
                    any one day     values for thirty
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         (Metric units)   kg/kkg of product

        (English units)   lb/1000 Ib of product

TSS*                    0.0156     0.0052
Dissolved Iron          0.0063     0.0021
Oil and Grease*         0.0063     0.0021
pH                      Within the range 6.0 to 9.0.
                                 755
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Combination Acid Pickling - Other Batch

Annual Cost = Based on Ten Year Capital  Recovery
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            + Operating & Maintenance  Costs based  on 3.5%
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Cost based on 131 kkg/day (144 tons/day)  steel  processed.
This graph cannot be used for intermediate values.
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               Scale Removal - Kolene

       Annual Cost - Based on Ten Year Capital Recovery
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       Cost based on 26 kkg/day (29 tons/day) steel processed.
       This graph'cannot be used for intermediate values.
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             Figure 174-2
        Scale Removal - Hydride

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Cost based on 55 kkg/day (60 tons/day) steel processed.
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-------
                         SECTION XI

          EFFLUENT QUALITY ATTAINABLE THROUGH THE
      APPLICATION OF NEW SOURCE PERFORMANCE STANDARDS
INTRODUCTION

The effluent  limitations  that  must  be  achieved  by  new
sources  are  termed  new source performance standards.  New
Source Performance Standards apply to any source  for  which
construction  starts  after the promulgation and publication
of the standards.  The standards are determined by adding to
the considerations underlying the identification of the Best
Practicable  Control  Technology  Currently   Available,   a
determination of what higher levels of pollution control are
available  through the use of improved production processes,
and/or  treatment  techniques.    Thus,   in   addition   to
considering  the  best  in-plant  and end-of-process control
technology. New Source Performance Standards are based on an
analysis of how the level of  effluent  may  be  reduced  by
changing   the   production   process  itself.   Alternative
processes, operating  methods,  or  other  alternatives  are
considered.   However,  the end result of the analysis is to
identify  effluent  limitations  which  reflect  levels   of
control  achievable  through  the use of improved production
processes and practices   (as  well  as  control  technology)
rather  than  prescribing  a  particular  type of process or
technology which must be employed.  A further  determination
is  made  whether  a  limitation  permitting no discharge of
pollutants is practicable.  For purposes of  developing  the
BPCTCA  and BATEA technologies and limitations, the industry
was divided into the following subcategories:

G.  Basic Oxygen Furnace  (Wet Air Pollution Control Methods)
K.  Vacuum Degassing
L.  Continuous Casting and Pressure Slab Molding
M.  Hot Forming - Primary
N.  Hot Forming - Section
O.  Hot Forming - Flat
P.  Pipe and Tubes
Q.  Pickling - Sulfuric Acid - Batch and Continuous
R.  Pickling - Hydrochloric Acid
S.  Cold Rolling
T.  Hot Coating - Galvanizing
U.  Hot coating - Terne
V.  Miscellaneous Runoffs
W.  Pickling - Combination Acid-Batch and Continuous
X.  Scale Removal - Kolene and Hydride
Y.  Wire Pickling and Coating
                            773
-------
Z.  Continuous Alkaline Cleaning

With the exception of the  Hot  Coating  -  Galvanizing  and
Terne  subcategories  and  the absorber vent scrubber on the
hydrochloric acid subcategory, there are carbon steel plants
in all other categories which are  presently  achieving  the
BATEA   effluent  limitation  guidelines.   This  in  itself
justifies  the  fact  that  technology  is   available   and
demonstrates  that  the limitations can be achieved on a day
by day basis.  Therefore, in those  subcategories  where  an
existing facility is currently achieving the BATEA guideline
BADCT  is  the  same as BATEA and the New Source Performance
Standards are the same as for BATEA.  In  the  subcategories
apart  from these the flow basis corresponds with the BPCTCA
technology but with the BATEA concentrations.

NSPS DISCHARGE STANDARD

For the  following  subcategories,  refer  to  rationale  as
discussed in Section X - BATEA.

G.  Basic Oxygen Furnace (Wet Air Pollution Control Methods)
K.  Vacuum Degassing
L.  Continuous Casting and Pressure Slab Molding
N.  Hot Forming Section
O.  Hot Forming Flat
P.  Pipe and Tubes
Q.  Pickling - Sulfuric Acid - Batch
R.  Pickling - Hydrochloric Acid  (if spent liquor is
    neutralized)
S.  Cold Rolling
V.  Miscellaneous Runoffs
W.  Pickling - Combination Acid-Batch and Continuous
X.  Scale Removal - Kolene and Hydride
Y.  Wire Pickling and Coating
Z.  Alkaline Cleaning

For the remaining subcategories:

M.  Hot Forming Primary

The  New  Source  Performance  Standards  are  based  on the
performance of the best carbon steel plant operating  today.
Using direct transfer of technology, the guidelines for this
category were scaled up to reflect the higher water use rate
for alloy operations to arrive at the New Source Performance
Standards for alloy plants.

R.  Pickling - Hydrochloric Acid
     (B) Absorber Vent Scrubber
                              774
-------
If  acid regeneration is used the NSPS limitations are based
on the BATEA treatment technology (and  concentrations)   and
on   the   BPCTCA   waste   volume;   i.e.,   recycle  of  the
regeneration unit acid absorber vent scrubber water is not a
basis for the NSPS limitation.  Thus with acid regeneration,
the NSPS limitations are based on a  flow of 833  1/kkg  (100
gal/1000  Ibs)   as  in  BPCTCA limitations.  The recommended
recycle of scrubber water is BATEA technology which has  not
been  practiced  as yet on an actual operating acid recovery
unit although one surveyed plant is  modifying  their  system
to  accomplish  this.  For this reason, the NSPS limitations
were based on once-through discharge of the treated scrubber
waters.  For rinse water flows, and for fume  hood  scrubber
flows,  the  NSPS  limitations  are  the  same  as the BATEA
limitations.

T.  Hot Coating - Galvanizing
U.  Hot Coating - Terne

New  source   performance   standards   (NSPS)    for   these
subcategories  use  the  same  flow  basis  as  the effluent
limitations for BPCTCA.  As yet, neither  recommended  BATEA
flow  reduction  technique  has  been  applied to full scale
galvanizing operations, although they are used  successfully
in  pickling operations and in gas scrubbing systems in iron
and steel furnace operations.  However,  all  parts  of  the
end-of-process  treatment  technologies are currently in use
at existing plants in this subcategory.  BATEA concentration
limits were therefore used to establish loads,  even  though
BPCTCA flows had to be used.
                            775
-------
                        SECTION XII

                      ACKNOWLEDGEMENTS
This draft, contractor's reports from which this document was
prepared  was  written by the Cyrus Wm. Rice Division of NUS
Corporation,  for  the   Carbon   Steel   segment   and   by
Datagraphics,  Inc.,  for  the  Alloy  and  Stainless  Steel
segment.

The  preparation  and   writing   of   this   document   was
accomplished  by  Ms. Patricia E. Williams and Mr. Edward L.
Dulaney,  Project  officers,  EPA,  Mr.  John  G.  Williams,
Assistant  Project  Officer, EPA, and through the efforts of
Mr. Thomas J. Centi, Project Manager, Mr. Joseph  A.  Boros,
and  Mr. Wayne M. Neeley of C.W. Rice, and Dr. Henry Bramer,
Project Manager and Mr. Edward Shapiro of Datagraphics.

The support of the project by the  Environmental  Protection
Agency  and the excellent guidance provided by Mr. Walter J.
Hunt, Chief, Effluent Guidelines Development Branch, and Ms.
Patricia E. Williams and Mr. Edward L. Dulaney, the  Project
Officers, is acknowledged with grateful appreciation.

The  members  of  the  working  group/steering committee who
coordinated the internal EPA review are:

    Walter J. Hunt - Effluent Guidelines Division
    Edward L. Dulaney - Effluent Guidelines Division
                     (Project Officer)
    Patricia E. Williams - Effluent Guidelines Division
                     (Project Officer)
    John G. Williams - Effluent Guidelines Division
                     (Assistant Project Officer)
    Hugh Durham - Office of Research and Development
    Lee Evan Caplan - Office of General Counsel
    Barry Malter - Office of General Counsel
    James McDermott - Region V, EPA
    Matt Miller - Region III, EPA
    Dennis Ruddy - Office of Permit Programs
    Robert Burm - Region VIII, EPA
    Al Brueckmann - Office of Planning and Evaluation
    Steve Besse - Office of Planning and Evaluation

The excellent cooperation of the individual steel  companies
who   offered   their  plants  for  survey  and  contributed
pertinent data is gratefully  appreciated.   The  operations
and  the  plants  visited were the property of the following
                            777
-------
companies: Allegheny Ludlum Steel Corporation,  Armco  Steel
Corporation,  Avco  Thompson,  Bethlehem  Steel Corporation,
Branford  Pacific   Wire,   Cabot   Corporation,   Carpenter
Technology  Corporation,  Colorado  Fuel  & Iron, Copperweld
Steel  Corporation,   Crucible   Steel   Company,   Dominion
Foundries  and  Steel  Limited,  Fitzsimmons  Steel Company,
Inland  Steel  Corporation,  Interlake  Steel   Corporation,
Jessop   Steel   Corporation,   Jones   6   Laughlin   Steel
Corporation,   Joslyn   Stainless   Steel,   Kaiser    Steel
Corporation,  Lasalle  Steel,  Latrobe  Steel; Company,  Lone
Star Steel corporation. National Steel  Corporation,  Nelson
Steel   &   Wire,   Phoenix  Manufacturing,  Republic  Steel
Corporation, Sawhill Tubular, Sharon Tube  Corporation,  The
Steel   Company   of   Canada,  Ltd.,  United  States  Steel
Corporation,  Universal-Cyclops,  Walker  Wire,   Washington
Steel, Wheatland Tube Corporation, Wheeling-Pittsburgh Steel
Corporation,   Wire   Sales,   Inc.,   and  Wisconsin  Steel
Corporation.

Acknowledgment and appreciation is also  given  to  Ms.  Kay
Starr,  Word  Processing-Editor, to Ms. Nancy Zrubek and Ms.
Alice Thompson of the Effluent Guidelines Development Branch
secretarial staff, for their efforts in  typing  of  drafts,
necessary  revisions,  and final preparation of the original
documents and revisions.
                            778
-------
                        SECTION XIII

                         REFERENCES
1,  Aarons, Ralph and Taylor, Robert A., "The  DuPont  Waste
Pickle  Liquor  Process", Proceedings of the 22nd Industrial
Waste Conference, Purdue University, pp. 120-125  (1967).

2,  Adams, J. I. and  schaeffer,  G.  H.,  "Five-ton  Vacuum
Induction  Melting  Furnace",  Iron  and Steel Engineer Year
Book, 1965, pp. 123-129.

3.  Allen, Jones E., "Tin Line Conversion to  Chrome",  Iron
and Steel Engineer, 47, pp. 88-92  (May, 1970).

4.  Allison, R. J., et al, "Method for the  Regeneration  of
Hydrochloric   Acid   from  Spent  Pickle  Liquor  and  Like
Solutions",  United  States  Patent,  3,669,623,   (June  13,
1972) .

5.  American Iron and Steel Institute,  "Annual  Statistical
Report, 1972", Washington, D. C.

6.  American Iron and Steel Institute, Directory of Iron and
Steel Works of the United States and Canada,  American  Iron
and steel Institute, New York  (1970) .

7.  American Iron and steel Institute, "The  Steel  Industry
Today",  Submitted  by Domestic Member Companies of-American
Iron and Steel Institute, pp. 1-38  (May, 1971) .

8.  Anderson, J. R., Luttinger, L. B., and Schwoger, W.  L.,
"Gravity  Dewatering  of  Metal Hydroxide Sludges", Plating,
59, pp. 1,135-1,139  (December, 1972).

9.  Andon'ev, S. M., et al, "Increasing the Service Life  of
Emulsions  on  Cold-Rolling Mills", Steel in the USSR, 1, p.
966  (December, 1971) .

10. Andrews, D. M. , "Regeneration of HCl Waste Pickle Liquor
at stelco's Hilton Works", Iron and Steel Engineer, 48,  pp.
53-55 (August, 1971) .

11. "Annual  Review  Developments  in  the  Iron  and  Steel
Industry  During 1972", Iron and Steel Engineer, 50, pp. Dl-
D48  (January, 1973).
                          779
-------
12. "Annual  Review  Developments  in  the  Iron  and  Steel
Industry  During 1971", Iron and Steel Engineer, 49, pp. D2-
D52 (January, 1972).

13. Ardito, V. P. and  Shaw,  R.  B. ,  "The  AVR  (Allegheny
Vacuum  Refining)  Process", Iron and Steel Engineer, August
1972,  pp. 58-65.

14. Armco Steel Corporation, "Limestone Treatment  of  Rinse
Waters  from  Hydrochloric  Acid  Pickling  of Steel", Water
Quality Office, Environmenta1 Protection Agency, Project No.
12010DUL3171  (February, 1971).

15. "Ashland Inaugurates HC1 Acid  Regeneration  Plant",   33
Magazine, 10, pp. 30-32  (December, 1972) .

16. Ashmore, A. G., Catchpole, J. R. ,  and  Cooper,  R.  L.,
"The  Biological  Treatment  of Carbonization Effluents -  I,
Investigation  into  Treatment  by  the   Activated   Sludge
Process", Water Research, 1, pp. 605-624  (1967).

17. Ashmore, A. G., Catchpole, J. R.,  and  Cooper,  R.  L.,
"The  Biological  Treatment  of  Carbonization Effluents II,
Studies of the Influent of Liquor Composition", 2, pp.  555-
562 (1968) .

18. "A  Solution  to  Pollution  'Compound1  the   Problem",
Mechanical Engineering, 94, p. 49  (October, 1972).

19. Association of Iron and Steel Engineers, "The Hot   Strip
Mill Generation II", AISE,  (1970).

20. Balden, A. R. and Erickson,  P.  R.,  "Reuse,  Not  Just
Treatment...",  Water  and Wastes Engineering, 8, No. 1, pp.
A2-A4  (January, 1971).

21. Balzhi, N. M., et al, "Effect of Water  Quality  on the
Service  Properties  of Emulsion",  Steel  in the USSR, 2, pp.
810-812  (October, 1972).

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24. Barker, John E. and Pettit,  Grant  A.,  "Water  Reuse",
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28. Baughman,  M.  D.,  "High-Speed  Continuous  Galvanizing
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34. Beyer,  Stanley,  "Continuous  Regeneration  of   Ferric
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35. Blackburn, T.  L.  and  Dixon,  Norman  G.,  "Lone  Star
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36. Blanchard,   Thomas  A.,  "Incinerators  for  the   Metal
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                                781
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37. Bland, Marshall, "Three Ways to Minimize Water Pollution
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49. Brown, Daniel L., "Recovery of Acid  from  Spent  Pickle
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72. Davisson, G. and  Ullman, P., "Spent Pickling Liquors  as
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73.  Dean, John  G., Bosqui, Frank L.,  and Lanouette,  Kenneth
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74. "Deep Bed Filter Uses Polymer  Resin  Filter  Material",
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90. "Effluent Control in Wire  Production",  Wire  Industry,
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91. Eisenhuth, C. L., "The  Pickling  Process  and  Effluent
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105.     Frank,  V.  F.   and   Gravenstreter,   James   P.,
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106.     Galloway, R. E. and Colville, J. F., "Treatment  of
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107.     "Gary   Works   Latest   Tinning   Line   Still   a
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108.     Geny, P. and Dohen,  E.,  "Measures  Against  Water
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109.     George, L. C. and Cochran, Andrew A., "Recovery  of
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110.     Gillbanks,  P.  and  Burden,   E.   B.,   "Treating
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111.     Golomb, A.,  "Application  of  Reverse  Osmosis  to
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112.     Gomoa, H. M. and  Dempster,  J.  H. ,  "Disposal  of
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119.     Hay, Gordon J.  and Warner, John H., "Low Investment
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120.   Hayney,   Lloyd  J. ,  "A  Case History Water Pollution
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124.    Helwig,   L.   E. ,   "Chromate   Treatment  of Galvanized
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125.     Henn, H. J., Shimkets,  J.  D.  and  John,  T.  G.,
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126.   "Highly Efficient Fume Control System Checks Pickling
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134.     "Industry Profile Study on Blast Furnace and  Basic
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135.   "Inland  Steel's  Newest  Bar  Mill is Rated as a Top
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136.  "Interlake Converts Waste Pickle Liquor into  Harmless
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143.   Johnson,  W.  H.,  "Water Treatment and Reclamation",
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144.  Jones and Laughlin, "Welcome to the  Hennepin  Works",
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151.     Krueger, Glenn N., "Planning Your Caster-Its  Water
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156.  Lancy, Leslie E.,  "Metal  Finishing  Waste  Treatment
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158.   Langenberg,  F.  C.,  McCoy,  C. W., and Kern, E. L.,
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159.  Lawes, B. C., Fournier, L. B., and Mathie, O.  B.,   "A
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166.  Lowdre, L. R., "Fluoride Waste Puzzle  Solved",  Water
and Wastes Engineering, 8, pp. B6-B9 (March, 1971).

167.   Lowe,  W.,  "A Review of Effluent Treatment Systems",
Metal Finishing Journal,  15,  N.171,  pp.  103-105   (March,
1969) .

168.   McDonough, William P. and Steward, F. A., "The Use of
the  Integrated  Waste  Treatment  Approach  in  the   Large
Electroplating    Shop",   Chemical   Engineering   Progress
Symposium Series N.107. 67, pp. 428-431  (1971).

169.  McGavin, R. F., "Suppression of Liguid Effluents   from
Plants  Using  Hot Sulphuric Acid Solutions to Descale Plain
Carbon and Low-Alloy Steel Bars and Wire  Coils",  Iron  and
Industry, Special Report #128, pp. 112-119  (1970).

170.  Marnell, Paul, "Spent HCl Pickling Liguor Regeneration
in   Fluid  Bed", Chemical Engineering, 79, N.25, pp. 102-103
(November 13, 1972) .

171.  Maruszewski, J. A., Wilson, W. Jr., and  Young,  E.  F.
Jr.,  "Planning for Control of Stream Pollution at Jones and
Laughlin's Hennepin Works", Iron and Steel Engineer, 45, pp.
71-88 (May, 1968) .

172.   McGibbon,  V.  R. ,  "Industrial  Waste  Treatment by
Pressure  Filtration",   Iron  and  Steel  Engineer Yearbook,
1968, pp. 279282  (1968).

173.  Melyer, S. F. and  Taubken, T. L., "New Process Treated
Acid Rinse Waters", Water and Wastes Engineering, 8, pp. F6-
F8  (November, 1971).

174.  Mihok,  E. A., "Mine Water Research:   Plant Design  and
Cost Estimates   for Limestone Treatment",  Washington, U. S.
Department  of  Interior Bureau   of   Mines,  Report   of
Investigation 7368, pp.  1-13  (1970) .
                              792
-------
175.   Miller,  J.  H. , "Closed-Cycle Systems as a Method of
Water Pollution Control", Iron and Steel Engineer  Yearbook,
1967, pp. 285-288 (1967).

176.   "Mini-Mills,  to Build or Not to Build", 33 Magazine,
11, pp. 31-35  (January, 1973).

177.  "Mini-Plants in the U. S. - Rotlin  Steel's  Two  Join
Forty-Two  and  the Number Still Grows", 33 Magazine, 9, pp.
56-59  (March, 1971).

178.  Moore, John, "Wire Recycling:   Cash  is  Better  Than
Trash",  Wire  and  Wire  Products,  47,  N.12,  pp. 62D-62G
(December, 1972) .

179.  Morris, B.  G. and Spaty, D. D., "Pollution Control  of
Plating   Effluents",   Product  Finishing,  24,  pp.  20-23
(December, 1971) .

180.  National Industrial Pollution  Control  Council,  "The
Steel  Industry  and Environmental Quality", U.S. Department
of Commerce, pp.  1-26  (August, 1972) .

181.  Nebolsine,  Ross  and  Pouschine,  Ivan  Jr.,  "Federal
Water  Pollution  Control Bill and the Steel Industry", Iron
and Steel Engineer, 48, pp. 89-91  (December, 1972) .

182.  Nebolsine,  Ross, "Present Practice  and  New  Concepts
for  Handling  Effluents  from  Hot-Rolling Mills", Iron and
Steel Engineer, 47, pp. 85-92  (August, 1970) .

183.  Nebolsine,  Ross, "Steel Plant Wastewater Treatment and
Reuse", Iron and Steel Engineer Yearbook^ 1967, pp. 216-231.

184.  Nebolsine,  Ross and  Sanday,  Rudy,  "Ultra-High  Rate
Filtration,  A  New  Technique for Purification and Reuse of
Water", Iron and Steel Engineer Year Book,  1967,  pp.  877-
884.

185.  "Nelson Steel and Wire Improves Pickling Reduces Costs
With  Acid Recovery System", Wire and Wire Products, 45, pp.
67-69  (September, 1970).

186.  Nemeth, E.  L. and Wexler, C. H., "Phoenix Steel's  160
In.  Plate  Mill",  Iron  and  Steel Engineer, 47, pp. 33-40
(July, 1970) .

187.  "New Regeneration  Processes  Help  Wire  Mills  Fight
Pollution   from  Spent  Pickling  Liquor",  Wire  and  Wire
Products, 46, pp. 56-60  (July, 1971) .
                            793
-------
188.  "1973, Another Banner Year for  Steel",  33  Magazine.
10, pp.  42-45 (November, 1972).

189.  "1972 Steel Industry Outlook", 33 Magazine, 9, pp. 52-
56 (November, 1971).

190.    "Nonstop  Steelmaking:   Norm  for  the  70's?M,  .33
Magazine, pp. 47-50 (August, 1970).

191.  O'Bruzt, J. J.,   "Control  Pollution  without  Capital
Outlay", Iron Age, 209, pp. 48-50  (March 2, 1972) .

192.   O'Connor,  S. F., Mountjoy, B. W. Jr. and Chamberlin,
N. S., "Western Electric Builds Modern  Plant  for  Treating
Metal Finishing Wastes", 6, pp. D16-D19 (July, 1969) .

193.   Odar,  S.  P. and Pritchard, C. E., "The Conditioning
and Heating of Stainless Steel",   Iron  and  Steel  Engineer
Year Book, 1968, pp. 397-404.

194.  "Ohio Steel Tube's Waste Pickle Liquor Treatment Plant
On-Stream",  Iron and Steel Engineer, 46, pp. 128-132  (June,
1969) .

195.  Osada, Ya.  E.,  "Production of  Plastic-Lined  Steel
Tubes", Steel in the USSR, 2, pp.  731-732  (September, 1972).

196.   Ostrowski,  E. J.,  "Recycling of Tin-Free Steel Cans,
Tin Cans, and Scrap  from  Municipal  Incinerator  Residue",
Iron and Steel Engineer, 48, pp. 65-74  (July, 1971).

197.   Patterson,  J. W. and Cheng, M. H., "Steel Industry",
Water Pollution Control Federation Journal,  44,  pp.   1,093-
1,095  (June, 1972).

198.  Patterson, J. W. and Cheng,  M. H., "Steel  Industry pp.
1,184-1,188  (June, 1973).

199.   Pettit,  Grant  A.,   "Waste Pickle Treatment by Armco
Steel  Corporation  at  Butler,  Pennsylvania",  Sewage  and
Industrial Wastes, 24, N.I,  pp. 67-74  (January,  1952).

200.      "Pickle Effluent  Disposal", Chemical  and  Process
Engineering, 51, pp. 77-78 (January, 1970) .

201.    "Pickle  Liquor  Waste  Treatment  by Continuous Ion
Exchange", Federal Water Pollution Control  Administration,
Project No.  WPRD  41-01-(RI)-68, September, 1969,  31 pages.
                               794
-------
202.   Pilot,  J.,  "The  Treatment of Industrial Effluent",
Effluent and Water Treatment Journal, 10,  N.4,  supplement,
pp. 11-15 (April, 1970) .

203.   "Plating  Waste Treatment at Proctor-Silex", Products
Finishing, 35, N.4, pp. 43-49  (January, 1971) .

204.  Plumer, L., "Operation and Cost  of  an  Ion  Exchange
Circulation  Plant  for  the Treatment of Rinsing Water from
Pickling  Departments  in   Rolling   Mills",   Wire   World
International, 10, N.4, pp. 110-113  (July/August, 1968).

205.   "Pollution  Control:   Rinse Out a Profit", Iron Age,
pp. 48-49 (February 17, 1972).

206.   Pongia,  V.  J.,  "A   Specialty   Plate   Producer's
Experience   with   Continuous   Casting",   Iron  and  S teel
Engineer, October, J.972, pp. 33-50.

207.  "Profitable Pollution Control",  Automation.  16,  pp.
1718 (December, 1969) .

208.   "Quick  Facts  About  Alloy  Steels", Bethlehem Steel
Corporation,  Bethlehem,  Pennsylvania,  12th  edition,   43
pages.

209.   Randich,  E.  A.,  "Allegheny Ludlum1s High-Speed, 3-
Stand Tandem Cold Mill", Iron and Steel Engineer Year  Book,
1968, pp. 701-721.

210.   Republic,  "Republic Unveils 84 In. Hot Strip Mill At
Cleveland", Iron and Steel Engineer,  48,  pp.  83-84   (May,
1971).

211.   "Rochester Starts Up Its New Wire Drawing Mill", Wire
and Wire Products, 46, P. 72  (December, 1971).

212.  Saccomano, J. M., Choulet, R. J., and  Ellis,  J.  D.,
"Making  Stainless  Steel  in  the  Argon-Oxygen  Reactor at
Joslyn",  Proceedings   of   the   28th   Electric   Furnace
Conference, December 1968, pp. 119-124.

213.   Saros,  S.,  "Seventy-Two Inch Continuous Galvanizing
Line At Inland Steel", Blast Furnace and  Steel  Plant,  58,
pp. 648-652  (September, 1970).

214.   Schaffer,  Robert B., "Polyelectrolytes in Industrial
Waste Treatment", Industrial Water  and  Wastes,  pp.  33-39
(November/December, 1963) .
                           795
-------
215.  Schink, C. A., "Plating Wastes - A Simplified Approach
to Treatment", Plating, 55, N.12, pp. 1,302-1,305  (December,
1968) .

216.    Schreur,   N.,  "The  Lancy  Integrated  System  for
Treatment of Cyanide and Chromium Wastes  in  Electroplating
Plants",  Proceeding  of  the  Industriaj.  Waste Conference,
22nd,  Purdue University, pp. 310-316  (1967).

217.  Schuetz, James W., "Recent  Developments  in  Seamless
Tube  Mill  Technology",  .33 Magazine, 10, pp. 46-49  (March,
1972) .

218.  Shaw, Richard  B.,  "Basic  Hot  Blast  Cupola  -  EOF
Steelmaking",  Iron  and  Steel Engineer Year Book 1968, pp.
13-24.

219.  Smith, A. E., "A Study of the Variation with pH of the
Solubility  and  Stability  of  Some  Metal  Ions   at   Low
Concentrations   in  Aqueous  Solution'   (Parts  1  and  2) ",
Analyst, January and March 1973, pp. 65-68, pp. 209-212.

220.  Smith, R. D., "Burying  Your  Pickle  Liquor  Disposal
Problem", Civil Engineering, 39, pp. 37-38  (November, 1969).

221.    Smith,   R.   D.,  "Steel  Company  Builds  Flexible
Wastewater   Treatment    System",    Water    and    Wastes
Engineering/Industrial  (March, 1969).

222.   Smith, Stuart E., "Plating and Cyanide Wastes", Water
(June, 1972) .

223.  Smithson, G. R. Jr., "An Investigation  of  Techniques
for   Removal   of  Chromium  from  Electroplating  Wastes",
Battelle Memorial  Institute,  Program  112010  EIE   (March,
1971).

224.   Snowden,  F.  C.,   "Metal Finishing Wastes  Can Become
Potable Effluents", Water and Sewage Works, 116, pp.  IW9IW11
(May, 1969).

225.  "Solid and Liquid Wastes   Incinerator  Systems",  Iron
and Steel Engineer, 47, pp. 116-117  (November, 1970).

226.  "Some New Developments in  Rolling Mills", 33 Magazine,
10, pp. 41-45  (March,  1972).

227.   Spatz,  D.  D.,  "Electroplating Wastewater  Processing
with Reverse Osmosis",  Products  Finishing,  36, N.ll,  pp.  79-
83  (August, 1972).
                             796
-------
228.  Spencer, Leonard C.r "Practical Approach to Scale  Pit
Pumping",  Iron  and  Steel  Engineer,  50,  pp. 68-74  (May,
1973) .

229.  "Steelmen and Scientists Join Forces in the  Pollution
Control  Effort",  33  Magazine,  10,  pp.  33-35 (February,
1972).

230.  Stoner, L. B., "Waste Treatment Facilities  for  Jones
and  Laughlin Steel Corporation Hennepin Works", Proceedings
of the 26th Industrial Waste Conference, Purdue  University,
(1971).

231.   Stove,  Ralph  and  Schmidt,  Carter,  "A  Survey  of
Industrial Waste Treatment Costs and  Charges",  Proceedings
of  the 23rd Industrial Waste Conference, Purdue University,
pp. 49-63  (1968) .

232.   "Subsurface  Disposal   of   Pickle   Liquor",   U.S.
Department of the Interior.

233.   Symons,  C. R., "Treatment of cold Mill Wastewater by
Ultra-High-Rate   Filtration",   Water   Pollution   Control
Federation, Journal, 43, pp. 2,280-2,286  (November, 1971).

234.   Talbott,  John  A.,  "Building A Pollution Free Steel
Plant", Mechanical  Engineering,  93,  pp.  25-30   (January,
1971) .

235.   "Technology  the  Key  to  Pollution  Control", Metal
Progress, 98, N. 6, pp. 54-57  (December, 1970).

236.  Temmel, F. M., "Treatment of  Acid  and  Metal-Bearing
Wastewaters   by   the  High-Density  Sludge  Process",  San
Francisco Regional  Technical  Meeting,  American  Iron  and
Steel Institute, pp. 343-357  (November 18, 1971) .

237.    "The  Steel  Industry  and  Environmental  Quality",
National Industrial Pollution Control Council, August   1972,
26 pages.

238.   Thompson, J. and Miller, V. J., "Role of Ion Exchange
in Treatment of Metal Finishing Wastes",  Plating,  58,  pp.
809812 (August, 1971).

239.   Thompson, Ronald J., "Water Pollution Control Program
at Armco's Middletown Works", Iron and Steel  Engineer,  49,
pp. 43-48  (August, 1972) .
                           797
-------
240.   Tihansky, D. P., "A Cost Analysis of Waste Management
Association, 22, N.5, pp. 335-341  (May, 1972).

241.   Tihansky,  Dennis  P.,  "A  Cost  Analysis  of  Waste
Management   in  the  Steel  Industry",  National  Technical
Information Service, No. AD-742-381, January 1972, 18 pages.

242.  "Today's Pollution Control Practices in  the  American
Steel  Industry",  33 Magazine, 10, N.I, pp. 33-36 (January,
1972) .

243.  Toureene,  Kendall  W.,  "Wastewater  Neutralization",
Iron   and   Steel  Institute,  Chicago  Regional  Technical
Meeting, pp. 99-117  (October 15, 1970).

244.  "The Making, Shaping, and Treating of  Steel",  United
States  Steel  Corporation,  Pittsburgh,  Pennsylvania,  9th
Edition, 1971, 1,420 pages.

245.  "Treatment of Wastewater-Waste Oil Mixtures",  Federal
Water  Pollution  Control  Administration,  Water  Pollution
Control Research Series, Program 12010 EZU, May,  1970,  137
pages.

246.   "Universal-Cyclops  Installs  New  Blooming  Mill  at
Bridgeville Plant",  Iron and Steel  Engineer,  August  1973,
page 78.

247.  "Up-Flow Filters  Help Chicago Area Mine Mill Clean Its
Cooling  Water",  33  Magazine,  10,  N. 6,   pp.  50-51  (June,
1972).

248.  U. S. Department  of Commerce, Bureau  of   the  Census,
Census of Manufacturers, 1967, Washington, D. C.

249.   U.  S.  Steel's   Fairless   Works,  "Modifications  to
Fairless Pickle Line Improves  Strip Quality", Iron and Steel
Engineer, 48, p. 87  (November, 1971) .

250.  "U. S. Steel's 'Texas Works'  Euilt  With   Ecology  in
Mind", Water and Sewage Works, 118, p.  241  (August,  1971).

251.   Vorga, J. and Lownie, H. W., "A  System Analysis Study
of   the  Integrated  Iron  and Steel   Industry",   Battelle
Memorial Institute  (May 15, 1969).

252.   Vasil'ev,  V.   I.,  et  al,  "Selection   of  Types of
Equipment  for  the  Clarification of  Neutralized   Iron
Containing  Acidic   Wastewaters",  Chemical Abstracts,  77, 4,
pp.  349  (1972) .
                           798
-------
253.  Vivian, Gordon, "Disposal  of  Cyanide  Heat   Treating
Wastes", Metal Progress, 98, N.6, p. 61  (December,  1970).

254.   Wagstaff,  R.  S.,  Stock,  G.  E., and Layne,  G. N.,
"Continuous Casting  of  Stainless  Slabs  at  Atlas  Steels
Quebec  Plant", Iron and Steel Engineer  Year Book,  1966, pp.
479-484.

255.  Walton, G. L., "Effluent Treatment in  Steel Works",
Metal Finishing Journal, 18, pp. 276-279 (September, 1972) .

256.  "Water Pollutant or Reusable Resource?", Environmental
Science and Technology, 4, N.5, pp. 380-382  (May, 1970).

257.   Water and Sewage Works, 113, "Bethlehem Steel's Burns
Harbor Wastewater Treatment Plant", pp.  468-470   (December,
1966) .

258.    "Water   Use   in  Manufacturing",   1967  Census   of
Manufactures, U. S. Department of Commerce,  Bureau of the
Census, MP67 (l)-7, April, 1971, 361 pages.

259.   "Watkins  Cyclopedia  of  the   Steel  Industry",  Steel
Publications, Inc., Pittsburgh, Pennsylvania, 13th   Edition,
1971, 533 pages.

260.   Weinberg,  H.  I.,  "Inland Steel «s New 80 In.  Pickle
Line", Iron and Steel  Engineer,  49,  pp.   70-76   (January,
1972).

261.   Welded  Steel  Tube Institute,  Member Companies, p.  2
(1967) .

262.  Weymier, R. C., "Operation  of   Wastewater  System  at
Inland's  80  In.  Hot  Strip Mill", Iron and Steel Engineer
Yearbook, 1968, pp. 183-191  (1968) .

263.  "When it  Comes  to  Pollution   Control,  Steel   Isn't
Dawdling   -  It's  Acting",  33  Magazine,  10,  pp.   23-29
(January, 1972).

264.   Whither  Goest  Thou,  U.  S.   Steel  Industry?",   .33
Magazine, 9, pp. 36-55  (April, 1971) .

265.   "Whither  Goest  Thou,  U.  S.  Steel  Industry?",  _33_
Magazine, 9, pp. 50-55  (May, 1971) .

266.  "Whither  Goest  Thou,  U.  S.   Steel  Industry?",   33
Magazine, 9, pp. 38-43  (June, 1971) .
                             799
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267.  "Who's on First In Wide Hot Strip Mills", 33 Magazine,
8, pp. 88-101 (March, 1970).

268.   Wiedemann,  Chester  R.,  "Control  Considerations in
Washing, Painting, and Soluble Oil Removal", Metal Progress,
98, N. 6, pp. 66-67 (December, 1970).

269.  Wiedmann, H., "Regeneration of  Pickling  Hydrochloric
Acid  by  Liquid Anion Exchange", Chemical Abstracts, 76, p.
306 (1972) .

270.  Wight, R. D., "A Unique Water System for an Integrated
Steel Plant", AIChE workshop. Industrial Process Design  for
Water Pollution Control, Vol. 3, April 1970, 116 pages.

271.   Wight,  Robert  D.,  "Water  System for an Integrated
Steel Plant", American Water Works Association Journal,  61,
pp. 432-435  (1969) .

272.   Wilcox, Michael S. and Lewis, Roy T., "A New Approach
to Pollution Control in an Electric Furnace Melt Shop", Iron
and Steel Engineer Year Book, 1968, pp. 839-846.

273.   Wilthew,  Robert  M.   and   Davidson,   Robert   M.,
"Youngstown1s  84  In.  Hot  Strip  Mill",  Iron  and  Steel
Engineer, 49, pp. 5363  (May, 1972).

274.  Wittman, I. E. and Shephard, G. S., "Integrated  Steel
Pickling  Rinse  Water  Treatment  System",  Iron  and Steel
Engineer, 49, pp. 69-71  (February, 1972).

275.  "World's First Continuous Cold Mill Ready to Roll", 3_3
Magazine, 9, pp. 30-33  (April, 1971) .

276.  Wykoff, Richard H., "Major Filtration  Development  at
New  Steel   Mill", Water and Sewage Works, 117, pp. IW8-IW10
(July/August, 1970).

277.   Yunghahn,  R.  J.,   "Profitable  Pollution  Control",
Modern Metals, 26, p. 62  (July, 1970) .

278.   Zievers,  J. F.  and Novotry, "Recovery  of Mixed Rinse
Water by Means of Ion Exchange", Plating, 58,  N. 5, pp.   482-
485  (May, 1971).

279.   Zievers,  J.  F.,  "Pressure  Filtration of Clarifier
Under-Flow", Chemical Engineering  Progress,  67,  N.12,  pp.
47-48  (December,  1971) .
                             800
-------
280.   Zievers,  J.  F.,  Grain,  R. W., and Barclay,  F.  G. ,
"Metal Finishing Wastes:  Methods of Disposal",  Plating,  57,
pp. 56-59  (January, 1970) .

281.  Zievers, J. F., Grain, R.  W.,  and  Barclay,   F.   G.,
"Waste  Treatment  in  Metal  Finishing:  U. S.  and  European
Practices", Plating, 55, pp. 1,171-1,179  (November,  1968).
                              801
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                        SECTION XIV

                          GLOSSARY


Acid Furnace.  A furnace lined with acid brick as contrasted
to one lined with basic brick.  In this instance  the  terms
acid  and  basic  are  in  the same relationship as the acid
anhydride and basic anhydride  that  are  found  in  aqueous
chemistry.   The  irost  common acid brick is silica brick or
chrome brick.

Air Cooled Slag.  Slag which is cooled slowly in large  pits
in  the  ground.   Light  water sprays are generally used to
accelerate the cooling over that which would  occur  in  air
alone.   The  finished  slag  is generally gray in color and
looks like a sponge.

Alloying  Materials.   Additives  to  steelmaking  processes
producing alloy steel.

Annealing.    A   process  for  producing  certain  physical
properties in steel.  The process consists  of  raising  the
temperature of the steel to a pre-established level and then
slowly cooling the steel at a prescribed rate.

Alkaline   Chlorination.    The   oxidation  of  undesirable
substances with chlorine under alkaline conditions.

Alkaline Cleaning.   A  process  for  cleaning  steel  where
mineral  and  animal  fats and oils must be removed from the
surface.  Solutions at high temperatures containing  caustic
soda,  soda ash, alkaline silicates, and alkaline phosphates
are commonly used.

Apron Rolls.  Rolls used in the casting strand  for  keeping
cast products aligned.

Bar.   A  long,  thin, relatively stiff steel shape.  Bar is
produced by rolling from billets.  It can be round,  square,
hexagonal, or rectangular in shape.  It is generally handled
straight  in  cut  lengths  of  20  or  more  feet  long  as
contrasted by rod (which may be larger in diameter than some
bars) which is coiled in lengths of several hundred feet.

Basic Brick.  A brick made of a material which  is  a  basic
anhydride  such  as  MgO  or  mixed  MgO plus CaO.  See acid
furnace.
                               803
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Basic Furnace.  A furnace in which the  refractory  material
is composed of dolomite or magnesite.

Basic  Oxygen  Steelmaking.   The  basic  oxygen  process is
carried out in a basic lined furnace which is shaped like  a
pear.   High pressure oxygen is blown vertically downward on
the surface of the molten iron through a water cooled lance.

Billets.  A bar shaped intermediate steel product  which  is
rolled from a bloom.  While billets are usually smaller than
blooms,  all  billets  are  not necessarily smaller than all
blooms.  Blooms are rolled from ingots,  while  billets  are
rolled from blooms.

Bjllet  Mill.   The  area  and  mechanical equipment for hot
rolling blooms to billets.

Black Plate.  A steel generally used in the  manufacture  of
containers.   It  is  similar to tin-plate except that it is
not coated with tin or any other metal.

Blast Furnace.  A large, tall conical shaped furnace used to
reduce iron ore to iron.

Bloom.  A semi-finished piece of steel, which has  a  cross-
sectional  area  that  is  square or slightly oblong and not
less than 36 sq. in., that has been rolled or forged from an
ingot.

Blooming Mill.  The area and mechanical  equipment  for  hot
rolling steel ingots to blooms.

Slowdown.    A   relatively   small   bleed-off   discharge,
continuous or periodic, from a recirculated closed system.

Briquette.  An agglomeration of steel plant  waste  material
of   sufficient  strength  to be a satisfactory blast furnace
charge.


Carbon  Steel.  Steel which owes its  properties  chiefly  to
various percentages of carbon without substantial amounts of
other   alloying  elements.   Steel  is  classified as carbon
steel when no minimum content of elements other than  carbon
is   specified  or   required  to  obtain  a  desired alloying
effect.

Charge.  The  minimum combination of  skip or bucket loads  of
material  which  together  provide   the  balanced complement
necessary to  produce hot metal of the desired specification.
                               804
-------
Checker.  A regenerator  brick  chamber  which  is  used  to
absorb heat and cool the waste gases to 650-750°C.

Cinder.  Another name for slag.

Clarification.    The   process   of   removing  undissolved
materials from a liquid by settling or filtration.

Closed Hood.  A system in which the hot gases from the basic
oxygen furnace are not allowed to  burn  in  the  hood  with
outside  air  infiltration.   These  hoods  cap  the furnace
mouth.

Coagulant.  A substance that  enhances  the  aggregation  of
undissolved suspended matter.

Coke.   The  carbon residue left when the volatile matter is
driven off of coal by high temperature distillation.

Cold Metal Furnace.  A furnace that is usually charged  with
two batches of solid material.

Cold  Rolling.  Cold rolling is a form of cold working which
is the general term for reducing the size (or thickness)  of
an  ambient temperature piece of steel.  Cold working causes
significant changes in the physical properties of steel.

Cooling Bed.  The area in a process line where product speed
and temperature are controlled to provide a required cooling
rate.

Continuous Casting.  A new process  for  solidifying  liquid
steel  in  place  of  pouring  it into ingot molds.  In this
process the solidified steel is in the form of cast  blooms,
billets,  or  slabs.   This  eliminates the need for soaking
pits and primary rolling.

Descaling.  The removal, through the use  of  high  pressure
water  sprays,  of  the iron oxide scale formed on the steel
product during hot forming processes.

Double Slagging.  Process in which the first oxidizing  slag
is removed and replaced with a white, lime finishing slag.

Drags.   Flat  bed  railroad  cars.   A  drag will generally
consist of five or six coupled cars.

Duplexing.  An operation in which a lower grade of steel  is
produced  in  the basic oxygen furnace or open hearth and is
then alloyed in the electric furnace.
                              805
-------
Electric Furnace.  A furnace  in  which  scrap  iron,   scrap
steel,  and  other  solid  ferrous  materials are melted and
converted to finished steel.  Liquid iron is rarely used  in
an electric furnace.

Electrolytic  Pickling.   Removal  of surface scale and rust
from steel by an induced current in an acidic bath.

Electrostatic Precipitator.  A gas cleaning device using the
principle  of  placing  an  electrical  charge  on  a  solid
particle  which  is  then attracted to an oppositely charged
collector plate.  The collector  plates  are  intermittently
rapped to discharge the collected dust to a hopper below.

Evaporation Chamber.  A method used for cooling gases to the
precipitators  in  which an exact heat balance is maintained
between water required  and  gas  cooling;  no  effluent  is
discharged in this case as all of the water is evaporated.

Fettling.  The period of time between tap and start.

Finishing  Mill  Stand.   The  mill  stand in a process line
where the product is rolled into its final shape.

Flocculation.   The  aggregation  of  undissolved  suspended
matter into larger conglomerates.

Flux.  Material added to a fusion process for the purpose of
removing impurities from the hot metal.

Flying  Shear.   A  shear  that moves with the product while
operating.

Fourth Hoie.  A fourth refractory lined hole in the roof  of
the electric furnace which serves as an exhaust port.
Fugitive  Emissidns.   Emissions  that  are  expelled to the
atmosphere in an uncontrolled manner.

Fume.   A  collection  of  micron  or  submicron  size  dust
particles.

Horizontal  Stand.   A mill stand having the work rolls in a
horizontal position which is parallel to the mill table.

Hot  Forming.  The processes by which hot  steel  ingots  are
converted  by rolling under pressure of steel rolls to slabs
and  blooms.  The  processes  by  which  slabs,  blooms,  and
castings  are   further   shaped   through rolling, forging, or
                                806
-------
extruding into various finished  or  semi-finished  products
such  as  plates,  strips,  pipes,  bars, structural shapes,
billets, and special shapes.

Hot Metal.  Melted, liquid iron or steel.  Generally  refers
to the liquid metal discharge from blast furnaces.

Hot Metal Furnace.  A furnace that is initially charged with
solid  materials  followed  by  a  second  charge  of melted
liquid.

Hot Rolling.  A form of hot working of steel where the steel
is heated to about 1,800°F  and  passed  through  a  rolling
mill.

Hot  Saw.   A  circular  saw  used for cutting semi-finished
steel pieces at elevated temperatures.

Hot Scarfing Machine.  A machine which utilizes oxyacetylene
burner nozzles for removing surface defects from  blooms  or
billets by desurfacing.

Ingot.   A  large  block  shaped  steel casting.  Ingots are
intermediates from which other steel products are made.   An
ingot  is usually the first solid form the steel takes after
it is made in a furnace.

Ingot Mold.  A mold in which ingots are cast.  Molds may  be
circular,  square,  or  rectangular  in shape, with walls of
various thickness.  Some molds are of larger  cross  section
at the bottom, others are larger at the top.

Inhibitor.   Any  substance added to a solution that lessens
acid  attack  on  the   steel   itself,   while   permitting
preferential attack on the iron oxides.

Iron.   The product made by the reduction of iron ore.  Iron
in the steel mill sense is impure  and  contains  up  to  4%
dissolved carbon along with other impurities.  See Steel.

Iron  Ore.  The raw material from which iron is made.  It is
primarily iron oxide with impurities such as silica.

Iron Oxide.  Compounds containing metallic iron  and  oxygen
in various proportions including ferrous oxide  (FeO), ferric
oxide  (Fe2Q3) and magnetite (Fe2[O4).

Kish.  A graphite formed on hot metal following tapping.
                              807
-------
Lime  Boil.  The turbulence created by the release of carbon
dioxide in the calcination of the limestone.

Manipulator.  A steel fingered device that seizes the  bloom
and turns it so that all four sides will be kneaded evenly.

Meltdown.  The melting of the scrap and other solid metallic
elements of the charge.

Mill Scale.  The iron oxide scale which breaks off of heated
steel  as  it passes through a rolling mill.   The outside of
the piece of steel is generally completely coated with scale
as a result of being heated in an oxidizing atmosphere.

Mill Stand.  The portion of the mill eguipment  that  houses
the work rolls.

Mill Table.  The portion of the mill equipment composed of a
framework and small rollers used to convey product to, fromr
or between work areas of a mill.

Molten Metal Period.  The period of time during the electric
furnace  steelmaking  cycle when fluxes are added to furnace
molten bath for forming the slag.

Normalizing.  Heating of the sheet  to  its  upper  critical
temperature  and  then  cooling  at a rate which permits the
proper ferrite grain size.

Oil Quenching.   A  method  of  cooling  which  changes  the
chemical properties and structure of steel.

Open  Hearth  Furnace.  A furnace used for making steel.  It
has a large flat saucer shaped hearth  to  hold  the  melted
steel.   Flames  play  over  top  of  the  steel and melt is
primarily by radiation.

Open Plate Panel Hood.  A  4.5  meter  to  6  meter  square,
rectangular or circular cross sectional shaped conduit, open
at  both  ends, which is used in the EOF steelmaking process
for the combustion and conveyance of hot gases, fume,  etc.,
which are generated in the basic oxygen furnace to the waste
gas collection system.

Ore   Boil.   The  generation  of  carbon  monoxide  by  the
oxidation of carbon.

Oxidizing Slags.  Fluxing agents that  are  used  to  remove
certain  oxides  such  as  silicon dioxide, manganese oxide,
phosphorus pentoxide and iron oxide from the hot metal.
                               808
-------
Pass.  The movement of product once through a mill.

Pelletizing.  The processing of dust from the steel furnaces
into a pellet of uniform size and weight for recycle.

Pickling.  A process where scale is removed from the surface
of steel by the action of strong mineral  acids.   Steel  is
usually  pickled  between  the  hot working and cold working
phases of the operation.

Piercing.  The operation of making the hole down  through  a
length of seamless pipe.

Pig	Iron.   Impure  iron cast into the form of small blocks
that weigh about 30 kilograms each.  The blocks  are  called
pits.

Pinch  Rolls.  Rolls used to regulate the speed of discharge
of cast product from the molds.

Plate.  A product rolled from a slab.  Plate is more  nearly
square than a slab which is generally much longer than it is
wide.   Plate  is  generally  made  by  rolling  slabs  both
crosswise and lengthwise to obtain greater width.

Polyelectrolvte.  A substance that enhances the flocculation
mechanism.

Pouring.  The transfer of molten metal from the  ladle  into
ingot  molds  or  other  types  of  molds;  for  example, in
castings.

Quenching.  A process of  rapid  cooling  from  an  elevated
temperature by contact with liguids, gases, or solids.

Reducing  Slag.   Used in the electric furnace following the
slagging off of an oxidizing slag to minimize  the  loss  of
alloys by oxidation.

Refining  Oxidation  cycle for transforming hot metal (iron)
and other metallics into steel by removing elements  present
such as silicon, phosphorus, manganese and carbon.

Reversing  Mill.  A type of rolling mill that passes product
back and forth through the rolls or initiates  rolling  from
either side of the rolls.

Rinse Water.  Water that is used for removing a concentrated
solution from a material prior to further processing.
                              809
-------
Rod.   A  long,  slender, generally round steel intermediate
product produced by hot rolling.  It is generally handled in
coils of a hundred feet or more in length.

Rolling Mill.  The machinery and equipment that is  used  to
change  the shape and chemical structure of steel by passing
the steel between rollers under pressure.

Roughing Mill Stand.  The first mill stand in a process line
where the product receives its first reduction.

Runner.  A channel through which molten  metal  or  slag  is
passed  from  one  receptacle to another; in a casting mold,
the portion of the gate assembly that connects the  downgate
or sprue with the casting.
RunQut.   Escape  of  molten  metal  from a furnace, mold or
melting crucible.

Scale.  The by-product of hot  rolling  operations  composed
primarily of various iron oxides.

Scarfing.   The  operation  of removing surface defects from
blooms, billets, or slabs (primary rolled  products)  before
reheating for secondary reduction.  This is done with a high
temperature torch similar to an oxyacetylene cutting torch.

Sheet.   A  product  made  by  cutting  strip  into  shorter
lengths.  Sheet is handled as a pile of flat pieces.

Skelp.  A narrow strip of hot rolled steel generally used in
the manufacture of pipe.

Skin Rolling.  A  cold  rolling  operation  that  effects  a
relatively  light  reduction  in  thickness  of  the  rolled
material.

Slab.  A thick, heavy, slab shaped  piece  of  steel  rolled
from   an ingot.  It is the primary intermediate product from
which  strip, sheet, plate, etc., are made.  Slabs   bear  the
same   relationship  to  the  above  products as blooms do to
billets.  A typical slab is 8 in. thick by 48 in. wide by 20
ft long.

Slag.  The mixture of the oxides formed during the  oxidation
of  various  compounds  in  the  steelmaking  and   finishing
processes.  A product resulting from the action of  a flux on
the  nonmetallic  constituents of a processed ore,  or on the
oxidized  metallic  constituents   that   are   undesirable.
Usually  slags  consist  of combinations of acid oxides with
                             810
-------
basic  oxides,  and  neutral  oxides  are   added   to   aid
fusibility.

Soaking  Pj.t.   A  form of reheat furnace.  Soaking pits are
used to heat and equalize the temperature of ingots prior to
putting them into a rolling mill.

Spent  Pickle  Liquor.   The  pickling  solution  that   has
progressively  become  saturated  with ferrous salts and the
bath has become ineffective in removing scale.

Steel.  Refined iron.  Typical blast furnace  iron  has  the
following  composition:   Carbon - 3 to 4.5%; Silicon - 1 to
3%; Sulfur -  0.04  to  0.2%;  Phosphorus  -  0.1  to  1.0%;
Manganese - 0.2 to 2.0%.  The refining process (steelmaking)
reduces the concentration of these elements in the metal.  A
common  carbon  steel  1020  has  the following composition:
Carbon - 0.18 to 0.23%; Manganese - 0.3 to 0.6%;   Phosphorus
-  less  than  0.04%;  Sulfur  -  less than 0.05%.  Type 316
stainless steel has the following carbon  composition  .08%;
Manganese 2% max; Phosphorus less than .045%; Chromium 16 to
18% and Nickel 10 to 14% and Molybdenum 2 to 3%.

Steel  Ladle.   A  vessel  for receiving and handling liquid
steel.   It  is  made  with  a  steel  shell,   lined   with
refractories.

Stools.   Flat  cast  iron plates upon which the ingot molds
are seated.

Strand.  A term applied to  each  mold  and  its  associated
mechanical equipment.

Steel.   Any  alloy  of iron containing less than 1% carbon.
Iron that has been refined.

Strip.  A long, thin, flat, wide piece of steel produced  by
hot rolling of a slab.  Strip is handled in coil form.

Sump.   Storage  area,  normally located below ground level,
used for collecting liquids or solids.

Support Rolls.  Rolls used in the casting strand for keeping
cast products aligned.

Tandem Mill.  A rolling mill with more than one stand  where
the  steel  passes  through the stands in sequence with each
stand taking a reduction over that  taken  by  the  previous
stand.
                               811
-------
Tap  Hole.  A hole approximately fifteen (15)  centimeters in
diameter located in the hearth brickwork of the furnace that
permits flow of the molten steel to the ladle.

Tapping.  Transfer of hot metal from a furnace  to  a  steel
ladle.

Tap  to  Tap  Period  of time after a heat is poured and the
other necessary cycles are performed to produce another heat
for pouring.

Teeming.  Casting of steel into ingots.

Temper Mi11.  A cold rolling mill that takes  a  very  small
reduction on the cold steel to alter its physical properties
by cold working.

Terne Metal.  An alloy of lead and tin.

Tundish.    A   preheated  covered  steel  refractory  lined
rectangular container with several  nozzles  in  the  bottom
which  is  used  to  regulate the flow of hot steel from the
teeming ladles.

Universal Mill.  A reversing mill, which  has  vertical  and
horizontal rolls, used for hot rolling steel.

Vacuum  Degassing.  A  process  for removing dissolved gases
from liquid steel by subjecting it to a vacuum.

Venturi Scrubber. A wet type collector that uses the  throat
for  intermixing  of  the  dust  and  water  particles.  The
intermixing  is  accomplished  by  rapid   contraction   and
expansion of the air stream and a high degree of turbulence.

Vertical  Stand.   A  mill  stand having the work rolls in a
vertical position which is perpendicular to the mill tables.

Walking Beam Furnace.  A furnace that conveys the product in
a step type motion.

Waste Heat Boiler. Boiler  system  which  utilizes  the  hot
gases from the checkers as a source of heat.

Water   Tube   Hood.  Consists  of  steel  tubes,  four   (4)
centimeters to five  (5) centimeters laid  parallel  to  each
other   and   joined   together   by  means  of  steel  ribs
continuously welded.  This type hood is used  in  the  basic
oxygen steelmaking process for the combustion and conveyance
of hot gases to the waste gas collection system.
                               812
-------
Wet Scrubbers.  Venturi or orifice plate units used to bring
waterintointimate contact with dirty gas for the purpose
of its removal from the gas stream.

Wetting  Agent.   An  organic  compound  which  lowers   the
interfacial tension between the steel and the liquid.
                                 873
-------
                                             TABLE  198
                                           METRIC UNITS
                                         CONVERSION TABLE
MULTIPLY  (ENGLISH UNITS)
  ENGLISH UNIT
  acre
  acre-feet
  British Thermal Unit
  British Thermal Unit/
       cubic foot
  British Thermal Unit/pound
  cubic feet/minute
  cubic feet/second
  cubic feet
  cubic feet
  cubic inches
  degree Fahrenheit
  feet
  gallon
  galIon/mi nute
  gallon/ton
  horsepower
  inches
  inches of mercury
  million gallons/day
  mile
  pounds
  pound/square inch(gauge)
  pounds/ton
  square feet
  square inches
  tons(short)
  yard
TO OBTAIN  (METRIC UNITS)
ABBREVIATION
ac
ac ft
BTU
BTU/cu
id BTU/lb
cfm
cfs
cu ft
cu ft
cu in
«F
ft
gal
gpm
gal/t
hp
in
in Hg
mgd
mi
Ib
psig
Ib/t
sq ft
sq in
t
y
CONVERSION ABBREVIATION
0.405
1233.5
0.252
9.00
0.555
0.028
1.7
0.028
28.32
16.39
0.555(°F-32)*
0.3048
3.785
0.0631
4.17
0.7457
2.54
0.03342
3,785
1.609
0.454
(0.06085 psig+1)*
0.501
0.0929
6.452
0.907
0.9144
ha
cu m
kg cal
kg cal/
cu in
kg cal/kg
cu m/min
cu m/min
cu m
1
cu cm
°C
m
1
I/sec
1/kkg
kw
cm
atm
cu m/day
km
kg
atm
kg/kkg
sq m
sq cm
kkg
m
METRIC UNIT
hectares
cubic meters
kilogram - calories
kilogram calorie/
cubic meter
kilogram calories/kilogram
cubic meters/minute
cubic meters/minute
cubic meters
liters
cubic centimeters
degree Centigrade
meters
liters
liters/second
liter/metric ton
kilowatts
centimeters
atmospheres
cubic meters/day
kilometer
kilograms
atmospheres (absolute)
kilograms/metric ton
square meters
square centimeters
metric tons (1000 kilograms)
meters
  •Actual conversion,  not a multiplier
                                                815
-------
                                TABLE 199
                       CLASSIFICATION BY SUBCATEGORY
Product or Operation
         Description
Applicable or Most
Appropriate Subcategory
Abrasive Cleaning
Alkaline Cleaning
Aluminizing
Armor Plate
Axles
Billets
Billet Casting
Black Plate
Bloom Casting
Channels

Electric Resistance
Weld Pipe
Removal of oxides via treat-
ment with abrasives
Degreasing of steel
in an alkaline bath
Hot Dip
Steels of special metallurgi-
cal composition for use as
armor

Rolled, forged, and/or rough-
turned, usually in one heating

Intermediate shape between
blooms and a wide variety of
other finished and semi-
finished products

Continuous conversion of
molten steel directly into
billets

Uncoated, cold rolled coils
or sheets, usually temper
rolled also

Continuous conversion of
molten steel directly into
blooms

See Structural Shapes

See Pipe and Tube
Subcategory Discussion
No regulation required,
single operation gener-
ates no wastewaters

Prior to a hot coating,
see Hot Coating.  For
specialty steel, see
Continuous Alkaline Cleaning

No present regulation
may be similar to
Galvanizing

Hot Forming-Flat-Plate
Hot Forming-Section
Hot Forming-Section
Continuous Casting
Cold Rolling-Direct
Application; Combina-
tion; or Recirculation

Continuous Casting
Pipe and Tube  (Cold
Worked)
                                          816
-------
             ,te»
ate



*
.?0<
&
-•
tsv^
t?
t:^
^66
!
1
«&
n
,t
00S



-------
                                       a   °U*,
                                       a COD,.'
                                                                           ?-s,
>eet
                                               ns
  91

                           A
                                        §Ur
-------
Direct Reduction



Fence Posts

Forgings


Frogs


Hot Coating Cleaning
Operations

Galvanizing-Post
Coating Operating

Gun Forgings

Hoops
Iron from Direct
Reduction Units
I-Beaas

Molten Lead Annealing
Nails & Staples




Nut Rods


Pilings

Pipe & Tube Pickling

Rails & Rail Joints
Iron making via an alternate
technique which replaces
blast furnace operations

See Structural Shapes

Hot working of metal by
hammering or pressing

Crossover sections allowing
rails to intersect each other

Alkaline cleaning and
acid pickling

Hot rinse or chemical treat-
ment (dichromate dip)

See Forgings

Narrow flat rolled product
joined to form a continuous
loop

Iron making via an alternate
technique which differs from
conventional blast furnaces

See Structural Shapes

Hot dip, rinse and clean
(acid pickle)
Fasteners made from wire or
small rods, sometimes coated
before shipment
Hot rolled shapes from which
nuts and bolts are formed

See Sheet Pilings

Acid Pickling

Hot rolled shapes used for
laying tracks of various
types
No present regulation
Not covered by this
regulation

Hot Forming-Section
Hot Coating (Galvanizing
or Terne)

Hot Coating
Hot Forming-Flat-Hot
Strip & Sheet
No present regulation
No present regulation.
Flows may be similar to
Pickling and constituents
may be similar to Pickling
and Terne

Forming is a dry opera-
tion; for Coating - See
Hot Coating subcategories
or electroplating

Hot Forming-Section
Acid Pickling

Hot Forming-Section
                                         817
-------
Pickling for Cold
Rolling

Rings
Rounds
Sheet Pilings
Slab Casting
Spiegeleisen
Spikes & Chains
Submerged Arc
(Pipe) Weld Mill

Structural Shapes
Tie Plates
Well Casings &
Couplings
Wheels, Forged

Wheels, Forged and
Rolled
Acid Pickling
Hot rolled product cut
from an ingot or round,
center punched out, and
rolled into a continuous
ring

Billets of circular cross-
section, used in forming
seamless pipe and tube,
some axles and bars, and
some forged products

A special structural shape
hot rolled from blooms into
a variety of configurations

Continuous or batch conversion
of molten steel directly into
slabs

A ferroalloy containing
16-28% Mn, and less than
6.5% carbon

Hot formed shapes made from
rods or small bars in a
variety of sizes

24" to 36", cold formed
Standard hot rolled sections,
such as I-beams, channels,
angles, beams, tees, and zees

Hot rolled shapes used for
connecting other sections

Special strength pipe and tube
products for oil, gas and
water wells

See Forgings

Forged wheel blanks further
processed by hot rolling to
produce a flange and tread
Acid Pickling
Hot Forming-Section
Hot Forming-Section
Hot Forming-Section
Continuous Casting and
Pressure Slab Molding
Blast Furnace-Ferro-
Manganese


Hot Forming-Section
Pipe & Tube  (Cold
worked)

Hot Forming-Section
Hot Forming-Section
Pipe & Tube
Hot  Forming-Section
                                         818
-------
Wire & Wire            Products made by drawing rods      Drawing is a dry opera-
Products               through a series of dies to        tion;  for other wire-
                       greatly reduce diameters.          making processes, see
                       Product may be pickled and/or      Pickling, Hot Coating
                       coated prior to shipment           or electroplating wire
                                                          pickling and coating
                                                          Subcategories

Wire Pickling          Acid pickling                      Acid Pickling or Wire
                                                          Pickling and Coating
                                                          for specialty steel
                                        819
-------