United States
                   Environmental Protection
                   Agency
Industrial Environmental Research
Laboratory
Research Triangle Park NC 27711
                   Research and Development
EPA-600/S9-82-021 May 1983
£EPA         Project  Summary
                   Proceedings:  Symposium  on
                   Iron  and  Steel   Pollution  Abate
                   ment Technology for  1981
                   Franklin A Ayer
                     Summaries  or  abstracts  of  the
                    speakers' presentations contained in
                    the proceedings of the third EPA-spon-
                    sored Symposium on Iron and Steel
                    Pollution Abatement Technology held
                    on October 6-8, 1981, in Chicago, IU
                    are contained in this report The sym-
                    posium provided a  forum for the ex-
                    change of information on technology
                    problems related to air,  water,  and
                    solid waste pollution abatement in the
                    iron and steel industry.  This symposi-
                    um brought together international rep-
                    resentatives  from  industry,  associ-
                    ations, academic institutions, research
                    organizations. Federal, state, and local
                    government agencies, equipment man-
                    ufacturers and suppliers, scientists,
                    engineers, and consultants.  The pro-
                    gram included sessions on Air Pollution
                    Abatement (inhalable particulates, fu-
                    gitive emission control,  coke plant
                    emission control, innovative air pollu-
                    tion technology, and iron- and steel-
                    making emission control); Solid Waste
                    Pollution Abatement; and WaterPollu-
                    tion Abatement (recycle/reuse of water,
                    coke plant wastewater treatment, and
                    new developments in wastewater treat-
                    ment). The symposium was attended
                    by 226 participants.
                     This Project Summary was developed
                    by EPA's Industrial Environmental Re-
                    search Laboratory, Research Triangle
                    Park. NC, to announce presentations
                    at a symposium that is  fully docu-
                    mented in a separate proceedings of
                    the same title (see  ordering informa-
                    tion at back).
                     Summaries or abstracts of speakers'
                    remarks follow:
 Opening Session

 Richard D. Stern, Chairman
 Industrial Environmental Research
 Laboratory U.S. EPA, Research
 Triangle  Park, NC 27711

  Stern called  the symposium to order,
 welcomed the participants, and introduced
 John S. Ruppersberger, General Chairman,
 U.S. EPA, IERL-RTP.

 Symposium Objectives and An-
 nouncements

 John S.  Ruppersberger,
 Symposium  General Chairman
 Industrial Environmental Research
 Laboratory  U.S. EPA,  Research
 Triangle  Park, NC 27711

  Ruppersberger informed the participants
 that the objective of the third symposium
 was to provide a forum for the exchange of
 information on  iron and steel multi-media
 pollution abatement technology.  In addi-
 tion, he emphasized that the symposium
 continues as a high-priority activity due
 primarily to the opportunity it provides for
 learning and cooperation (encouraged by
 attendees)  in pollution abatement for the
 iron and steel industry.  The results
 achieved by the interchange of ideas will
 provide for better solutions to pollution
abatement  problems, more efficient and
cost-effective technology, more productive
research and engineering, and improved
equipment  design and operation.  He also
emphasized that the program was well
balanced—one-fourth of the papers being

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presented by EPA ORD and the remainder
of the papers presented by industry, foreign
governments, academia, EPA program of-
fices, and others.
Keynote Address

Carl J. Schafer, Director, Industrial
and Extractive Processes Division
Office of Environmental Engineer-
ing and Technology U.S. EPA,
Washington, DC 20460
  Schafer reviewed some of the coopera-
tive efforts and the  people involved in
those projects which began over a decade
ago.  These projects included the com-
bined treatment of steel mill and municipal
wastewater, countercurrent rinsing on the
halogen tin plate line which demonstrated
the large blowdown  reduction and ac-
companying economic benefits, and sev-
eral projects to encourage increased pro-
cess water reuse/recycle.  On the air
program side, there were the coke oven
charging  and pushing  demonstrations,
development and demonstration of im-
proved coke oven door seals, measure-
ment of inhalable paniculate emissions,
assessment of blast  furnace cast house
emission control technology, measure-
ment of open source emissions, evalu-
ation of control technologies,  and other
major programs with AISI, universities,
and  foreign countries.  He stated that
renewed emphasis on the handling and
disposal of hazardous waste has spurred
renewed emphasis on prevention, recovery,
and more cost-effective and environment-
ally sound alternatives to disposal.

Whither Research?

Earle F. Young, Jr.
Vice President,  Energy and En-
vironment
American Iron, and Steel Institute,
Washington, DC  20036

  This paper reviews the WHO, WHAT,
WHEN, and WHERE of environmental re-
search in the iron and steel industry and
makes projections and suggestions as to
future  conduct  of research in the field.
Young reviews what has been covered in
past symposia and what is being covered
in this one. He looked for trends and made
projections as to what should be covered
in the future.
  He reviewed  subject  matter from the
viewpoint of air, water, and solid  waste
(multimedia) pollution control; sources of
papers (who made the presentations) —
EPA, EPA contractors, steel companies,
joint research, and others; and his self-
defined types of papers (regulatory analy-
ses, technical reviews, quantifications of
emissions and effluents, laboratory con-
ceptual studies, pilot studies, demonstra-
tions,  environmental  assessments, and
cost-effectiveness/cost-benefit analyses).
  Young covers a whole series of factors
which he believes will change the way we
look at iron and steel pollution abatement
technology in the future. Using the same
framework discussed  above, he projects
where  he thinks the program should go
and what should be emphasized.

The Unfinished Agenda:  An
Environmentalist's View of
Steel Mill Air Pollution

Kevin Greene
Research Associate
Citizens for a Better Environment,
Chicago, IL  60605

  The steel industry has made substantial
progress  in controlling air pollution.  Par-
ticularly noteworthy are efforts to control
coke oven emissions in a comprehensive
manner.  In  addition,  several companies
are developing noncapture  systems  to
control fugitive emissions  from  iron-and
steel-making facilities.
  But the job is not done. Total suspended
paniculate levels still exceed the primary
standards in  major steel-making areas of
the country by a significant margin. There-
fore, additional controls on process sources
will be necessary.  Attainment of stand-
ards will also depend  on achieving good
work practices. To make sure such prac-
tices become part of the daily operating
routine, self-monitoring programs should
be instituted at steel mills.

Session 1.  Air Pollution Abate-
ment

Philip X. Masciantonio, Chairman
U.S. Steel  Corporation
Pittsburgh, PA  15230

Inhalable Paniculate Matter
Sampling  Program for Iron and
Steel:  An  Overview Progress
Report

Robert C. McCrillis
Industrial Environmental Research
Laboratory
U.S. EPA Research Triangle Park,
NC  27711
  EPA's Office  of Research and Develop-
ment has entered into a major program to
develop inhalable paniculate (IP) matte
emission factors (IP is defined as airborn
particles of < 15/xm aerodynamic equivi
lent diameter). The Industrial Processe
Branch of EPA's IERL-RTP is responsib
for the ferrous metallurgical industry se<
ment of this program.  Efforts to date fi
the iron and steel category are summi
rized in this paper. IP  requirements ar
meshed with those of other EPA samplir
programs whenever possible, thus redu
ing overall cost to EPA and minimizir
inconvenience to the host plants.
  A thorough literature review and comp
lation of existing data revealed the exii
tence of particle size data for several <
the major iron and steel sources. Hov
ever, none of these data was obtain*
using current IP measurement techno
ogy; most of them do not cover the full
size range and, in  many cases, there
insufficient documentation to complete
determine test procedures followed at
to  fully define the process operatic
during the tests. The  current field te
program is  designed  to augment th
existing data base by directing resourci
toward these sources with the combin
tion of high priority and low existing da
quality. Both process sources and opi
sources are  included. To date, process
tested  are basic oxygen furnace (BO
charging and tapping, hot metal desulf i
ization, blast furnace  cast house  (bo
building evacuation and local control tec
nologies), sinter discharge, and BOF me
stack (limited combustion system  afl
scrubber). Open sources tested are pav
and unpaved roads and coal storage p
maintenance, all both with and withe
controls, and an uncontrolled open an
Several additional tests are underway
scheduled. All data gathered will be sui
marized and published in a single rep<
early next year.
Cost Effectiveness Evaluatio
of Road Dust Controls

Chatten Cowherd, Jr., Thomas >
Cuscino, Jr., and Mark Small
Midwest Research  Institute
Kansas City, MO 64110
  Preliminary analysis  of control me;
ures for  fugitive  paniculate  emissi
sources in the  iron and steel  indus
indicates that control of open dust sourc
has a highly favorable cost effective™
ratio in comparison with control of procf
sources of fugitive paniculate emissio
However,  rigorous cost effectivene
evaluation must await accurate and we
documented information on control pi
formance and cost. This paper address

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 he analytical and practical considerations
involved in acquiring meaningful  cost
effectiveness data for the major open
dust sources in the iron and steel industry-
vehicular traffic on unpaved and paved
roads.
  Results of extensive performance test-
ing of road dust controls are presented.
The control measures tested were water-
ing and chemical treatment of unpaved
roads and vacuuming, flushing, and broom
sweeping  of paved  roads.  The mean
efficiencies of control measures tested,
except for vacuum  sweeping  of paved
roads, were found to be independent of
particle size.  The mean control efficiency
of freshly applied Coherex® to unpaved
roads was higher than the efficiencies of
the other measures tested.  An analytical
framework for control cost effectiveness
analysis is proposed, and control cost data
for road dust controls at two steel plants
are given.

Blast Furnace Casthouse
Control Technology- Fall 1981
Update

Thomas J. Maslany
U.S. EPA, Region 3
Philadelphia, PA  19106

Peter D. Spawn
GCA/Technology Division
Bedford, MA 01730

  This paper describes blast furnace cast-
house information that has become avail-
able in the past 6 months. Results of total
mass and inhalable paniculate testing on
the baghouse inlet at Bethlehem Steel's
Sparrows Point L furnace are presented.
Baghouse outlet test data are also pre-
sented for I nland Steel's No. 7 fu rnace and
Wheeling-Pittsburgh's Monessen No. 3
furnace.  The status of United States and
Canadian casthouse control systems as of
September 1981 is provided along with a
listing of worldwide controlled casthouses,
excluding Japan.  Cost data for installed
systems are also given.

Coke Quench Tower Emissions
and Emissions Control

Dennis Wallace
.Midwest Research Institute
Kansas City, MO 64110

Naum T. Georgieff
U.S. EPA, Emission Standards and
Engineering Division Research
Triangle Park, NC 27711
 Dana Peckworth
 Midwest Research Institute
 Raleigh, NC  27612

 Sandra Stell
 Midwest Research Institute
 Kansas City, MO  64110

  Available  test data indicate that the
 mass of particulate emissions from a coke
 quench tower may be affected by quench
 water quality (based on dissolved or total
 solids in the quench water), and the design
 and location of baffles in the tower.  This
 paper examines the impacts of the water
 quality and baffle design on quench tower
 emissions and emissions control. Emis-
 sions test data and engineering models
 are used to estimate the relationship of
 these parameters to emissions. Six possi-
 ble control schemes are defined and the
 impacts of the controls are evaluated.

 Current Regulations and Con-
 trol Performance for Visible
 Emissions from Wet-Coal
 Charging.  Door Leaks, and Top-
 side Leaks

 Marvin R.  Branscome
 Research Triangle Institute
 Research Triangle Park, NC 27709

William L. MacDowell
 U.S. EPA, Region 5
 Chicago, IL 60604

  The Research Triangle Institute, under
 contract to the U.S. Environmental Pro-
 tection Agency  (EPA), compiled  back-
 ground information on emissions from
 wet-coal charging, door leaks, and topside
 leaks from coke ovens.  The study was
 undertaken  as part of EPA's effort to
 examine the  need for coke oven regula-
 tions. This paper summarizes a portion of
 the background  information which was
 compiled. Current regulations from State
 Implementation Plans, consent decrees,
 and  Occupational Health  and  Safety
 Administration (OSHA) requirements are
 summarized.  Emission test results  and
 performance data in terms of visible emis-
 sion  control are presented.

 A Review of Shed  and  Gas
 Cleaning Systems for Control-
 ling Coke Pushing Emissions
 from Coke Plants
Jack Shaughnessy and Dilip Parikh
MikroPul Corporation
Summit, NJ  07901

  The body of information in this paper is
directed to coke producers and their man-
agement the environmental control agen-
cies, and labor organizations interested in
further protection of their members.
  There are a number of different areas of
concern in pollution control for coke ovens.
We are directing our efforts to properly
control all the emissions on the coke side
of the oven.
  In the United States in the past 7-10
years, there have been a number of con-
cepts used by the steel industry and coke
producers to control pushing emissions
and door  leakage on coke side of ovens.
These concepts included various  types of
quench cars, land-based systems, hooded
hot cars, and sheds.
  The purpose of this paper is to review
the evolution of the shed concept up to the
present and the new concepts presently
being offered We will also review and
compare the gas cleaning devices used on
the early  sheds which were either high
energy scrubbers or wet electrostatic pre-
cipitators versus the baghouse which is
today's accepted technology on coke
pushing emissions.

Armco's Experience with
Application of the Bubble Con-
cept

B. A. Steiner
Armco,  Inc.
Middletown,  OH 45043

  Armco's early efforts to demonstrate
the advantages of the Bubble Concept led
to the implementation of a comprehensive
fugitive dust control program at its Middle-
town  Works.   The program was fully
operational by August 1980 and  led to an
acceptable alternative control plan  ap-
proved by U.S. EPA in March 1981. The
prototype program has shown that sig-
nificant improvements in ambient air con-
centrations of total suspended particulates
are possible with a comprehensive fugitive
dust control program and that improve-
ments in smaller particle size fractions are
realized as well.

Engineering  Study   of  Roof
Mounted Electrostatic Prec/pf-
tator(REP) for Fugitive Emission
Control on Two Basic Oxygen
Furnaces of30O Ton Capacity

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Richard Jablin
Richard Jablin & Associates
Durham, NC  27705

David W. Coy
Research Triangle Institute
Research Triangle Park, NC 27709
  Several alternatives are available  for
controlling fugitive dust emissions from
basic oxygen furnace operations.  Local
hoods and partial building evacuation are
the common means for capturing emissions:
An alternative  not used in  the United
States, but successfully used in Japan, is
roof-mounted  electrostatic  precipitators
(REPs). This paper presents the results of
a study examining the feasibility of REP
installation for a BOF shop with two 225
metric ton (280 ton) vessels. The purposes
of the study were to determine the applica-
bility of the devices to the BOF fugitive
dust sources, examine the changes needed
to existing plant facilities to interface the
new equipment with the old, estimate the
costs  for modification of existing plant
facilities and the addition of new facilities,
and examine the expected performance of
the proposed  REPs.   In performing  the
study, a preliminary quote for the REP was
obtained from Sumitomo Heavy Industries,
Ltd, electrical  power supply and  spray
washing system requirements were in-
vestigated, structural reinforcement to the
existing BOF building was investigated, an
estimate of cost to install and to operate
the REP was then generated, and, finally,
the quantity of fugitive furnace emissions
escaping  the building with the REPs in
place was estimated.

Demonstration of the Use of
Charged Fog in Controlling
Fugitive Dust from a Coke
Screening Operation at a Steel
Mill

Edward T. Brookman and Kevin J.
Kelley
TRC-Environmental Consultants, Inc.
Wethersfield, CT 06109

Robert C  McCrillis
U.S. EPA Industrial Environmental
Research Laboratory
Research Triangle Park, NC 27711
  TRC-Environmental Consultants,  Inc.
(TRC) has been contracted by the Indus-
trial Environmental Research Laboratory
of the Environmental Protection Agency at
Research Triangle Park, North Carolina
(EPA/IERL-RTP), to test a commercially
available electrostatically charged fogger
on several large-scale industrial sources
within the iron and steel and sand and
gravel industries.  This paper discusses
tests conducted at a coke screening opera-
tion at a steel mill. Tests were run with no
fog, uncharged fog,  negatively  charged
fog, and  positively charged fog.  Data
analysis  indicates a  doubling  in total
suspended paniculate control efficiency
when a positively charged fog was used
relative to uncharged fog.  For the same
case, removal efficiency for particles less
than 16jum improved 2.5 times.

Performance of BOF Emission
Control Systems

Leonard J. Goldman, David W.
Coy, and James H. Turner
Research Triangle Institute
Research Triangle Park, NC 27709

John O. Copeland
U.S. EPA, Emission Standards and
Engineering Division
Research Triangle Park, NC 27711
  Many of the recently constructed BOF
facilities worldwide have incorporated both
primary and  secondary emission control
systems in initial construction programs.
Domestically, as a result of consent decrees
and state air regulations, some older plants
have retrofitted secondary emission con-
trol systems  and upgraded their primary
emission control systems. The effective-
ness of these recent  air pollution control
systems varies widely. The performance
of most primary control systems has been
good. The largest variation in performance
domestically  appears among  secondary
control systems.  This paper discusses the
technology in use at some  plants, and
reports the performance as well. Some
data reported in this paper have been
obtained  in  the process of developing
background information for New Source
Performance Standards for the U.S. EPA.

Investigation of Opacity and
Paniculate Mass Concentrations
from Hot  Metal Operations

David S. Ensor
Research Triangle Institute
Research Triangle Park, NC 27709
  The objective of this study was  the
investigation of  possible  relationships
between plume opacity, mass concentra-
tion, and sub-10- /im mass concentration
for three  hot metal processes. Size dis-
tribution data from a blast furnace cast-
house, BOF shop, and hot metal desulfu
ization were used to compute mass lig
extinction coefficients.  A wide range
materials (iron oxide, carbon, and glas
were assumed to  model the emission
The results  suggest that opacity-to-ma.'
concentration  should be insensitive
composition, and  a good correlation
mass-to-plume opacity is expected. Tl
emissions studied  were of similar optic
activity as those reported in the literatu
in  other industries.  The results of tl
analysis also  imply that the sub-10-ju
particles should be well correlated to mas
  It is recommended that future field tes
to measure particle size distribution shou
include  instrumental  measurements
opacity. Thus, opacity, massconcentratic
and  sub-10-/um  particle concentrati<
could be subjected to a correlation an
ysis.  In addition, the refractive index ai
particle  density of paniculate mater
should be measured on bulk material
aid in explanation of the test results.

Retrofitting Emission Contro
on Electric Furnaces at a Ste
Mill

Michael P. Barkdoll
Enviro-Measure, Inc.
Knoxville, TN 37901

Donald E. Baker
Rockwood Iron & Metal Compa
Rockwood,  TN  37854
  The body of information  presented
this paper is directed to design engine*
electric  arc  furnace owners, and oth
who are interested in air pollution emiss
control technology. This paper prese
the methodology and results of a 2 -y
project at the Knoxville Iron Company.
extensive field measurement program v
conducted to  quantify  plume general
rates from two 30-ton electric arc furna
melting scrap.  Plume measurements w
made for charging, tapping,  and meltii
Measurements were also made for t
dish  lancing  and  billet cutting.   M
tenance and operational problems of
first-generation side draft-hood and fc
house system were inventoried. Basec
the source  characterization  and sys
performance,  an integrated air pollu
control system was designed and instal
Installed system capacity was 300,(
acfm, utilizing two shaker-type baghoi
with flow switching and continuous li
stone injection.   Capital  and installa
costs are presented by major category
addition, pertinent design parameters
system  performance data are presen

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 The Present and the Future for
 the Industrial Treatment of
 Fumes in the French Steel
 Industry
 Jacques Antoine
 Laboratoire d'Etude et dp Controls
 de I'Environnement Siderurgique
 Metz, France

 Alain Milhau
 Ministere de I'Environnement
 Neuilly/Seine, France

 Jean  Raguin
 Chambre Syndicate de la SideVurgie
 Franca ise
 Paris, France
  Over the last few years, the French steel
 industry has committed  large sums and
 made an uprecedented technological ef-
 fort to improve the environment around its
 plants.   Thus, during 1976-1980, 880
 million  francs were spent in antipollution
 investments in spite of  the unfavorable
 economic situation.  Two-thirds of these
 investments were devoted to the fight
 against air pollution and,  in several cases,
 new technologies were used.
  This report covers the present situation
 in seven  projects:  two coking  plants
 (Sollac and Pont-a-Mousson), three oxy-
 gen steelmaking shops (Fos, Mondeville,
 and  Neuves-Maisons), and two electric
 steelmaking shops (Firminy and Les Dunes).
 For each, the authors analyze the problems
 to be solved on a technical and regulatory
 level, the solution applied (especially when
 technologically unusual), and the results
 obtained. From the present situation  we
 can anticipate an evolution of  pollution
 standards and of antipollution technology.

 Modeling of Hood Control  of
 Blast Furnace Casting Emissions

 S. F. Fields, C. K.  Krishnakumar,
and J.  B. Koh
Card,  Inc.
 Niles,  IL 60648
  A laboratory scale model test technique
has been developed to simulate the ther-
mal and flow characteristics of blast furnace
casting  emissions and  to evaluate the
 jerformance of potential hood collection
devices.  The  test system utilizes fresh
water (as the source fluid to model casting
emissions) and concentrated sodium chlo-
ride  solution (to model  the denser sur-
rounding environment).  Excellent flow
visualization is obtained through the gen-
eration of light-reflecting hydrogen bubbles
in the source fluid stream by electrolysis.
Application of the technique to qualitative
evaluation of hood performance is illus-
trated by an example.  In addition, use of
the technique to generate numerical values
of hood collection efficiencies is described

Session 2. Solid Waste Pollution
Abatement

Thomas M. Barnes, Chairman
Research and Development
Heckett  Butler, PA  16001

Robert S. Kaplan, Cochairman
Extractive Processes
U.S. Bureau of Mines, Washington,
DC  20241

RCRA Regulatory Changes and
the Steel Industry

Stephen A. Lingle and William
J. Kline
U.S. EPA Hazardous and Indus-
trial Waste Division
Washington,  DC 20460
  The objectives of the Resource Conser-
vation and Recovery Act  (RCRA) in the
management of  solid and hazardous
wastes are to promote the protection of
human health and the enviroment and to
conserve valuable material  and energy
resources.  This paper updates actions
being  taken by the Environmental Pro-
tection Agency  (EPA) in fulfilling the ob-
jectives of RCRA with respect to hazardous
waste management It discusses: (1) the
status of regulations promulgated to man-
age hazardous  wastes, and (2)  RCRA
activities specifically associated with steel
industry hazardous wastes.
  Standards were published in May 1980,
establishing a foundation for the manage-
ment of hazardous waste.   Additional
technical standards necessary  to permit
treatment storage, and disposal facilities
were published in January and  February
1981.
  However, some wastes listed as hazard-
ous in May 1980 have subsequently been
delisted, and the effective dates of some of
the January and February standards have
been deferred.
  EPA has also been involved in the inves-
tigation of means to alleviate the problem
of spent pickle liquor  generated by the
steel industry via increased reuse/recov-
ery. With  regard to the latter,  EPA has
recently  promulgated  a conditional ex-
emption from RCRA management stand-
ards for spent pickle liquor use, and is also
currently considering a Section 6002 pro-
curement guideline for the specific use of
spent pickle liquor in wastewater treat-
ment as a phosphorous removal agent
  An overview of each of these E PA activi-
ties under RCRA is provided in this paper.

Characterization, Recovery,
and Recycling of Electric Arc
Furnace Dust

N.  H.  Keyser
Consultant
Hinsdale, IL  60521

J. R. Porter,  A J. Valentino, M. P.
Harmer, and J. I. Goldstein
Lehigh University
Bethlehem, PA  18015
  Electric arc furnace dust samples have
been obtained  from a number of steel
companies representing the broad spec-
trum of steelmaking practice. The samples
have beert chemically and structurally ana-
lyzed in the bulk, and individual particles
have been characterized using analytical
electron microscopy. (Most particles ana-
lyzed were complex iron-rich spinel oxides
with varying amounts of other elements in
solid solution.)   Procedures to extract
elements from the dust have been investi-
gated both  physically and chemically.
Magnetic separation shows some prom-
ise  for recovering zinc from high-zinc-
bearing dust Other options for resource
recovery are discussed including the tech-
nologies which exist for processing high
grade dust

Treatment of Carbon Steel
Electric Furnace Flue  Dust by
Sulfation

Pinakin C.  Chaubal
University  of Utah
Salt Lake City, UT 85112

Thomas J. O'Keefe and Arthur E.
Morris
University  of Missouri-Rolla
Rolla,  MO  65401
  The zinc content of electric furnace flue
dust can be sulfated by the action of iron
sulfate  in  briquetted samples  at 600-
650°C. Up to 96% of the contained zinc is
converted to  water-teachable zinc sulfate
under optimum conditions.  The other
product is a relatively low-zinc iron oxide.
A Plackett-Burman statistical design was
used to quantify the factors affecting the

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sulfation process. The mechanism of the
process is explained by the use of thermo-
chemical diagrams for the Fe-Zn-S-0 sys-
tem at different temperatures. The results
suggest a process for rendering the elec-
tric furnace flue dust suitable for recycling
into the steel plant flowsheet. The process
may also be effective in detoxifying dust
which does not otherwise  pass the EP
toxicity test
Panel: Destruction of Hazardous
Waste in Iron and Steel Furnaces

Engineering Requirements for
Thermal Destruction of Hazard-
ous Waste in High Temperature
Industrial Processes

E. Timothy Oppelt
U.S. EPA Industrial Environmental
Research Laboratory
Cincinnati, OH 45268
  A number of high temperature industrial
processes offer temperature, mixing, and
gaseous residence time conditions which
may  be sufficient to thermally destroy
hazardous wastes of various types.  Indus-
trial boilers and cement kilns are most
often considered for this purpose.  Incin-
eration in lime kilns, steelmaking furnaces,
and other processes may also be technically
feasible and economically attractive. Con-
sideration must be given, however, to the
physical form of wastes, firing methods,
residue handling, air pollution control, "in-
cinerability" of the waste, and compatibili-
ty of the waste material with the industrial
process of interest

Suitability of Open Hearth
Furnaces for Destruction of
Hazardous Waste

William F. Kemner
PEDCo Environmental,  Inc.
Cincinnati, OH 45246
  The high temperatures and retention
times achieved  in open  hearth  furnaces
suggest their consideration as candidates
for destruction of hazardous wastes. Con-
ceptually, liquid wastes could be co-fired
with fuel in the burners, and semisolid and
solid wastes could  be charged into the
furnace. A particularly difficult problem in
present hazardous waste destruction is
the disposal of contaminated  drums.
Complete cleaning is expensive and time
consuming. Destruction of contaminated
drums and other solid wastes is an oppor-
tunity not offered in many other destruction
schemes.
  Serious complications coexist with the
advantages of this concept.  Control of
fugitive emissions, explosion hazards, and
potential worker exposure are among the
problems to be  evaluated.  It appears
unlikely that hazardous waste destruction
could be accommodated in an ongoing
steelmaking operation. An alternative is
the conversion of an abandoned furnace to
serve primarily as a destruction operation
with the production of low-grade steel as a
byproduct   Economics will dictate the
ultimate viability of such an approach as
site  cleanup activities proceed over the
next 5 years under EPA's Superfund pro-
gram.

Suitability of Blast Furnaces for
Destruction of Hazardous Wastes


George R. St  Pierre
Ohio State University
Columbus, OH  43210

  The potential for the injection of hazard-
ous wastes in the tuyeres of a blast furnace
is  discussed in terms  of  the thermo-
chemical conditions that exist in the race-
ways and smelting zone of an operating
blastfurnace. The temperature in the blast
furnace tuyere is about2121°C (3850° F).
As the preheated air with additives enters
the furnace through the   tuyeres, the
chemical potential of oxygen rapidly de-
creases because of the excess supply of
hot coke. Hence, the conditions are char-
acterized by high temperature (>2000°C),
strong reducing potential (P02 <10"20 atm),
and moderate pressure (<10 atm). Under
such conditions, many hazardous materials
may be dissociated into simple molecules.
Currently, tars, oils, and pulverized coals
are injected into the tuyeres.  Hence, a
technology  for tuyere  injection is  well
developed.  During the presentation, the
fate  of injected  hazardous  wastes (e.g.,
PCS)  and the potential  effects on blast
furnace operations are discussed.
Session 3:  Water Pollution
Abatement

Terry N.  Oda, Chairman
U.S.  EPA, Region 3
Philadelphia, PA  19106


Minimizing Recycled Water
Slowdown from Blast Furnace
Gas  Cleaning Systems
Richard L Nemeth and Leonard D.
Wisniewski
Republic Steel Corporation
Cleveland, OH 44101
  Retrofit water recycle systems were pu
in  operation  late in 1976 on the  gas
cleaning systems for two blast furnac<
complexes at Republic Steel Corporation'!
Cleveland  District  steelmaking facility
Since the start-up of these systems, ef
forts have been made to reduce blowdowi
by identification  and elimination of extra
neous water sources. The overall effect o
these  efforts  has  caused  significan
changes  in constituent  loadings fron
these systems to the receiving stream, th
Cuyahoga  River.   Recently, the goal c
blowdown reduction has shifted to th
elimination of discharge to the river, wit
efforts directed toward continued operatic
of  a  very "tight" recycle system.   Lone
term effects are yet to be resolved.
  The paper maps the development of
blast furnace treatment facility from "one
through" to "recycled" with a low blov
down rate. Current work concerning th
continuous operation of a tightly close
recycle system is presented. This include
maintaining hydraulic balance, monitorir
water chemistry, and feeding differei
treatment chemicals to control potenti
problems associated with highly cycle
water.  It also  presents a pictorial displ;
and schematic representation of the sy
tern, and a graphic analysis of key par
meters and water quality trends.
  Finally, the  paper focuses on studii
conducted jointly by Republic Steel  ar
U.S.  EPA  on  one of the recycle  wat
systems. This was accomplished with tl
use of the U.S. EPA Mobile Wastewat
Treatment System during the spring ai
summer of 1981.  Initial work includi
testing on a pilot plant scale (5-6 gpm)
softening a portion of the recycle strea
Secondary work investigated propos
BAT/BCT Alternate #4  (Alkaline-Chic
nation) for blowdown treatment from
very highly cycled  blast furnace recyi
system.

Minimizing Water B/owdowi
from Selected Steel Plant
Processes

Harold J. Kohlmann and
Harold Hofstein
Hydrotechnic Corporation
New York, NY  10001
  Objectives of the project were to mi
mize the volumes of water blown do1
from blastfurnaces, BOF, continuous c

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ters, hot forming mills, sinter plants, elec-
tric arc furnaces, and vacuum degassers,
and, at the same time: use existing treat-
ment facilities, use no major capital equip-
ment and  have the reduction have no
adverse impact  on the production facili-
ties.
  To meet the project objective, the meth-
odology was to:  review existing literature
to determine which plants have extensive
recirculation systems installed and which
plants discharge volumes that are close to
BAT volumes (October 1979 proposed
guidelines), visit candidate plants; inter-
view  personnel;  obtain data;   perform
studies; establish modified operating pro-
cedures and/or design  system modifi-
cations; discuss results with plant opera-
tors; and allow plants  enough time to
make and operate the modified systems to
determine if the systems can be operated
with reduced blowdown without adverse
effects.

Zinc Control in a Blast Furnace
Gas Washwater Recirculation
System

R Gregory Elder and Roy Littlewood
Stelco Inc.
Hamilton, Ontario, Canada L8N 3T1
   In general, it  is  not possible to operate
blast-furnace-gas-washwater circuits at a
high degree of recirculation in a steel plant
which also recycles  a large proportion of
zinc-containing  scrap and  solid wastes.
Certain undesirable elements, particularly
zinc, are not removed  during  iron- and
steel-making, and  will accumulate to dan-
gerous levels under high  recycle  con-
ditions.
  The most serious danger is to blast
furnace operations.  Zinc threatens these
operations  by: (a) endangering refractor-
ies (which can lead to blowout, collapse, or
premature shutdown of the furnace); (b)
causing the descending charge to stick
(leading to operating irregularities,  de-
creased furnace efficiency, and hazardous
 slips'); and (c)  depositing solids in water
recirculating systems (which can block
pipes and cause the collapse of cooling
towers).
  To avoid  these problems, all steel com-
panies restrict the  amount of zinc in mate-
rials fed to blast furnaces.   A typical
maximum  permissible  level is 0.5 kg/
tonne  of iron  produced—equivalent to
about 0.02%of zinc in the raw materials
fed to the furnace.
  Stelco's  Hilton Works  in Hamilton,
Ontario, recycles solid wastes,  including
all blast furnace dust from both wet and
dry collection systems.  Severe operating
problems were caused when a recircula-
tion system was commissioned in 1978
for three blast furnaces which had pre-
viously operated with a once-through gas-
washing and solids-separation system.
Subsequently, it was found possible to
operate,  if blast furnace  dusts  (up to
40,000 tonne/year) were dumped.
  To  avoid this problem,  a method of
generating a zinc-laden blow-down stream
has been devised, which enables zinc to
be selectively purged from the system.
This technique allows the water recircula-
tion system  to  be  operated, while  still
recycling most of the blast furnace dusts.


Investigation of Reverse
Osmosis for the Treatment of
Recycled Blast-Furnace
Scrubber Water


M. E. Terril
U.S.  Steel Corporation
Monroeville,  PA  15146
R .D. Neufeld
University of Pittsburgh
Pittsburgh,  PA 15213

  Entrained dust in blast-furnace off-gas
must be removed before the gas can be
used as fuel. Wet scrubbing is the standard
method for cleaning blast-furnace gas.
Scrubber water, in addition to removing
dust, also dissolves contaminants includ-
ing ammonia,  phenol, and cyanide from
the blast-furnace gas.  The scrubber water
is  contained in a  recycle system and, a
sidestream must be discharged to prevent
scaling in the recycle system.
  The objective of this research was to
evaluate reverse osmosis (RO) as a candi-
date technique to minimize the quantity of
wastewater discharged  from the  gas-
scrubber recycle system.  The  RO per-
meate would  be recovered as  make-up
water for the recycle system. The concen-
trate stream  would  be  discharged for
further treatment or possible evaporation
via slag quench. Samples of blast-furnace
recycle water were obtained  locally, and
tests were conducted with a spiral-wound
cellulose acetate RO  module at  a pH of
about 5. Operating pressures investigated
were 350 - 450 psig, and feed operating
temperatures were 74 - 86° F. Permeate
flux rates (gpd/ft2) were measured as a
function of water-volume recovery level.
Recovery levels were 10-80% plus.
   Low membrane rejections were obtain-
 ed for phenol, free cyanide, thiocyanate,
 and sulfide,  indicating that these sub-
 stances would be returned via the perme-
 ate to the recycle loop.  Consequently,
 significant reductions in the discharge
 loadings  of  these  materials could be
 achieved in the concentrate stream. These
 substances may not be conserved in the
 recycle  system and,  therefore, may not
 increase in concentration in the system.
 Aqueous  discharge reductions of 70  -
 80%  appear possible.
   Evaluation procedures for the RO system
 are discussed, applicability advantages and
 disadvantages are reviewed, and concep-
 tual flow diagrams showing further treat-
 ment and disposal options for the reject
 stream are presented.


 Review of Water  Usage in the
 Iron and Steel Industry: Blast
 Furnace and Hot Forming
 Subcategories

 Albert  P. Becker,  III, and Thomas
 M. Lachajczyk
 Envirodyne Engineers, Inc.
 St. Louis, MO  63141

  This paper gives results  of a study of
 water usage and recirculation techniques
 in the iron and steel industry blast furnace
 and hot  forming subcategories. The pro-
 ject was conducted for U.S. EPA's Indus-
 trial Environmental Research Laboratory,
 Research Triangle Park, NC. Initially, a list
 of zero-  and low- discharge plants in the
 subject  subcategories  was   developed
 from information provided  in the "Draft
 Development Document for Proposed Ef-
 fluent Limitations Guidelines for the Steel
 Industry." U.S. EPA wishes to verify the
 water application and discharge rates pre-
 sented in the Development Document and
 update this information if necessary. The
 work  also  included a determination of
 specific  process water quality require-
 ments in blast furnace  and hot forming
 operations, and identification  of factors
 which limit process water recyclability, a
 survey of techniques  used to implement
 zero-  or  low-discharge systems,  and a
 study of the  feasibility  of implementing
these techniques at existing plants.  The
 study included:  telephone and written
communications with  plant  personnel,
American  Iron and Steel Institute repre-
 sentatives,  EPA Regional  and Effluent
Guidelines staff members, and equipment
 manufacturers; a review of technical litera-
ture; and plant visits.

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Control of Scale Formation in
Steel Plant Water Recycle
Systems

G.  R. St Pierre and A. H. Khan
Ohio State University
Columbus, OH 43210
  Several options  for scale formation
control  are discussed  with particular
reference to the recycling of scrubber
water for blast furnace top gas. Experi-
ments on carbonate scale formation are
described and several important operating
variables are discussed. Several types of
sensors that might be used to aid in the
avoidance of scaling are reviewed.

Reduction of Wastes
Discharged from Steel Mills in
Metropolitan Chicago through
Local Ordinance Enforcement

Richard Lanyon and  Cecil Lue-
Hing
The Metropolitan Sanitary District
of Greater Chicago
Chicago, IL 60611
  The Metropolitan  Sanitary District of
Greater Chicago (District) is a municipal
corporation authorized under Illinois law
to maintain and operate facilities for col-
lecting and treating waterborne wastes in
an 886 mi2 area in northeastern Illinois.
The District also enforces  its Sewage and
Waste Control Ordinance  in an industrial
community with in excess of 6,000 wet
industries that discharge into sewers, in-
land waterways, and Lake Michigan.
  Metropolitan  Chicago   contains  the
nation's largest industrial concentration.
Included in the District's  jurisdiction are
five major steel-making facilities, all within
10  miles  of the Calumet River.   The
facilities have a combined total production
capacity of  7.8 million tons of steel per
year.  One  of the District's major water
pollution  enforcement activities involves
the  five steel mills and began in 1969.
Then, the five mills discharged 546 mgd
of wastes into the Calumet River and Lake
Michigan from 45 separate outfalls.
  Enforcement action against the five
plants was initiated after a comprehensive
sampling effort  The laboratory analyses
indicated that the discharges from the
plants violated the  District's ordinance
limits, which incorporated State of Illinois
waterway effluent standards.  Following
attempts at administrative conciliation and
show-cause action, the  District entered
into protracted litigation against the five
corporations owning and  operating the
plants.
  Results of this local enforcement action
were complete elimination of all process
water discharged to the Calument River
and Lake  Michigan, and  installation of
process water treatment  and  recycling
with residual blowdown to the District's
sewer system The only remaining dis-
charges to the lake or river are non-contact
cooling water.


A Mass Balance Model for
Rinsewater in a Continuous
Strip Halogen Electrolytic
Tinning  Operation  for  Use in
Evaluating Wastewater
Treatment and Recovery
Alternatives


James Skubak
Jones & Laughlin Steel Corporation
Aliquippa, PA  15001


Ronald D. Neufeld
University of Pittsburgh
Pittsburgh, PA  15261

  The operation and rinsewater applica-
tion of J&L's electrolytic tinning operation
at Aliquippa are studied to specify a plat-
ing chemical  recovery technology for
wastewaters.    The existing  treatment
method for wastewaters, hydroxide pre-
cipitation,  is adequate to meet discharge
limits, but economics favor a change that
uses a form of recovery.
  A mathematical mass balance model is
developed to  predict rinsewater concen-
tration changes as flowrates are varied.
The relationships described by the model
are tested, and it is  shown that the model
for tin is followed within a narrow margin
of error.  The significance of this is that
wastewater flow (and mass rate of tin  in
the wastewater)  can be measurably re-
duced with no apparent product defects.
  The model is refined to reflect the instal-
lation of rinsewater controls that optimize
rinsewater use,  and  various  recovery
techniques are applied to this refined
model.  A comparison  of these recovery
methods indicates that several alterna-
tives can recover plating chemicals suc-
cessfully and have capital recovery periods
of less than  1  year.   In  summary, the
importance of modeling in this type  of
application is paramount to successful
recovery.
Investigation of the Solid/
Liquid Phase Separation of
Preheated and Pipeline Charged
Coke Battery Charging Liquor

S. R. Balajee, A I. Aktay, and R. R.
Landreth
Inland Steel Company
East Chicago, IN  46312

  Inland's preheat and pipeline charged
"C" Battery was built with a solid/liquid
phase  separation  system containing  a
series of tanks to separate the coal fines
collected during  the charging  process
from the charging liquor.  This  phase
separation system did not remove enough
coal fines to prevent plugging of the charg-
ing liquor spray nozzles and a buildup of
material in the charging main when the
liquor was recycled. Consequently, several
phase separation methods were investi-
gated on the laboratory, pilot plant,  and
plant scales to establish their ability to
decrease the  solids  content of the  "C"
Battery charging liquor to a concentration
suitable for recycling.   These  methods
were:   gravity settling, horizontal  belt
filtration with and without precoat, hydro-
cyclone separation,  spiral rake classifi-
cation, conventional flotation,  and  dis-
solved air flotation.
  All of the  phase separation methods
separated coal  fines to some degree, but
three methods (i.e., gravity settling,  dis-
solved  air flotation,  and horizontal  belt
filtration with  precoat) gave the best re-
sults.  Gravity settling is easy to operate,
but requires a large amount of land area for
installation of a pit and the use of chemical
additives to accelerate the settling of fines.
Dissolved air flotation requires chemical
additives and a liquor with a high solids
content for best operation.  In view of the
variable solids  and tar concentrations in
the charging liquor,  the gravity settling
method was selected  and settling  pits
were installed to separate coal fines from
charging liquor at Inland's "C" and No. 11
preheated and pipeline charged coke bat-
teries.

Assessment of the Biological
Treatment of Coke-Plant
Wastewaters with Addition of
Powdered Activated Carbon
(PAC)

Leon W. Wilson,  Jr.
U.S. Steel Corporation
Monroeville, PA  15146
                                   8

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 Bernard A.  Bucchianeri
 U.S.  Steel Corporation
 Clairton, PA 15025

 Kenneth D. Tracy
 Environmental Dynamics, Inc.
 Greensboro, NC  27407
  The U.S. Steel Corporation, in coopera-
tion with the U.S. EPA, has conducted an
extensive experimental  biological-treat-
ment program to develop data relative to
Best Available Technology  Economically
Achievable (BATEA) for coke-plant waste-
waters. This program included testing at
both bench-and pilot-scale levels.  One
feature of this program was an assessment
of the benefits of adding powdered acti-
vated carbon (PAC) to the biological reactor.
In bench-scale reactors, gross removal ef-
ficiencies (measured by chemical oxygen
demand (COD) and total organic carbon
(TOQ) were determined with and without
PAC.  Comparisons  were based on the
effects of solids-retention  time and on
PAC-dose levels.  A dual-train pilot-scale
study was made  at optimum  conditions
established during  the  bench-scale re-
search to confirm the bench-scale com-
parisons.  Results indicate that PAC does
not significantly enhance effluent quality,
compared with the effluent quality of a
biological reactor operated at optimum
conditions. Also, PAC-supplemented bio-
logical reactors treating coke-plant waste-
water may undergo desorption of a sub-
strate toxic to the thiocyanate-degrading
organisms.
 Biological Treatment of
 By-Product Coke Plant
 Wastewater for the Control of
 BA T Parameters

G. M. Wong-Chong
 Environmental Research  El-
Technology, Inc.
 Pittsburgh,  PA  15219

S. C.  Caruso
Mellon Institute, Carnegie-
Mellon University
Pittsburgh,  PA  15213

  This paper gives results of an evaluation
of the activated sludge  process for the
treatment of coke  plant  wastewaters
(CPW) to meet compliance with BAT limi-
tations for conventional/nonconventional
 parameters.  The evaluation entailed the
operation of batch and  continuous flow
 laboratory scale reactors, and a 50 gpd
 pilot plant
  The study produced understanding of
(a) the sequence in which the different
components in CPW are removed, (b) the
order of the degradation reaction associ-
ated with each component, (c) the potential
inhibitory effects of different CPW com-
ponents on the different degradation re-
actions, and (d) kinetic expressions associ-
ated with treatment rates and sludge pro-
duction which could be used to design the
biological treatment system.

Two-Stage Biological
Fluidized-Bed Treatment of
Coke Plant Wastewater for
Nitrogen Control

S. G. Nutt
Dearborn Environmental
Consulting Services, Mississauga,
Ontario, Canada L5A 3T5

H. Melcer
Wastewater Technology Centre,
Environment Canada
Burlington,  Ontario, Canada L7R
4A6

J. H. Pries
Canviro  Consultants,  Ltd.
Kitchener, Ontario, Canada N2H
5M5

  The feasibility of the  biological fluidized-
bed  process has been demonstrated for
both carbpn and nitrogen removal from
municipal and concentrated wastewaters.
The process can provide significant advan-
tages over conventional suspended growth
activated  sludge systems owing to the
high biomass concentrations that can be
maintained in the reactors. The technical
and economic feasibility of treating coke-
plant wastewater in a two-stage fluidized-
bed system, operated in the predenitrifi-
cation/nitrification mode, is being evalu-
ated  at  pilot scale at the Wastewater
Technology Centre, Burlington, Ontario.
This  paper reports on  the experiences of
operating this process configuration.
  The pilot plant consists of a 150 mm
diameter anoxic denitrification fluidized-
bed reactor, coupled to a 290 mm diameter
oxygenic  nitrification  fluidized-bed  re-
actor. Biomass is retained as a fixed film
on a support medium of 0.48 mm diameter
quartzite sand. Bed reaction volumes are
58.5 and 210 litres,  respectively. Pure
oxygen is supplied to  the nitrification re-
actor through a proprietary oxygen trans-
fer device provided by Dorr-Oliver Inc.
Raw  feed consists of limed ammonia still
effluent and light oil interceptor sump
wastewater from Dominion Foundries and
Steel Ltd (DOFASCO) in Hamilton, Ontario.
  At anoxic and aerobic hydraulic reten-
tion times (HRTs) of 0.13-0.4 and 1.13-
1,9 days, respectively, complete nitrogen
control and high levels of contaminant
removal were effected in undiluted waste-
water.  Very high recycle ratios for both
reactors were required to maintain ad-
equate flux rates to  fluidize the sand
support medium.  Operational problems
associated with the accumulation of in-
organic (calcium phosphate) and organic
residues in the biomass films have been
overcome successfully.    High  effluent
suspended solids have prevented strict
solids retention time control. Steady-state
experiments are continuing to define the
minimum system HRT required to achieve
consistent nitrogen control.
  Based on these results a comparison is
made with the results obtained with a
suspended growth predenitrification/ni-
trification system that was evaluated in an
earlier phase qf this work.

Trace Metal Removal from
Steel Plant Wastewaters Using
Lime and Ferrate

J. A FitzPatrick, J. Wang, and
K. Davis
The Technological Institute,
Northwestern  University
Evanston, IL 60201

  The potential of ferrate for disinfection
and chemical oxidation in potable water
production and domestic wastewater treat-
ment has been recently identified.  This
paper is primarily aimed at evaluating the
mechanism and effectiveness of ferrate
for trace metal and suspended material re-
moval for iron- and steel-making waste-
water application.  A combined experi-
mental and theoretical approach was used.
  Conclusions of this work are:
  1. Ferrate has prorhise for solids and
     metal removal in steel plant waste-
     waters.
  2. Lime pretreatment is effective to re-
     duce ferrate doses, but postfiltration
     may be required.
  3: Complex dependence on  solution
     chemistry is observed for lime-plus-
     ferrate or ferrate-only treatment
  4. Comparison  of  ferrate and  ferric
     shows varying optimal dependency
     on the metal ion to be removed.
  5. Preliminary theoretical computations
     show considerable difference from
     experiment except for Pb removal.

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  6. Removal of metals in actual waste-
     waters was high at low dose when
     provision for added settling is in-
     cluded.

  7. Conjunctive oxidation benefits of fer-
     rate should be explored for priority
     pollutant  removal  in  steel  plant
     wastewaters.
Pilot Evaluation of Alkaline
Chlorination Alternatives for
Blast Furnace Slowdown
Treatment


Stephen A. Hall, Karl A Brantner,
John W. Kubarewicz, and Michael
D. Sullivan
Metcalf & Eddy, Inc.
Boston, MA  02114

  To continue discharge of blowdown
from blast furnace  recycle systems in
upcoming years, blowdown water quality
will be required to meet the Best Available
Technology (BAT) effluent limitations. Pilot
plant investigations employing three alter-
native  alkaline  chlorination  process
schemes were conducted to evaluate their
effectiveness in  treating blast  furnace
blowdown.  The process schemes were
single-stage alkaline chlorination,  two-
stage alkaline chlorination,  and air strip-
ping followed by two-stage alkaline chlori-
nation. All three processes were effective
in removing ammonia  and cyanide,  al-
though with varying degrees of success in
meeting the presently proposed  BAT ef-
fluent limitations for the iron-making sub-
category of the iron and steel industry.
Single-stage alkaline chlorination very ef-
fectively removed cyanides but  did not
provide favorable conditions for complete
oxidation of cyanates and ammonia. Two-
stage alkaline chlorination provided favor-
able conditions for oxidation of cyanides,
cyanates, and  ammonia but required a
more complex control system.  The air
stripping/alkaline  chlorination  process
reduced chlorine  requirements by strip-
ping ammonia, while still providing favor-
able conditions for complete oxidation of
cyanide and additional ammonia removal.
A comparison  of  estimated capital and
operating costs for each of the alternative
schemes is presented.
  Abstracts of papers not presented at the
symposium but which are published in the
proceedings follow:
Application of Second
Generation Chemical
Solidification/Fixation
Processes to Iron and Steel
Hazardous Waste Problems

Jesse R. Conner
SolidTek Solidification Technology
Systems, Inc.
Morrow, GA  30260

  The iron and steel industries produce
various waste sludges and other liquid,
semiliquid, and solid wastes which con-
tain  toxic metals and other  hazardous
constituents. Since 1970, several chemi-
cal solidification/fixation processes have
been tested successf u I ly for some of these
waste streams but primarily due to eco-
nomics,  have not been extensively used.
The advent of RCRA has altered this situ-
ation, and it is expected that solidification
techniques will become important in the
near future. In the meantime solidification/
fixation technology has progressed from
the few,  early, broad-spectrum processes
to engineered systems which can be most
efficiently applied to specific waste streams.
This paper will discuss the basic chemical
systems in use, their properties and limi-
tations, and the delivery systems for apply-
ing them on a commercial basis. The de-
sign parameters which must be consid-
ered in  choosing a solidification  tech-
nology will also be described. In addition
to process and  system parameters, the
interaction of the treated  waste with the
environment—in this case, the land dis-
posal site—must be assessed.  The paper
discusses final disposal practices as they
affect, and are affected by, RCRA regula-
tions and the test methods used to deter-
mine  if  a treated waste  is hazardous.
Current economics of various processes
on typical waste streams are compared
with other  alternatives  for  hazardous
waste disposal.

Optimizing Existing
Wastewater Treatment
Facilities in Preparation of
Meeting BA T/BCT Regulations
in the  Iron and Steel Industy

Meint Olthof
Duncan, Lagnese and Associates,
Inc.
Pittsburgh, PA 15237
  This paper discusses the impact of the
BAT/BCT regulations on  existing central
treatment facilities. To prepare for these
new regulations,  it will be necessary to
review the origin of the waste sources and
install pretreatment facilities or internal
recycle loops to minimize the cost of end-
of-the-pipe treatment schemes.  The three
examples reviewed in this paper are for a
hot mill, a cold mill, and a by-product area.

Development of a Deoiling
Process for Recycling Mil/scale

Derek S. Harold
Luria Brothers & Company
Cleveland, OH   44122
  The paper presents the  practical ap-
proach to the recovery, processing,  and
recycling large tonnages of oily millscale.
This paper describes the basic design and
Operating  principles  of  a combustion
technique for deoiling and beneficiating
millscale  resulting in  a feed material of
consistent quality for sinter plant and blast
furnace.  Millscale composition,  particle
size distribution, and chemical analysis are
discussed with emphasis on proper  pre-
paration for economical recycling.  Also
covered are environmental and raw  ma-
terial implications in the present and future.

Recycling of  Tar Decanter
Sludge

R B. Howchin and M. S. Greenfield
DOFASCO, Inc.
Hamilton,  Ontario, Canada  L8N
3J5
  Tar is  a  saleable by-product of coke
making. The tar is driven off from the coal
in the coke ovens. It is collected, condensed,
and separated from the water phase in tar
decanters.  In the processing some of the
tar becomes contaminated  with solids
(primarily coke fines) and is unsuitable for
sale.
   Many different options were  examined
to most efficiently dispose of these wastes.
The use of tar sludge as a roofing material
and in asphalt mixing was studied. Exper-
iments are being conducted to recycle the
waste oil to the rolling mills. This paper
covers the most promising method of dis-
posal—recycling the oils and tars to either
the blast furnace or coke ovens.   Bench
scale mixes and pilot testing are covered.
                                  10

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The compiler.  Franklin A.  Ayer. is with Research Triangle Institue, Research
  Triangle Park, NC 27709.
John S. Ruppersberger is the EPA Project Officer (see below).
The  complete report, entitled "Proceedings: Symposium  on Iron and Steel
  Pollution Abatement Technology for 1981," (Order No. PB 83-164 038; Cost:
  $40.00. subject to change) will be available only from:
        National Technical Information Service
        5285 Port Royal Road
        Springfield, VA 22161
        Telephone: 703-487-4650
The EPA Project Officer can be contacted at:
        Industrial Environmental Research Laboratory
        U.S. Environmental Protection Agency
        Research Triangle Park, NC 27711
                                                                              11
                                                                               U. S. GOVERNMENT PRINTING OFFICE: 1983/659-095/194]

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