-------
Hot Coatings - Galvanizing Operations
Flow information relative to the four plants visited is
discussed in Section IX, along with the BPCTCA limitations.
The recommended BATEA limits follow parameter by parameter,
and are summarized in Table 106. Where necessary, estimates
were made of the load reductions brought about via cascade
rinsing techniques at the plant lines, and recycle of fume
hood scrubber waters for plants so equipped.
SusEended Solids. A BATEA limit of 0.0104 kg/kkg (0.0209
Ibs of suspended solids per ton) of steel coated is
recommended, equivalent to 25 mg/1 based on a 417 1/kkg (100
gal./ton) flow. An additional allowance of 0.0156 kg/kkg
(0.0312 Ibs/ton) is provided for plants utilizing wet fume
hood scrubbers over the coating lines. One hot galvanizing
plant with three coating lines of various widths, and using
wet fume hood scrubbers achieves a level of 0.0206 kg/kkg
(0.0411 Ibs of suspended solids per ton) of galvanized strip
by using equalization, mixing, lime treatment in carefully
controlled steps to precipitate dissolved metals, polymer
addition, clarification in a thickener, and vacuum
filtration of underflow sludges. The discharge flow
contains 8056 of the recommended BATEA limit, this
demonstrating the effectiveness of the treatment system.
Oil and Grease. A BATEA limit of 0.0042 kg/kkg (0.0083 Ibs
of oily matter per ton) of steel coated is recommended,
equivalent to 10 mg/1 based on a 417 1/kkg (100 gal./ton)
flow rate. An additional allowance of 0.0063 kg/kkg (0.0125
Ibs/ton) is provided for plants utilizing wet fume hood
scrubbers over the coating lines. Both of the continuous
strip galvanizing lines surveyed discharge oily matter at
0.10 Ibs/ton of coated product, exceeding the recommended
BATEA limit by a factor of five. However, the plant
described above (see suspended solids) does achieve 10 mg/1
in a considerably higher effluent flow rate, so the
concentration limit is attainable, using presently installed
equipment and technology. It is anticipated that flow
reductions achieved through cascade rinsing and fume hood
recycle (wherever fume hoods are used) will enable a plant
to achieve the recommended BATEA limits.
Zinc. A BATEA limit of 0.00083 kg/kkg (0.0016 Ibs of zinc
per ton) of galvanized product is recommended, equivalent to
2 mg/1 based on a 417 1/kkg (100 gal./ton) flow rate. An
additional allowance of 0.00125 kg/kkg (0.0025 Ibs/ton) is
provided for plants utilizing wet fume hood scrubbers over
the coating lines. One of the plants surveyed achieves
discharge loads of only 12% of the recommended limit through
500
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502
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/05 -
MOI\<:L co MB CATEGORY
ANNUAL COST'S ABASED OiV 7£M YEAfe CAP'TAL ZECOVE/2Y
y- INTERE -3 r &A 7£ 7 %
i-OPERATING COSTS ,,\'CLUOE LA8OK>CHEMtCAL'5 f}VT/U7l£S
+ MAtH7EK+\KC£ crOoTJ. .fi'JJ^O ON ^.S"/o OF CAP/TAL
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503
-------
the use of equalization, mixing, lime treatment, polymer
addition, and clarification in a thickener, essentially the
control equipment and treatment techniques recommended for
attainment of BATEA levels. Both continuous strip
galvanizing plants show less than 2 mg/1 zinc concentrations
in their effluents, despite processing 1,100 to 1,750 tons
of zinccoated product per day apiece. Thus, the recommended
BATEA limit for zinc is readily attainable using
conventional treatment techniques.
Hexavalent Chromium. A BATEA limitation for hexavalent
chromium of 0.000008 kg/kkg (0.000016 Ibs/ton) is
recommended, equivalent to 0.02 mg/1 based on a discharge
flow of 417 1/kkg (100 gal./ton). An additional load of
0.000013 kg/kkg (0.000026 Ibs/ton) is provided for plants
equipped with wet fume hood scrubbers. Although both
continuous strip galvanizing lines achieve the recommended
concentration limits at 0.005 and 0.012 respectively, the
flow rates are high enough to exceed the recommended load
limitations. As flow reductions are achieved through
cascade rinsing and fume hood recycling, where applicable,
the recommended limits should prove attainable using the
present technology and equipment, which has demonstrated the
ability to reduce hexavalent chromium concentrations
effectively.
Total Chromium. A BATEA limitation for total chromium has
been set at 0.000084 kg/kkg (0.000168 Ibs/ton), equivalent
to 0.2 mg/1 based on a discharge flow rate of 417 1/kkg (100
gal./ton). An additional allowance of 0.000126 kg/kkg
(0.000250 Ibs/ton) is provided for those galvanizing lines
utilizing wet fume hood scrubbers. One of the plants
surveyed is discharging total chromium at 105% of the
recommended limitation, but will readily meet the limits as
flow reductions via cascade rinsing and fume hood recycling
are provided. The other galvanizing plant is discharging
0.86 mg/1 total chromium, partly in the form of suspended
solids. Tighter control of suspended solids, in addition to
flow rate reductions, would be required to bring this plant
into compliance.
pjH. As in all other subcategories, the BATEA limitations
for pH specify a range from 6.0 to 9.0. Since treatment is
required to reach the BATEA limitations for zinc and
chromium, the attainment of pH limitations will not require
any additional equipment or expense.
Hot Coatings - Terne Operations
504
-------
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
anticipated in effluents from systems similar to those used
in the Hot Coatings - Galvanizing subcategory. Where
necessary, estimates included the beneficial effects of load
reductions brought about through use of cascade rinse and
fume hood scrubber recycle technologies. The recommended
BATEA limitations follow parameter by parameter, and are
summarized in Table 107.
Suspended Solidjj. A BATEA limitation for suspended solids
of 0.0104 kg/kkg (0.0209 Ibs/ton) of steel coated is
recommended, equivalent to 25 mg/1 based on a discharge flow
of 417 1/kkg (100 gal./ton). An additional allowance of
0.0156 kg/kkg (0.0312 Ibs/ton), equivalent to 25 mg/1 in a
flow of 626 1/kkg (150 gal./ton) is provided for plants
using wet fume hood scrubbers in conjunction with the
coating operation. Since both plants surveyed were
discharging wastewater oncethrough, both exceed the
recommended limit, even the one with only 9 mg/1 suspended
solids in the effluent. Use of the recommended flow
reduction techniques, cascade rinsing and fume hood scrubber
recycle, together with lime treatment to precipitate metals,
followed by polymer addition and clarification with oil
skimming would enable terne plates to attain the BATEA
suspended solids limits.
Oil and Grease. A recommended BATEA limit for oils and
greases is set at 0.0042 kg/kkg (0.0084 Ibs/ton), equivalent
to 10 mg/1 based on a discharge flow of 417 1/kkg (100
gal./ton) of steel coated. An added load of 0.0063 kg/kkg
(0.0125 Ibs/ton) is permitted for those plants using wet
fume hood scrubbers in conjunction with terne-plating
operations. Although both plants surveyed do discharge oil
and grease at less than 5 mg/1 in their effluents, neither
plant attains the required BATEA limit, since they operate
on a oncethrough basis at flows of five to nine times the
BATEA basis flow. The treatment system recommended above
for suspended solids removal would efficiently eliminate
oils and greases as well, both through provision of
continuous oil skimming, and via the scrubbing action of the
highly absorbent floes generated during removal of dissolved
metals. This treatment technology has proven effective on
wastewaters from a variety of other subcategories.
Tin. A BATEA limit for tin of 0.00083 kg/kkg (0.00167
Ibs/ton) of terne-coated product is set, equivalent to 2
mg/1 based on a 417 1/kkg (100 gal./ton) flow rate. An
505
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ANNUAL COSTi.
COSTS BASCD ON
MODI I (iV,r I IM C I M'l Ml :.S r.'IAoK'AM
HOI i i>.YJIN',-TI KNI" : UIK AFEGOKY
liAStO ON 71 M YCAR LAPnAI. RlCOVEUY
IMriVi:ST KATI /Z
cctRAiiNO co^rs iwcium I.ABOK, cmwicAii -! UTILITICS
MAINTCNANCC CO5TS BAP TO ON 3.57. OFCAPITAl COSTS
G^ KKG/L >Y (700 IONS/DAY ) MOT COATINO OPLR.
TI4IS GRAPH CANNOT Bt USCD TOR INTFJs'MEniATE VALUES
2034OO
164,330
NO INCREASED COSTS
IMPROVCMENTS ARIA
RCMJLTOF BtTTtR
(REFERENCE
LEVEL)
100
508
-------
additional allowance of 0.00125 kg/kkg {0.0025 Ibs/ton) is
provided for plants utilizing wet fume hood scrubbers,
equivalent to 2 mg/1 based on a flow of 626 1/kkg (150
gal./ton) . Although both plants surveyed were discharging
tin at less than 2 mg/1 concentration, the use of once-
through wastewater flows prevent these plants from attaining
the BATEA limits. However, the technology described under
suspended solids, coupled with the technique for reducing
flows, would enable terne-coating operators to comply with
BATEA load requirements.
Lead. A BATEA limit of 0.000104 kg/kkg (0.000209 Ibs of
lead per ton) of coated product is recommended, equivalent
to 0.25 mg/1 based on a 417 1/kkg (100 gal./ton) flow rate.
An additional allowance of 0.000156 kg/kkg (0.000312
Ibs/ton) is provided for plants using wet fume hood
scrubbers. Data were available from two plants, indicating
an average effluent load of 0.0005 kg/kkg (0.001 Ibs/ton) of
product, about twice the recommended limit. Currently, both
lines provide no. wastewater treatment and attain this low
discharge load by maintaining operating conditions on the
line with a high degree of attention to minimizing dragout
of solutions and reducing water flows wherever possible.
The treatment technique used to achieve BATEA suspended
solids limitation levels will yield lead concentrations at
or below the recommended levels.
pH. As in all subcategories, the BATEA pH limits require a
range between 6.0 to 9.0. Since pH control will be required
to attain BATEA limits on lead and tin, no additional
equipment or expense will be required.
Miscellaneous Runoffs - Storage Piles - Cgalj. 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.
Based upon the rationale and justification used to set
suspended solids and pH limits at the BATEA level for the
other industry subcategories covered by the segment and the
above discussion, limitations are set as follows: suspended
solids limit of 25 mg/1 and a pH range of 6.0 to 9.0.
509
-------
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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 installation costs of the BATEA collection and treatment
systems described above for a typical coal, stone, and ore
pile associated with a 5,000 ton per day ironmaking facility
would cost $600,000, $364,000, and $463,000, respectively.
This included costs for the collection and holding system,
and a clarifier with associated acid or alkaline and polymer
chemical feed systems.
The criteria and assumptions used to provide the basis for
sizing and costing these facilities include:
Raw material usage,
#/ton of iron
Storage capacity,
days
Bulk density,
#/ft3
Coal
2860
90
50
Stone
1000
180
155
Ore
4000
180
250
Stockpile height,
ft.
25
40
Max. mean 24 hr.
rainfall, inches
Runoff coefficient
2.5
0.90
2.5
0.90
2.5
0.90
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 24 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
511
-------
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,
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.
512
-------
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 100X. 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
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 c. general estimate covering most of the
areas of the country where steel production is located.
The following considerations were used for the design
parameters for the range of treatment technolgoy:
Max. Design Rainfall =2.5 inches/day, 45"/year
513
-------
Runoff Coef. (including seepage) = 0.90
Storage Capacity = One Day Max. Rain (2.5 inches)
Pump Storage Basins Dry in 5 days
Stockpile Enclosure Embankment = 2* High
Collection Ditches: 3* Deep, 4' Wide
Sublining 3.5* Deep
Lime Dosage = 75 mg/1
TSS of Runoff = 200 mg/1
Poly Dosage = 2 mg/1
Neutralization Tank TR = 5 minutes
Because the runoff storage basins are designed to be pumped
out through a treatment facility over a five day period, any
additional rainfall during the period could exceed the
storage capacity of the basins. Therefore, the limitations
will apply only when the rainfall is 2.5 inches or less in
any preceeding five day period.
Miscellaneous Runoffs - Casting and Slagging
The recommended BATEA limitations for casting and slagging
operations is the same as the BPCTCA limitations discussed
in Section IX; namely, no discharge of process (i.e.,
contact) wastewater pollutants from ingot casting, pig
casting or slagging operations. This technology represents
current general practice for such operations.
Noncgntact Coolimj Water Recirculation System Slowdown
The treatment and control of wastewaters blown down from
noncontact cooling water recirculation systems was discussed
in detail in Section IX, and BPCTCA concentration limits
were specified. Whereas chemical flocculation using
polymers or other flocculants was described as a possible
addition to lime precipitation systems for BPCTCA levels, it
will most likely be required to attain the more rigorous
concentration limits for BATEA levels. The BATEA ELGs for
this subcategory have been set as follows:
Suspended Solids - 25 mg/1
Total Chromium - 0.2 mg/1
514
-------
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Hexavalent Chromium - 0.02 mg/1
Zinc 2.0 mg/1
Phosphorous - 8,0 mg/1
pH 6.0 to 9.0
Utility Area Wastewaters
The treatment and control of utility area wastewaters was
discussed in detail in Section IX, and BPCTCA concentration
limits were specified. Corresponding BATEA concentration
limits for this subcategory are set as follows:
Suspended Solids - 25 mg/1
pH - 6.0 to 9.0
To attain these limits, the addition of chemical
flocculation to the BPCTCA system will probably be required.
Maintenance Department Wastewaters
The treatment and control of maintenance department
wastewaters was discussed in detail in Section IX, and
BPCTCA concentration limits were specified. Corresponding
BATEA concentration limits for this subcategory are set as
follows:
Suspended Solids - 25 mg/1
Oil and Grease - 10 mg/1
pH - 6.0 to 9.0
To attain these limits, the addition of chemical
flocculation to the BPCTCA system will probably be required.
Central Treatment
For all central treatment systems (as described in Section
IX), the allowable BATEA effluent loads for discharge will
be the sum of the BATEA loads from regulated sources, plus
the loads determined from the flow rates from unregulated
sources multiplied by the following allowable BATEA
concentrations:
Suspended Solids - 25 mg/1
Oil and Grease - 10 mg/1
Total Chromium - 0.2 mg/1
Hexavalent Chromium - 0.02 mg/1
Phosphorus - 8 mg/1
Zinc - 2 mg/1
pH - 6.0 to 9.0
516
-------
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529
-------
Cost to the Iron and Steel Industry
Table 108 presents a summary of projected capital and annual
operating costs for the hot forming and cold finishing
operations of the steel industry as a whole to achieve the
effluent quality proposed herein for BPCTCA and BATEA for
the steelmaking operations.
As presented in the table, an initial capital investment of
approximately $791,082,247 million with annual capital and
operating costs of $103,930,927 million would be required by
the industry to achieve BPCTCA guidelines. An additional
capital investment of approximately $589,941,780 million and
a total annual capital amortization and operating cost of
$222,980,909 million would be needed to achieve BATEA
guidelines. Costs may vary depending upon such factors as
location, availablility of land and chemicals, flow to be
treated, treatment technology selected where competing
alternatives exist, and the extent of preliminary
modifications required to accept the necessary control and
treatment devices.
521
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10 U
-------
SECTION XI
EFFLUENT QUALITY ATTAINABLE THROUGH THE
APPLICATION OF NEW SOURCE PERFORMANCE STANDARDS
INTRODUCTION
The Best Available Demonstrated Control Technology (BADCT)
is to be achieved by "New Sources." "New Sources" has been
defined as any source the construction of which is commenced
after the publication of the proposed regulations. The
BADCT technology is that level which can be achieved by
adding to the BATEA technology improved production processes
and/or treatment techniques. For purposes of developing the
BPCTCA and BATEA technologies and limitations, the industry
was divided into the following subcategories:
M. Hot Forming Primary
N. Hot Forming Section
O. Hot Forming Flat
P. Pipe and Tubes
Q. Pickling - Sulfuric Acid - Batch
R. Pickling - Hydrochloric Acid
S. Cold Rolling
T. Hot Coating - Galvanizing
U. Hot Coating - Terne
V. Miscellaneous Runoffs
W. Cooling Water Slowdown
X. Utility Slowdown
Y. Maintenance Department Wastes
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 proposed 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 except from this
the flow basis corresponds with the BPCTCA technology but
with extended settling to achieve the BATEA concentrations.
NSPS DISCHARGE STANDARD
For the following subcategories, refer to rationale as
discussed in Section X - BATEA.
525
-------
M. Hot Forming Primary
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. Cooling Water Slowdown
X. Utility Slowdown
Y. Maintenance Department Wastes
For the remaining subcategories:
R. Pickling - Hydrochloric Acid
(B) Absorber Vent Scrubber
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, therefore BATEA
concentration limits were used to establish loads, even
though BPCTCA flows had to be used.
526
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SECTION XII
ACKNOWLEDGEMENTS
This report was prepared under Contract t68-01-1507 by the
Cyrus Wm. Rice Division of NUS Corporation. The RICE
operations are based in Pittsburgh, Pennsylvania.
The preparation and writing of this document was
accomplished by Mr. Edward L. Dulaney, Project Officer, 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.
Field and sampling programs were conducted under the
leadership of Mr. Donald J. Motz, Mr. Joseph A. Boros, and
Mr. Richard C. Rice.
Laboratory and analytical services were conducted under the
guidance of Mr. Paul Goldstein and Miss C. Ellen Gonter.
The many excellent drawings contained within were provided
by the RICE drafting room under the supervision of Mr.
Albert M. Finke.
The work associated with the calculations of raw waste
loads, effluent loads, and costs associated with treatment
levels is attributed to Mr. Gregory A. Troilo, Mr. Michael
E. Hurst, and Mr. David A. Crosbie.
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 Mr.
Edward L. Dulaney, the Project Officer, is acknowledged with
grateful appreciation.
The members of the working group/steering committee who
coodinated the internal EPA review are:
Walter J. Hunt - Effluent Guidelines Division
Edward L. Dulaney - 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
James McDermott - Region V, EPA
Mat Miller - Region III, EPA
527
-------
John Whitescarver - Office of Permit Programs
Dennis Ruddy - Office of Permit Programs
Robert Burm - Region VIII, EPA
Patricia Diercks - Effluent Guidelines Division
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
companies: Armco Steel Corporation, Avco Thompson, Bethlehem
Steel Corporation, Colorado Fuel & Iron, Copperweld Steel
Corporation, Dominion Foundries and Steel Limited,
Fitzsirrunons Steel Company, Inland Steel Corporation,
Interlake Steel Corporation, Jones 6 Laughlin Steel
Corporation, Kaiser Steel Corporation, Lasalle Steel, 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, Walker Wire, Wheatland Tube Corporation,
Wheeling-Pittsburgh Steel Corporation, Wire Sales, Inc., and
Wisconsin Steel Corporation.
The assistance of steel industry consultants, namely Ferro-
Tech Incorporated, was utilized in several areas of the
project.
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, to Mrs. Minnie C. Herold, for library
assistance and to Ms. Denise Devlin, Ms. Mary Lou Simpson,
and Ms. Mary Lou Baronyak of the RICE Division for their
efforts in typing of drafts, necessary revisions, and final
preparation of the original RICE effluent guidelines,
documents, and revisions.
528
-------
SECTION XIII
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529
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-------
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531
-------
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533
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534
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Seriesc Office of Research and Monitoring, Washington, D.
C., pp. 1-40 (March, 1972).
81. Environmental Protection Agency, "Industry Profile Study
on Blast Furnace and Basic Steel Products", C. W. Rice.
82. Environmental Protection Agency, "Water Pollution
Control Practices in the Carbon and Allied Steel
Industries", EPA, Washington, D. C. (September 1, 1972).
83. Environmental Steel, The Council on Economic Priorities.
84. "EPA vs Mills: Costs are in Eye of Beholder", Iron Age,
210, p. 43 (October 12, 1972).
85. Ess, T. J., "The 80 In. Hot Strip Mill at Great Lakes",
Iron and Steel Engineer, 46, pp. 84-93 (April, 1969).
86. "The Fickle Future of Pickle Liquor", Iron Age, 210, p.
83, (October 19, 1972) .
87. "Flying Start at Weirton No. 5", 33 Magazine, 9, pp. 44-
51 (February, 1971) .
88. Foltz, V. W. and Thompson, R. J. , "Armco Developes Cold
Mill Waste Oil Treatment Process", Water and Wastes Engineer
Industrial, 7, pp. B16-B19 (March, 1970).
89. Foltz, V. W. , "Development of Waste Oil Recovery Process
at Armco Steel Corporation", Proceedings of the 25th (1970) .
535
-------
90. Frank, V. F. and Gravenstreter, James P., "Operating
Experience with High-Rate Filters", Water Pollution Control
Federation, Journal, 41, N.2 Pt. 1, pp. 292-296.
91. Galloway, R. E. and Colville, J. F., "Treatment of Spent
Pickling Plant Liquors", Iron and Steel Institute^ Report
1128, pp. 103-110 (1970) .
92. "Gary Works Latest Tinning Line Still a 'Thoroughbred1
at Age Five", 33 Magazine, 10 N. 6, pp. 52-54 (June, 1972).
93. Geny, P. and Dohen, E., "Measures Against Water
Pollution in the Iron and Steel Industry", Pure and Applied
gitem$etorye, L. Co land pfiocftrin}. Aitfflrew) A., "Recovery of
Metals from Electroplating Wastes by the Waste-Plus-Waste
Method", Bureau of Mines Solid Waste Research Program^
Technical Progress! Report 27, (August, 1970) .
95. Gillbanks, P. and Burden, E. B., "Treating Industrial
Effluent", Metal Finishing Journal, 17 N.6, pp. 172-173
(June, 1971).
96. Golomb, A., "Application of Reverse Osmosis to
Electroplating Waste Treatment", Plating, 57, pp. 1,001-
1,005 (October, 1970).
97. Gomoa, H. M. and Dempster, J. H., "Disposal of Pickling
Wastes - Is Recovery the Answer?", Wire and Wire Products,
46, pp. 53-55 (July, 1971).
98. Gravenstreter, James P., "Wastewater Treatment
Facilities at Gary's 84 In. Hot Strip Mill", Iron and Steel
Engineer Year book L 19J>.9, pp. 301-307 (1969) .
99. Handwerk, R. J., "Recycling Water Effectively", Foundry.
100, pp. 40-43 (July, 1972).
100. Hartman, C. D., "Use of Deep Well Method for Waste
Disposal at Midwest", Blast Furnace and Steel Plant, pp.
911916 (October, 1967) .
101. Hartman, C. D., Tucker, F. E., Simmons, P. D., and
Toth, T. S., "Wastewater Control at Midwest Steel's New
Finishing Mill", Iron and Steel Engineer Yearbook^ 1963, pp.
734-746 (1963).
536
-------
102. Haviland, Joseph M., "Effluent Treatment: Cutting
Cost of Compliance", Products Finishing, 35r No.5, pp. 46-55
(February, 1971).
103. Hayney, Lloyd J., "A Case History Water Pollution
Clean Up", Environmental Control Management, 137, pp. 52-54
(January, 1969).
104. Heaney, Donald F., "Deep-Bed Filter Systems for Mill
pp. B6-B7 (March, 1970).
105. Heit, A. H., "Electrodialytic Recovery of Sulfuric
Acid and the Iron Content Spent Pickling Process", Annual
Water Conference Engineering Society of Western
Pennsylvania, 30th, pp. 151-153 (1969).
106. Helwig, L. E., "Chromate Treatment of Galvanized
Sheet", Metal Finishing, 68, pp. 54-59 (July, 1970).
107. "Highly Efficient Fume Control System Checks Pickling
Exhaust Vapors At Republic", 33 Magazine, 10, pp. 50-51
(March, 1972) .
108. Hoak, R. D. and Bramer, H. C., "Pollution Control in
the Steel Industry", Chemical Engineering Progress, 62, pp.
48-52 (October, 1966).
109. Hogan, William T., "A Comprehensive Study of the
United States Iron and Steel Industry - 1645-1971", 33
Magazine, 10, N.5, pp. 40-41 (May, 1972).
110. Holt, Sondra E., "Automatic Treatment of Plating Rinse
Water at IBM", Industrial Finishing, 47, 12, pp. 43-55
(December, 1971).
111. Hughes, J., "Phosphate Waste Treatment", Metal
Finishing, 69, p. 70 (September, 1971).
112. "Hydrochloric Acid Dominates Steel Pickling", Chemical
and Engineering News, pp. 38-40 (March 3, 1969).
113. "Inland Steel's Newest Bar Mill is Rated as a Top
Performer", 33 Magazine, 10, p. 36 (July, 1972).
114. "Interlake Converts Waste Pickle Liquor into Harmless
Solids", Iron and Steel Engineer, 45, p. 150 (December,
1968).
537
-------
115. Iron <|nd Steel Engineer, "Annual Review of
Developments In the Iron and Steel Industry During 1972"
(January, 1973) .
116. Iron and Steel Engineer Yearbook, 197J), "Developments
in the Iron and Steel Industry During 1969", pp. 66-111
(1970) .
117. Iron and Steel Engineer Yearbook^ 1971, "Developments
in the Iron and Steel Industry During 1970", pp. 19-75
(1971) .
118. Jablin, Richard, "Environmental Control at Alan Wood:
Technical Problems, Regulations and New Processes", AISI
Yearbook^ 1971, pp. 263-285 (1971).
119. Jenkins, S. H. "Measures Against Water Pollution in
Industries Which Perform Metal Finishing", Pure and Applied
ChemistrY, 29, pp. 219-233.
120. Johnson, Kenn, "Effluent Control in Wire Production",
Wire Industry, 40, N.473, pp. 387-391 (May, 1973).
121. Johnson, W. H., "Water Treatment and Reclamation",
Iron and Steel Engineer Yearbook^ 1963, pp. 410-415 (1963).
122. Jones and Laughlin, "Welcome to the Hennepin Works",
Jones and Laughlin Steel.
123. Jukkola, W. H., "Flow Diagram for a New Steel Mill",
Industrial Water Engineering, pp. 32-34 (September, 1967).
124. Kolesar, T. J., "Closed-Loop Recycling of Plating
Wastes", Industrial Finishing, 48, N.9, pp. 22-25
(September, 1972) .
125. Kotsch, J. A., "A Look at the Mini-Plants", Iron and
Steel Engineer, 48, pp. 61-78 (August, 1971).
126. Kovacs, G. L., "Treatment of Waste HCl Pickle Liquor",
United States Patent, 3A682^.592, (August 8, 1972) .
127. Krikau, F. G., "Hydrochloric waste Pickle Liquor
Disposal - A New Process", Iron and Steel Engineer, pp. 7174
(January, 1969) .
128. Krikau, F. G., "Neutralization is Key to Acid -Liquid
Waste Disposal", Chemical Engineering, pp. 124-125 (November
18, 1968) .
538
-------
129. Kushner, Joseph B. , "Rinsing, Pollution, and Natural
Recycling of Plating Baths", Metal Finishing, 69, pp. 36-39
(July, 1971) .
130. Lacey, Robert E. , "An Electromembrane Process for
Regenerating Acid from Spent Pickle Liquor", Environmental
Protection Agency Water Quality Off icet Project No. 12010EQF
(March, 1971) .
131. Lackner, R. J. , "Closed-Loop Pickling System", Wire
l/ 4, N.12, pp. 43-47 (December, 1971).
Sulfate from Waste Pickle Liquor", Metal Progress, 98, No. 6,
pp. 58-59 (December, 1970) .
133. Lacy, W. J. and Cywin, A., "The Federal Water
Pollution Control Administration Research and Development
Program: Industrial Pollution Control", Plating, 55, pp.
1,299-1,301 (December, 1968).
134. Lancy, Leslie E. , "Metal Finishing Waste Treatment
Aims Accomplished by Process Changes", Chemical Engineering
Progress Symposium Series^ Water, pp. 439-441 (1970) .
135. Lancy, Leslie E., "Phosphate Waste Treatment", Metal
Finishing.* p. 123 (May, 1971) .
136. Lawes, B. C., Fournier, L. B. , and Mathie, O. B., "A
Peroxygen System for Destroying Cyanide in Zinc and Cadmium
Electroplating Rinse Waters", Plating, 60, N.9, pp. 902-909
(September, 1973) .
137. Lee, C. A., "Scale Pit Design", Iron and Steel
Engineer, 47, pp. 117-119 (December, 1970) .
138. Lee, Chesman A., "Simplify Terminal Treatment", Water
and Wastes Engineering, 8, N.7, pp. D12-D13 (July, 1971).
139. Leidner, R. N., "Burns Harbor - Waste Treatment
Planning for a New Mill", Blast Furnace and Steel Plant, pp.
316-321 (April, 1967) .
140. Liesegang, Wilhelm, "Supervision and Control of
Cooling Water for Hot Strip Mill Runout Tables", Iron and
Steel Engineer, pp. 158-162 (April, 1966) .
141. "Lorain has a New Look", 33 Magazine, pp. 80-89
(September, 1970) .
539
-------
142. Lowdre, L. R. , "Fluoride waste Puzzle Solved", Water
and Wastes Engineering, 8, pp. B6-B9 (March, 1971) .
143. Lowe, W. , "A Review of Effluent Treatment Systems",
Metal Finishing Journal, 15, N.171, pp. 103-105 (March,
1969).
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) .
145. McGavin, R. F, , "Suppression of Liquid 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 1128, pp. 112-119 (1970) .
146. Marnell, Paul, "Spent HC1 Pickling Liquor Regeneration
in Fluid Bed", Chemical Engineering, 79, N.25, pp. 102-103
(November 13, 1972) .
147. 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) .
148. McGibbon, V. R. , "Industrial Waste Treatment by
Pressure Filtration", Iron and Steel Engineer Yearbook^
1968, pp. 279282 (1968) .
149. Melyer, S. F. and Taubken, T. L. , "New Process Treated
Acid Rinse Waters", Water and Wastes Engineering, 8, pp. F6-
F8 (November, 1971) .
150. 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) .
151. Miller, J. H. , "Closed-Cycle Systems as a Method of
Water Pollution Control", Iron and Steel Engineer Yearbook,
1967, pp. 285-288 (1967) .
152. "Mini-Mills, to Build or Not to Build", 33 Magazine,
11, pp. 31-35 (January, 1973) .
153. "Mini-Plants in the U. S. - Roblin Steel's Two Join
Forty-Two and the Number Still Grows", 33 Magazine, 9, pp.
56-59 (March, 1971) .
540
-------
154. Moore, John, "Wire Recycling: Cash is Better Than
Trash", Wire and Wire Products, 47, N.12, pp. 62D-62G
(December7~1972) .
155. Morris, B. G. and Spaty, D. D., "Pollution Control of
Plating Effluents", Product Finishing, 24, pp. 20-23
(December, 1971).
156. National Industrial Pollution Control Council, "The
Steel Industry and Environmental Quality", UAS.. Department
of Commerce, pp. 1-26 (August, 1972).
157. 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).
158. Nebolsine, Ross, "Present Practice and New Concepts
for Handling Effluents from Hot-Rolling Mills", Iron and
Steel Engineer, 47, pp. 85-92 (August, 1970).
159. Nebolsine, Ross, "Steel Plant wastewater Treatment and
Reuse", Iron and Steel Engineer Yearbook, 196J7, pp. 216-231.
160. "Nelson Steel and Wire Improves Pickling Reduces Costs
With Acid Recovery System", Wire and Wire Products, 45, pp.
67-69 (September, 1970).
161. Nemeth, E. L. and Wexler, C. H., "Phoenix Steel's 160
In. Plate Mill", Iron and Steel Engineer, 47, pp. 33-40
(July, 1970) .
162. "New Regeneration Processes Help Wire Mills Fight
Pollution from Spent Pickling Liquor", Wire and Wire
Products, 46, pp. 56-60 (July, 1971).
163. "1973, Another Banner Year for Steel", 33 Magazine,
10, pp. 42-45 (November, 1972).
164. "1972 Steel Industry Outlook", 33 Magazine, 9, pp. 52-
56 (November, 1971).
165. "Nonstop Steelmaking: Norm for the 70"s?", 33
Magazine, pp. 47-50 (August, 1970).
166. O'Bruzt, J. J., "Control Pollution without Capital
Outlay", Iron Age, 209, pp. 48-50 (March 2, 1972).
167. 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).
541
-------
168. "Ohio Steel Tube's Waste Pickle Liquor Treatment Plant
On-Stream", Iron and Steel Engineer, 46, pp. 128-132 (June,
1969) .
169. Osada, Ya. E. , "Production of Plastic-Lined Steel
Tubes", Steel in the USSR, 2, pp. 731-732 (September, 1972).
170. Ostrowski, E. J., "Recycling of Tin-Free Steel Cans,
Tin Cans, and Scrap from Municipal Incinerator Residue",
l£2S and Steel Engineer, 48, pp. 65-74 (July, 1971).
171. Patterson, J. W. and Cheng, M. H., "Steel Industry",
Water Pollution Control Federation, Journal, 44, pp. 1,093-
1,095 (June, 1972).
172. Patterson, J. W. and Cheng, M. H., "Steel Industry pp.
1,184-1,188 (June, 1973).
173. 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).
174. "Pickle Effluent Disposal", Chemical and Process
Engineering, 51, pp. 77-78 (January, 1970) .
175. "Pickle Liquor Waste Treatment by Continuous Ion
Exchange", Federal Water Pollution Control Administration,
Project No. WPRD 41-01-(RI)-68, September, 1969, 31 pages.
176. Pilot, J., "The Treatment of Industrial Effluent",
Effluent and Water Treatment^ Journal, 10, N.4, supplement,
pp. 11-15 (April, 1970) .
177. "Plating Waste Treatment at Proctor-Silex", Products
Finishing, 35, N.4, pp. 43-49 (January, 1971).
178. 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).
179. "Pollution Control: Rinse Out a Profit", Iron Age,
pp. 48-49 (February 17, 1972) .
180. "Profitable Pollution Control", Automation, 16, pp.
1718 (December, 1969).
181. Republic, "Republic Unveils 84 In. Hot Strip Mill At
Cleveland", Iron and Steel Engineer, 48, pp. 83-84 (May,
1971) .
542
-------
182. "Rochester Starts Up Its New Wire Drawing Mill", Wire
Wire Products, 46, P. 72 (December, 1971).
183. Saros, S.t "Seventy-Two Inch Continuous Galvanizing
Line At Inland Steel", Blast Furnace and Steel Plant, 58,
pp. 648-652 (September, 1970).
184. Schaffer, Robert B. , "Polyelectrolytes in Industrial
Waste Treatment", Industrial Water and Wastes, pp. 33-39
(November/December, 1963).
185. Schink, C. A. , "Plating Wastes - A Simplified Approach
to Treatment", Plating. 55, N. 12, pp. 1,302-1,305 (December,
1968) .
186. Schreur, N. , "The Lancy Integrated System for
Treatment of Cyanide and Chromium Wastes in Electroplating
Plants", Proceeding of the Industrial Waste Conference^
22nd, Purdue University, pp. 310-316 (1967) .
187. Schuetz, James W., "Recent Developments in Seamless
Tube Mill Technology", 33 Magazine, 10, pp. 46-49 (March,
1972) .
188. Smith, R. D., "Burying Your Pickle Liquor Disposal
Problem", Civil Engineering, 39, pp. 37-38 (November, 1969).
189. Smith, R. D. , "Steel Company Builds Flexible
Wastewater Treatment System", Water and Wastes
Engineer ing/ Industrial (March, 1969) .
190. Smith, Stuart E., "Plating and Cyanide Wastes", Water
(June, 1972) .
191. Smithson, G. R. Jr., "An Investigation of Techniques
for Removal of Chromium from Electroplating Wastes",
Battelle Memorial Institute, Program t 12010 EIE (March,
1971)."
192. Snowden, F. C. , "Metal Finishing Wastes Can Become
Potable Effluents", Water and Sewage Works, 116, pp. IW9IW11
(May, 1969) .
193. "Solid and Liquid Wastes Incinerator Systems", Iron
and Steel Engineer, 47, pp. 116-117 (November, 1970).
194. "Some New Developments in Rolling Mills", 33 Magazine,
10, pp. 41-45 (March, 1972) .
543
-------
195. Spatz, D. D., "Electroplating Wastewater Processing
with Reverse Osmosis", Products Finishing, 36r N.ll, pp. 79-
83 (August, 1972) .
196. Spencer, Leonard C., "Practical Approach to Scale Pit
Pumping", Iron and Steel Engineer, 50, pp. 68-74 (May,
1973).
197. "Steelmen and Scientists Join Forces in the Pollution
Control Effort", 33 Magazine, 10, pp. 33-35 (February,
1972).
198. Stoner, L. B., "Waste Treatment Facilities for Jones
and Laughlin Steel Corporation Hennepin Works", Proceedings
of the 26th Industrial Waste Conference, Purdue University,
(1971) .
199. 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).
200. "Subsurface Disposal of Pickle Liquor", U.S..
Department of_ the Interior.
201. Symons, C. R., "Treatment of Cold Mill Wastewater by
Ultra-High-Rate Filtration", Wa£e£ Pollution Control
Federation, Journal, 43, pp. 2,280-2,286 (November, 1971).
202. Talbott, John A., "Building A Pollution Free Steel
Plant", Mechanical Engineering, 93, pp. 25-30 (January,
1971) .
203. "Technology the Key to Pollution Control", Metal
Progress, 98, N.6, pp. 54-57 (December, 1970).
204. 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).
205. Thompson, J. and Miller, V. J., "Role of Ion Exchange
in Treatment of Metal Finishing Wastes", Plating, 58, pp.
809812 (August, 1971) .
206. Thompson, Ronald J., "Water Pollution Control Program
at Armco's Middletown Works", Iron and Steel Engineer, 49,
pp. 43-48 (August, 1972).
544
-------
207. Tihansky, D. P., "A Cost Analysis of Waste Management
Association, 22, N.5, pp. 335-341 (May, 1972).
208. "Today's Pollution Control Practices in the American
Steel Industry", 33 Magazine, 10, N.I, pp. 33-36 (January,
1972) .
209. Toureene, Kendall W., "Wastewater Neutralization",
Steel Institute^ Chicago Regional Technical
.
Meeting, pp. 99-117 (October 15, 1970) .
210. "The Making, Shaping, and Treating of Steel", United
States Steel Corporation, Pittsburgh, Pennsylvania, 9th
Edition, 1971, 1,420 pages.
211. "Treatment of Wastewater-Waste Oil Mixtures", Federal
Water Pollution Control Administration, Water Pollution
Control Research Series, Program 12010 EZU, May, 1970, 137
pages.
212. "Up-Flow Filters Help Chicago Area Mine Mill Clean Its
Cooling Water", 33 Magazine, 10, N. 6, pp. 50-51 (June,
1972) .
213. U. S. Department of Commerce, Bureau of the Census,
Census of Manufacturers;, 1967, Washington, D. C.
214. Water and Sewage Works, 113, "Bethlehem Steel's Burns
Harbor Wastewater Treatment Plant", pp. 468-470 (December,
1966) .
215. U. S. Steel's Fair less Works, "Modifications to
Fairless Pickle Line Improves Strip Quality", Iron and Steel
Engineer, 48, p. 87 (November, 1971) .
216. "U. S. Steel's 'Texas Works' Built With Ecology in
Mind", Water and Sewage Works, 118, p. 241 (August, 1971).
217. Vorga, J. and Lownie, H. W. , "A System Analysis Study
of the Integrated Iron and Steel Industry", Battelle
Memorial Institute (May 15, 1969) .
218. Vasil'ev, V. I., et al, "Selection of Types of
Equipment for the Clarification of Neutralized Iron -
Containing Acidic Wastewater s" , Chemical Abstracts, 77, 4,
pp. 349 (1972) .
219. Vivian, Gordon, "Disposal of Cyanide Heat Treating
Wastes", Metal Progress, 98, N. 6, p. 61 (December, 1970).
545
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220. Walton, G. L., "Effluent Treatment in Steel Works",
Metal Finishing Journal, 18, pp. 276-279 (September, 1972).
221. "Water Pollutant or Reusable Resource?", Environmental
Science and Technology, 1, N.5, pp. 380-382 (May, 1970).
222. "Water Use in Manufacturing", 1967 Census of
Manufactures, U. S. Department of Commerce, Bureau of the
Census, MP67 (l)-7, April, 1971, 361 pages.
223. "Watkins Cyclopedia of the Steel Industry", Steel
Publications, Inc., Pittsburgh, Pennsylvania, 13th Edition,
1971, 533 pages.
224. Weinberg, H. I., "Inland Steel's New 80 In. Pickle
Line", Iron and Steel Engineer, 49, pp. 70-76 (January,
1972).
225. Welded Steel Tube Institute, Member Companies, p. 2
(1967) .
226. 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) .
227. "When it Comes to Pollution Control, Steel Isn't
Dawdling - It's Acting", 33 Magazine, 10, pp. 23-29
(January, 1972) .
228. Whither Goest Thou, U. S. Steel Industry?", 33
lazine, 9, pp. 36-55 (April, 1971) .
229. "Whither Goest Thou, U. S. Steel Industry?", 33
Magazine, 9, pp. 50-55 (May, 1971).
230. "Whither Goest Thou, U. S. Steel Industry?", 3_3
Magazine. 9, pp. 38-43 (June, 1971).
231. "Who's on First In Wide Hot Strip Mills", 3_3 Magazine,
8, pp. 88-101 (March, 1970).
232. Wiedemann, Chester R., "Control Considerations in
Washing, Painting, and Soluble Oil Removal", Metal Progress,
98, N.6, pp. 66-67 (December, 1970).
233. Wiedmann, H., "Regeneration of Pickling Hydrochloric
Acid by Liquid Anion Exchange", Chemical Abstracts, 76, p.
306 (1972) .
546
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234. Wight, Robert D., "Water System for an Integrated
Steel Plant", American Water Works Association Journal, 61,
pp. 432-435 (1969).
235. Wilthew, Robert M. and Davidson, Robert M.,
"Youngstown's 84 In. Hot Strip Mill", Iron and Steel
Engineer, 49, pp. 5363 (May, 1972).
236. Wittman, I. E. and Shephard, G. S., "Integrated Steel
Pickling Rinse Water Treatment System", Iron and Steel
Engineer, 49, pp. 69-71 (February, 1972).
237. "World's First Continuous Cold Mill Ready to Roll", 33
Magazine, 9, pp. 30-33 (April, 1971).
238. Wykoff, Richard H., "Major Filtration Development at
New Steel Mill", Water and Sewage Works, 117, pp. IW8-IW10
(July/August, 1970) .
239. Yunghahn, R. J., "Profitable Pollution Control",
Modern Metals, 26, p. 62 (July, 1970).
240. Zievers, J. F. and Novotry, "Recovery of Mixed Rinse
Water by Means of Ion Exchange", Plating, 58, N.5, pp. 482-
485 (May, 1971) .
241. Zievers, J. F., "Pressure Filtration of Clarifier
Under-Flow", Chemical Engineering Progress, 67, N.12, pp.
47-48 (December, 1971)7
242. Zievers, J. F., Grain, R. W., and Barclay, F. G.,
"Metal Finishing Wastes: Methods of Disposal", Plating, 57,
pp. 56-59 (January, 1970) .
243. 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).
547
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SECTION XIV
GLOSSARY
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.
gar. 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.
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.
Billet 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.
!i2P.!D- 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.
549
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Carbon Steel. Steel which owes its properties chiefly to
various percentages of carbon without substantial amounts of
other alloying elements.
Clarification . The process of removing undissolved
materials from a liquid by settling or filtration.
Coagulant. A substance that enhances the aggregation of
undissolved suspended matter.
£°i
-------
extruding into various finished or semi-finished products
such as plates, strips, pipes, bars, structural shapes,
billets, and special shapes.
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.
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 de surfacing.
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.
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 H%
dissolved carbon along with other impurities.
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 (Fe2O3) and magnetite (Fe3O4) .
Manipulator. A steel fingered device that seizes the bloom
and turns it so that all four sides will be kneaded evenly.
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 equipment 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, from,
or between work areas of a mill.
551
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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.
Pass. The movement of product once through a mill.
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.
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.
Polyelectrplvte. A substance that enhances the flocculation
mechanism.
Quenching. A process of rapid cooling from an elevated
temperature by contact with liquids, gases, or solids.
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.
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.
Scale. The by-product of hot rolling operations composed
primarily of various iron oxides.
552
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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.
SJsin 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.
Soaking Pit. 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 Eickle Liquor. The pickling solution that has
progressively become saturated with ferrous salts and the
bath has become ineffective in removing scale.
Steel. Any alloy of iron containing less than 1% carbon.
Iron that has been refined.
Strj.p. 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.
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.
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Temper Mill. 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.
Universal Mill. A reversing mill, which has vertical and
horizontal rolls, used for hot rolling steel.
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.
Wetting Ag_e_nt. An organic compound which lowers the
interfacial tension between the steel and the liquid.
554
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TABLE
METRIC UNITS
CONVERSION TABLE
flJLTIPLY (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
i
gallon,
gallon/minute
galjjan/ton
horsepower
inches
inches of mercury
million gallons/day
mile
pounds
pound/square inch(gauge)
pounds/ton
square feet
square inches
tons(short)
yard
ABBREVIATION
CONVERSION
ABBREVIATION
TO OBTAIN (METRIC UNITS)
METRIC UNIT
ac
ac ft
BTU
BTU/cu
d BTU/lb
cfm
cfs
cu ft
cu ft
cu in
oF
ft
gal
gpm
gal/t
hp
in
in Hg
mgd
mi
Ib
psig
Ib/t
sq ft
sq in
t
y
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+D*
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 in/day
km
kg
atm
kg/kkg
sq m
sq cm
kkg
m
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
1 iters/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
555
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TABLE 112
CLASSIFICATION BY SUBCATEGORY
Product or Operation
Abrasive Cleaning
Armor Plate
Axles
Billets
Billet Casting
Black Plate
Bloom Casting
Channels
Direct Reduction
Fence Posts
Forgings
Frogs
Description
Removal of oxides via treat-
ment with abrasives
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
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
Applicable Subcategory
No regulation required,
single operation gener-
ates no wastewaters
Hot Forming-Flat-Plate
Hot Forming-Section
Hot Forming-Section
Continuous Casting
Cold Rolling-Direct
Application; Combina-
tion; or Recirculation
Continuous Casting
No present regulation
Hot Forming-Primary
Hot Forming-Section
557
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Product or Operation Description
Gun Forgings See Forgings
Hoops
Iron from Direct
Reduction Units
I-Beams
Nails & Staples
Nut Rods
Pilings
Rails & Rail Joints
Rings
Rounds
Sheet Pilings
Slab Casting
Spiegeleisen
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
Fasteners made from wire or
small rods, sometimes coated
before shipment
Hot rolled shapes from which
nuts and bolts are formed
See Sheet Pilings
Hot rolled shapes used for
laying tracks of various
types
Hot rolled product cut from an
ingot or round, center punched
out, and rolled into a con-
tinuous 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 conversion of
molten steel directly into
slabs
A ferroalloy containing
16-28% Mn, and less than
6.5% carbon
Applicable Subcategory
Hot Forming-Flat-Hot
Strip & Sheet
No present regulation
Forming is a Dry Opera-
tion; for Coating - See
Hot or Cold Coating
subcategories
Hot Forming-Section
Hot Forming-Section
Hot Forming-Section
Hot Forming-Section
Hot Forming-Section
Continuous Casting
Blast Furnace-Ferro-
manganese
558
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Product or Operation
Spikes & Chains
Structural Shapes
Tie Plates
Well Casings &
Couplings
Wheels, Forged
Wheels, Forged and
Rolled
Wire & Wire
Products
Description
Hot formed shapes made from
rods or small bars in a
variety of sizes
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
Products made by drawing rods
through a series of dies to
greatly reduce diameters.
Product may be pickled and/or
coated prior to shipment.
Applicable Subcategory
Hot Forming-Section
Hot Forming-Section
Hot Forming-Section
Pipe & Tube
Hot Forming-Section
Drawing is a Dry Opera-
tion; For other wire-
making processes, see
Pickling, Hot Coating
or Cold Coating Sub-
categories
559
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