EPA-440/1-75/048
Group I, Phase II
        Development Document for
Advanced Notice of Proposed Rule Making
  for Effluent Limitations Guidelines and
    New Source Periormance Standards
                  for the
        Hot Forming and Cold Finishing


              Segment of the

          Iron and Steel Manufacturing

          Point Source Category
                         \
                         Z.
 UNITED STATES ENVIRONMENTAL PROTECTION AGENCY

                 AUGUST 1975

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         DEVELOPMENT DOCUMENT

                  for

    EFFLUENT LIMITATIONS GUIDELINES

                  and

   NEW SOURCE PERFORMANCE STANDARDS

                for the

 HOT FORMING & COLD FINISHING SEGMENT

                of the

     IRON AND STEEL MANUFACTURING

         POINT SOURCE CATEGORY
           Russell E. Train
             Administrator

             James L. Agee
   Assistant Administrator for Water
        and Hazardous Materials
              Allen Cywin
Director, Effluent Guidelines Division

           Edward L. Dulaney
            Project Officer

           John G. Williams
       Assistant Project Officer
             August, 1975

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

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                                                      DRAFT
                         ABSTRACT
This document presents  the findings of an extensive study of
the hot forming  and  cold  finishing operations  of  the  iron
and  steel   industry for the purpose of developing effluent
limitations  guidelines, Federal  standards  of  performance,
and  pretreatment  standards for this segment of the industry
to implement Sections 304, 306, and 307 of the "Act".

Effluent limitations guidelines contained herein  set   forth
the  effluent  quality  attainable through the application of
the best practicable control technology currently  available
(BPCTCA)  and  the  best  available  technology economically
achievable  (BATEA) which  must be achieved by existing   point
sources  by   July  1,   1977, and July 1, 1983, respectively.
The  standards  of  performance  for  new   sources   (NSPS)
contained  herein  set  forth  the effluent quality which is
achievable  through the  application  of  the  best  available
demonstrated    control   technology   (BADCT),   processes,
operating methods, or other alternatives.

Supporting   data  and   rationale  for  development  of   the
effluent limitations guidelines and standards of performance
are contained in this report.
                              i i i

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                          CONTENTS


Section                                                  Page

I        CONCLUSIONS                                       1

II       RECOMMENDATIONS                                   3
           BPCTCA Effluent Limitations                     3
           BATEA Effluent Limitations                      11
           NSPS Effluent Limitations                       19

III      INTRODUCTION                                      27
           Purpose And Authority                           27
           Methods Used To Develop Limitations             28
           General Description Of The Industry             29
           General Description Of The Operations            37

IV       INDUSTRY SUBCATEGORIZATION                        45
           Description Of The Operations                   45
             Hot Forming Primary                           46
             Hot Forming Section                           49
             Hot Forming Flat                              53
             Pipe And Tube                                 60
             Pickling - Sulfuric Acid - Batch              68
             Pickling - Hydrochloric Acid                  72
             Cold Rolling                                  77
             Hot Coatings - Galvanizing                    84
             Hot Coatings - Terne                          85
           Rationale For Categorization - Factors
            Considered                                     93
           Selection Of Candidate Plants For Visits         105

V        WATER USE AND WASTE CHARACTERIZATION              123
             Hot Forming Primary                           124
             Hot Forming Section                           125
             Hot Forming Flat                              125
             Pipe And Tube                                 127
             Pickling - Sulfuric Acid - Batch              132
             Pickling - Hydrochloric Acid                  132
             Cold Rolling                                  134
             Hot Coatings - Galvanizing                    141
             Hot Coatings - Terne                          142
             Miscellaneous Runoffs                         142
             Maintenance Department Wastes                 149
           Noncontact Cooling Water                        150
           Classification Of Water Used In The Steel
            Industry                                       153
           Wastes From Water, Steam And Electric  Power
            Generation                                     153
                               v

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           Wastes Generated From Water Treatment
            Operations                                     163

VI       SELECTION OF POLLUTANT PARAMETERS                 173
           Broad List Of Pollutants                        173
           Rationale For Selection Of Control Parameters    173
           Selection Of Critical Parameters By Operations   180
           Environmental Impact Of Pollutants              181

VII      CONTROL AND TREATMENT TECHNOLOGY                  191
           Range Of Technology And Current Practice        191
             Hot Forming Primary                           191
             Hot Forming Section                           205
             Hot Forming Flat - Plate Mills                206
             Hot Forming Flat - Hot Strip And Sheet Mills   214
           Pipe And Tube Mills - Hot Worked                217
             Butt Welded Pipe Mills                        217
             Electric Resistance Welded Pipe Mills         221
             Seamless Tube Mills                           221
           Pipe And Tube Mills - Cold Worked               226
           Pickling                                        226
             Disposal Processes                            226
             Recycling Processes                           233
             Crystallization Processes                     234
             Spray Roaster Processes                       238
             Fluid-Bed Processes                           239
             Sulfuric Acid Processes                       241
             Hydrochloric Acid Processes                   241
           Cold Rolling Operations                         273
           Coating Operations                              275
           Specific Parameter Discussion                   288
           Reference Level Of Treatment                    312

VIII     COST, ENERGY, AND NON-WATER QUALITY ASPECTS       315
           Introduction                                    315
           Costs                                           315
           Basis Of Cost Estimates                         317
           Reference Level And Intermediate Technology, Energy
            And Non-Water Impact By Subcategory            320
           Advanced Technology, Energy, And Non-
            Water Impact By Subcategory                    326

IX       BPCTCA EFFLUENT LIMITATIONS GUIDELINES            369
           Rationale For Selection Of BPCTCA               370
             Size, Age, Land Availability Considerations   370
             Consideration Of Processes Employed           370
             Consideration Of Non-Water Quality
              Environmental Impact                         371
             Impact On Energy Requirements                 371
             Engineering Aspects Of The Application Of
                             VI

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              Control Techniques                           372
             Consideration Of Process Changes              372
             Consideration Of Cost Versus Effluent
              Reduction Benefits                           372
           Identification And Discussion Of BPCTCA
            Effluent Limitations Guidelines By
            Subcategory                                    373
           Treatment Models                                378

X        BATEA EFFLUENT LIMITATIONS GUIDELINES             441
           Rationale For The Selection Of BATEA            442
             Size, Age, Land Availability Considerations   442
             Consideration Of Processes Employed           442
             Consideration Of Non-Water Quality
              Environmental Impact                         443
             Impact On Energy Requirements                 444
             Consideration Of Process Changes              444
             Consideration Of Cost Of Achieving BATEA
              Effluent Limitations Guidelines              444
             Identification And Discussion Of BATEA
              Effluent Limitations Guidelines By
              Subcategory                                  445
             Cost Versus Effluent Reduction Benefits       446
           Treatment Models                                450
           Cost Effective Diagrams                         451

XI       NEW SOURCE PERFORMANCE STANDARDS (NSPS)            525
           Introduction                                    525
           NSPS Discharge Standard By Subcategory          525

XII      ACKNOWLEDGEMENTS                                  527

XIII     REFERENCES                                        529

XIV      GLOSSARY                                          549
                               •V13.

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                              FIGURES

                    OMIT THE FOLLOWING FIGURES

Number                         Ti tl e

  15     Sulfonic Acid Tin Line Cold Coating Process
         Flow Diagram

  16     Cold Coating Halogen Tin Line Process Flow
         Di agram

  17     Cold Coating Alkaline Tin Line Process Flow
         Diagram

  18     Cold Coating Chrome Plate Line Process Flow
         Diagram

  19     Cold Coating Zinc Plate Line Process Flow
         Diagram
                                   IX

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                                                        DRAFT
                         FIGURES
Number                    Title                      Page

  1       Hot  Forming-Cold Finishing Process               38
           Flow Diagram

  2       Hot  Forming Type I Process Flow Diagram          50

  3       Hot  Forming Type III Process Flow Diagram        54

  3A     Wire-Making System Process Flow Diagram          55

  4       Hot  Forming Type II Process Flow Diagram         57

  5       Butt Weld Pipe Mill Seamless Tube Mill
           Process Flow Diagram                          61

  5A     Tubing Mill Electric Resistance Welded
           Process Flow Diagram                          62

  6       Continuous Strip Pickling Hydrochloric Acid
           Process Flow Diagram                          69

  6A     Continuous Strip Pickling Sulfuric  Acid
           Process Flow Diagram                          70

  7       Batch Pickling Sulfuric Acid Process
           Flow Diagram                                  71

  8       Cold Rolling Mill Type I Process Flow
           Diagram                                       80

  9       Flat Products General Process Flow  Diagram       81

  10     Hot  Coating Galvanizing (ZN) Type I
           Process Flow Diagram                          86

  11     Hot  Coating Galvanizing (ZN) Type II USS
           Steel  Process
           Process Flow Diagram                          87

  12     Hot  Coating Galvanizing (ZN) Type II
           Process Flow Diagram                          88

  13     Hot  Coating Terne Plate Process Flow
           Diagram                                       90

  14     Hot  Coating Aluminizing Process Flow             92

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                                FIGURES
DRAFT
NUMBER                           TITLE                       PAGE
            Diagram

   15     Sulfonic Acid Tin  Line Cold Coating
            Process Flow Diagram                               N/A

   16     Cold Coating Halogen Tin Line Process
            Flow Diagram                                      N/A

   17     Cold Coating Alkaline Tin Line Process
            Flow Diagram                                      N/A

   18     Cold Coating Chrome Plate Line Process
            Flow Diagram                                      N/A

   19     Cold Coating Zinc  Plate Line Process
            Flow Diagram                                      N/A

   20     Typical Sources Of Treatment Makeup Water
            To Steel  Industry Subcategory Processes            151

   21     Hot Forming Wastewater Treatment System
            Water Flow Diagram                                 200

   22     Hot Forming Wastewater Treatment System
            Water Flow Diagram                                 202

   23     Hot Forming Wastewater Treatment System
            Water Flow Diagram                                 203

   24     Hot Forming Wastewater Treatment System
            Water Flow Diagram                                 204

   25     Hot Forming Wastewater Treatment System
            Water Flow Diagram                                 209

   26     Hot Forming Section Wastewater Treatment
            System Water Flow Diagram                          210

   27     Bar Mills Wastewater Treatment System
            Water Flow Diagram                                 211

   28     Hot Forming Wastewater Treatment System
            Water Flow Diagram                                 212

   29     Combined Wire, Rod, Pickling Wastewater
            Treatment System Water Flow Diagram                213

   30     Hot Strip Mill Wastewater Treatment
            System Water Flow Diagram                          218

                                   xi

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                                FIGURE
NUMBER                           TITLE                       PAGE
   31      Hot Rolling Mill Wastewater Treatment
            System Water Flow Diagram                          215
   32      Hot Forming Wastewater Treatment System
            Water Flow Diagram                                 205
   33      Hot Forming Wastewater Treatment System
            Water Flow Diagram                                 219
   34      Hot Forming Wastewater Treatment System
            Water Flow Diagram                                 220
   35      Pipe and Tube Mill Wastewater Treatment
            System Water Flow Diagram                          224
   36      Pipe and Tube Mill Wastewater Treatment
            System Water Flow Diagram                          225
   37      Pipe and Tube Mill Wastewater Treatment
            System Water Flow Diagram                          227
   38      Pipe and Tube Mill Wastewater Treatment
            System Water Flow Diagram                          228
   39      Pipe and Tube Mill Wastewater Treatment
            System Water Flow Diagram                          229
   40      Sulfuric Acid Recovery Process Flow
            Diagram                                            236
   41      Pickling and Acid Recovery Process
            Flow Diagram                                       237
   42      HC1 Regeneration Type I Process Flow
            Diagram                                            240
   43      HC1 Regeneration Type II Fluid Bed
            Roaster  Process Flow Diagram                       242
   44      HC1 Regeneration Type III Wet Chemical
            Process
            Process  Flow Diagram                               244
   45      Sulfuric Acid Pickling and Acid Recovery
            Operation Wastewater Treatment System
            Water Flow Diagram                                 249
   46      Sulfuric Acid Recovery Wastewater Treat-
            ment System Water Flow Diagram                     25°
                                  xii
                                                           DRAFT

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                                 FIGURES                      DRAFT

NUMBER                            TITLE                        PAGE

   47      Batch H2S04. Pickling and Acid Recovery
            Wastewater Treatment  System Water
            Flow Diagram                                        251

   48      Sulfuric Acid Pickling  and Recovery
            Batch Operation Wastewater Treatment
            System Water  Flow Diagram                           252

   49      H£S04_ Pickling  Line Wastewater Treatment
            System Water  Flow Diagram                           253

   50      Batch H£S04_ Pickling Wastewater Treatment
            System Water  Flow Diagram                           254

   51      Continuous  Strip Pickling Wastewater
            Treatment System Water Flow Diagram                 256

   52      HC1  Pickling Line Wastewater Treatment
            System Water  Flow Diagram                           262

   53      HC1  Pickling Line Wastewater Treatment
            System Water  Flow Diagram                           263

   54      Hot  Coating Line-Galvanizing Wastewater
            Treatment System Water Flow Diagram                 264

   55      Continuous  HC1  Pickling and Recovery
            Wastewater Treatment  System Water
            Flow Diagram                                        265

   56      Cold Forming and HC1 Pickling Waste-
            water Treatment System Water Flow
            Diagram                                             266

   57      HC1  Regeneration Wastewater Treatment
            System Water  Flow Diagram                           267

   58      HC1  Pickle  Line Wastewater Treatment
            System Water  Flow Diagram                           268

   59      HC1  Regeneration Wastewater Treatment
            System Water  Flow Diagram                           269

   60      HC1  Pickling Line Wastewater Treatment
            System Water  Flow Diagram                           270

   61      HC1  Pickling Line Wastewater Treatment
            System Water  Flow Diagram                           271

   62      Cold Rolling and HC1 Pickling Waste-


                                  xiii

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                                 FIGURES

NUMBER                            TITLE
            water Treatment System Water Flow
            Diagram                                             272

   63     Cold Rolling Wastewater Treatment
            System Water Flow Diagram                           277

   64     Cold Rolling Wastewater Treatment
            System Water Flow Diagram                           278

   65     Cold Rolling Wastewater Treatment
            System Water Flow Diagram                           279

   66     Hot and Cold Coating Lines Wastewater
            Treatment System Water Flow Diagram                 284

   67     Hot Coating Line Wastewater Treatment
            System Water Flow Diagram                           285

   68     Hot Coating - Terne Plating Waste-
            water Treatment System Water Flow
            Diagram                                             286

   69     Hot Coating - Terne Plating Waste-
            water Treatment System Water Flow
            Diagram                                             287

   70     Cold Coating Lines - Tin and Chromium
            Wastewater Treatment System Water
            Flow Diagram                                        289

   71     Cold Coating - Tin or Chromium Waste-
            water Treatment System Water Flow
            Diagram                                             290

   72     Cold Coating Lines - Tin and Chromium
            Wastewater Treatment System Water
            Flow Diagram                                        291

   73     Cold Coating Line - Tin Wastewater
            Treatment System Water Flow Diagram                 292

   74     Hot Forming/Primary Subcategory
            BPCTCA Model                                        378

   75     Hot Forming/Section Subcategory
            BPCTCA Model                                        381

   76     Hot Forming/Flat-Hot Strip and Sheet
            Subcategory  BPCTCA Model                           385
                                    xiv

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                                FIGURES                     DRAFT

NUMBER                           TITLE                       PAGE

    77     Hot Forming/Flat-Plate Subcategory
            BPCTCA Model                                      387

    78     Pipe And Tube Subcategory
            BPCTCA Model                                      391

    79     Pickling/H2S04_ Batch - Concentrated
            Subcategory  BPCTCA Model                          394

    80     Pickling/H2S04_ Batch - Rinse
            Subcategory  BPCTCA Model                          398

    81     Pickling/HCL - Concentrated  - Alternate I
            Subcategory  BPCTCA Model                          401

    82     Pickling/HCL Rinse Alternate I
            Subcategory  BPCTCA Model                          402

    83     Pickling/HCL - Concentrates  And  Rinses
            Alternate II Subcategory  BPCTCA Model             403

    84     Cold Rolling - Recirculation Subcategory
            BPCTCA Model                                      414

    85     Cold Rolling - Combination Subcategory
            BPCTCA Model                                      417

    86     Cold Rolling - Direct Application
            Subcategory   BPCTCA Model                        420

    87     Hot Coating/Galvanizing Subcategory
            BPCTCA Model                                      423

    88     Hot Coatings - Terne Subcategory
            BPCTCA Model                                      427

    89     Non-Contact Cooling Water Slowdown
            Subcategory  BPCTCA Model                          432

    90-1   Utility Area Wastewater System Coke Making,
            Degassing And Pickling Concentrates
            Subcategory  BPCTCA Model                          434

    90-2   Utility Area Wastewater System Hot And
            Cold Coatings Subcategories
            BPCTCA Model                                      435

    90-3   Utility Area Wastewater System Steel-
            Making, Casting, Hot Forming,  Cold
            Rolling And Pickling - All Rinse Sub-


                                    xv

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                                 FIGURES

NUMBER                            TITLE                        	
            categories  BPCTCA Model                            436

   91     Maintenance Department Wastes Subcategory
            BPCTCA Model                                        438

   92A    Hot Forming/Primary Subcategory
            BATEA Model                                         450

   92B    Model Cost Effectiveness Diagram
            Hot Forming - Primary Subcategory                   451

   93A    Hot Forming/Section Subcategory
            BATEA Model                                         454

   93B    Model Cost Effectiveness Diagram
            Hot Forming - Section Subcategory                   455

   94A    Hot Forming/Flat - Hot Strip And
            Sheet Subcategory  BATEA Model                      459

   94B    Model Cost Effectiveness Diagram
            Hot Forming - Flat - Hot Strip And
            Sheet Subcategory                                   460

   95A    Hot Forming/Flat - Plate Subcategory
            BATEA Model                                         462

   95B    Model Cost Effectiveness Diagram
            Hot Forming - Flat Plate Subcategory                463

   96A    Pipe And Tube Subcategory  BATEA Model                467

   96B    Model Cost Effectiveness Diagram
            Pipe And Tubes Subcategory                          468

   97A    Pickling/H2S04_ - Batch - Concentrated
            Subcategory  BATEA Model                            472

   97B    Model Cost Effectiveness Diagram
            Pickling - Sulfuric Acid - Batch -
            Concentrated Subcategory                            473

   98A    Pickling/H2SO£- Batch - Rinse
            Subcategory  BATEA Model                            475

   98B    Model Cost Effectiveness Diagram
            Pickling - Sulfuric Acid - Batch -
            Rinse Subcategory                                   476

   99A    Pickling/HCL - Concentrated - Alternate  I
                                    xvi

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                                FIGURES

NUMBER                           TITLE                      r£/£& A W"f
—                                                      DRAFT

            Subcategory  BATEA Model                           480

   99B    Model Cost Effectiveness  Diagram
            Pickling Hydrochloric Acid  - Concen-
            trated Subcategory - Alternate  I                   481

   100A   Pickling/HCL - Rinse - Alternate  I
            Subcategory  BATEA Model                           488

   100B   Model Cost Effectiveness  Diagram
            Pickling - Hydrochloric Acid -  Rinse
            Subcategory - Alternate I                          489

   101A   Pickling/HCL Concentrates And Rinses
            Alternate II Subcategory  BATEA Model              484

   101B   Model Cost Effectiveness  Diagram
            Pickling - Hydrochloric Acid -  Concen-
            trated And Rinse - Subcategory  -
            Alternate II                                      485

   102A   Cold Rolling - Recirculation
            Subcategory  BATEA Model                           492

   102B   Model Cost Effectiveness  Diagram
            Cold Rolling - Recirculation Subcategory           493

   103A   Cold Rolling - Combination Subcategory
            BATEA Model                                       495

   103B   Model Cost Effectiveness  Diagram
            Cold Rolling - Combination  Subcategory             496

   104A   Cold Rolling - Direct Application
            Subcategory  BATEA Model                           498

   104B   Model Cost Effectiveness  Diagram
            Cold Rolling - Direct Application
            Subcategory                                       499

   105A   Hot Coatings - Galvanizing Subcategory
            BATEA Model                                       502

   105B   Model Cost Effectiveness  Diagram
            Hot Coating - Galvanizing -
            Subcategory                                       503

   106A   Hot Coatings - Terne Subcategory
            BATEA Model                                       507
                                  xvn

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                                 FIGURES

NUMBER                            TITLE

   106B   Model Cost Effectiveness Diagram
            Hot Coating - Terne Subcategory                     508

   107    Miscellaneous Runoffs Subcategory
            BATEA Model                                         510

   108    Non-Contact Cooling Water Slowdown
            Subcategory  BATEA Model                            515

   109-1  Utility Area Wastewater System Coke
            Making, Degassing And Pickling Concen-
            trates Subcategory  BATEA Model                     517

   109-2  Utility Area Wastewater System Hot And
            Cold Coatings Subcategories
            BATEA Model                                         518

   109-3  Utility Area Wastewater System Steel-
            Making, Casting, Hot Forming Cold
            Rolling And Pickling - All  Rinse
            Subcategories  BATEA Model                          519

   110    Maintenance Department Wastes Sub-
            category  BATEA Model                               520
                                  xviii

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                                                            DRAFT
                              TABLES
                      OMIT THE FOLLOWING TABLES

NUMBER                         TITLE
 15     Plant Age and Size - Cold Coatings  - Tin
 16     Plant Age and Size - Cold Coatings  - Chrome
 36     Characteristics of Cold Coatings -  Halogen - Tin Plant Wastes
 37     Characteristics of Cold Coatings -  Sulfonic - Tin Plant Wastes
 38     Characteristics of Cold Coatings -  Alkaline - Tin Plant Wastes
 39     Characteristics of Cold Coatings -  Chrome Plant Wastes
 47     Cold Coatings - Chrome and Plating  Operation Parameters
 61     Water Effluent Treatment Costs - Cold Coatings - Tin
 62     Water Effleunt Treatment Costs - Cold Coatings - Chrome
                                   xix

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                                                      DRAF
                           TABLES

NUMBER                      TITLE                        PAGE

   1    United States Annual Steel  Ingot Ton
        Production                                        31

   2    Product Classification by SIC Code  (3312)          32

   3    Product Classification by SIC Code  (3315)          34

   4    Product Classification by SIC Code  (3316)          35

   5    Product Classification by SIC Code  (3317)          36

   6    Plant Age and Size  - Hot Forming Primary           94

   7    Plant Age and Size  - Hot Forming Section           95

   8    Plant Age and Size  - Hot Forming Flat              96

   9    Plant Age and Size  - Pipe and Tubes                97

  10    Plant Age and Size  - Pickling - Sulfuric
        Acid - Batch                                      98

  11    Plant Age and Size  - Pickling - Hydrochloric
        Acid - Batch and  Continuous                        99

  12    Plant Age and Size  - Cold Rolling                 100

  13    Plant Age and Size  - Hot Coatings - Galvanizing   101

  14    Plant Age and Size  - Hot Coatings - Terne         102

  15    Plant Age and Size  - Cold Coatings - Tin          103

  16    Plant Age and Size  - Cold Coatings - Chrome       104

  17    Subcategorization of the Hot Forming and
        Cold Finishing Operations                         106

  18    Rationale for Plant Selections                    107

  19    Industrial Categorization and Survey
        Requirements for  Hot Forming and Cold
        Finishing Operations                             120

  20    Characteristics of  Hot Forming Primary
        Plant Wastes                                     126
                               XX

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                                                     DRAFT
                       TABLES (Cont'd)

NUMBER                      TITLE                        PAGE

  21    Characteristics of  Hot Forming Section
        Plant Wastes                                      126

  22    Characteristics of  Hot Forming Flat
        Plant Wastes                                      128

  23    Characteristics of  Pipe and Tubes  - Hot Worked
        Plant Wastes                                      128

  24    Characteristics of  Pipe and Tubes  - Cold
        Worked Plant Wastes                               131

  25    Characteristics of  Pickling - Sulfuric Acid
        Batch Plant Wastes  - Spent Pickle  Liquor           131

  26    Characteristics of  Pickling - Sulfuric Acid
        Batch Plant Wastes  - Rinses                        135

  27    Characteristics of  Pickling - Hydrochloric Acid
        Batch Plant Wastes  - Spent Pickle  Liquor           136

  28    Characteristics of  Pickling - Hydrochloric Acid
        Batch Plant Wastes  - Rinses                        136

  29    Characteristics of  Pickling - Hydrochloric Acid
        Continuous  Plant Wastes - Spent Pickle Liquor      137

  30    Characteristics of  Pickling - Hydrochloric Acid
        Continuous  Plant Wastes - Regeneration             137
        Absorber  Scrubber

  31    Characteristics -of  Pickling - Hydrochloric Acid
        Continuous  Plant Wastes - Rinses                   138

  32    Characteristics of  Pickling - Hydrochloric Acid
        Continuous  Plant Wastes - Fume Hood Scrubbers      138

  33    Characteristics of  Cold Rolling Plant Wastes       140

  34    Characteristics of  Hot  Coatings -  Galvanizing      140
        Plant Wastes

  35    Characteristics of  Hot  Coatings -  Terne Plate
        Plant Wastes                                      143

  36    Characteristics of  Cold Coatings - Halogen
        Tin  Plant Wastes
                           XXI

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                                                      DRAFT
                       TABLES  (Cont'd)

NUiMBER                      TITLE                        PAGE

  37    Characteristics of  Cold  Coatings - Sulfonic
        Tin Plant Wastes                                  N/A

  38    Characteristics of  Cold  Coatings - Alkaline
        Tin Plant Wastes                                  N/A

  39    Characteristics of  Cold  Coatings - Chrome
        Plant Wastes                                       N/A

  40    Industry Group - Water Intake                      159

  41    Hot Forming Operation Parameters                   174

  42    Pipe and Tubes Operation Parameters                174

  43    Pickling Operation  Parameters                      175

  44    Cold Rolling  Operation Parameters                  176

  45    Hot Coatings  - Galvanizing Operation
        Parameters                                        177

  46    Hot Coatings  - Terne Plate Operation
        Parameters
                                                          178
  47    Cold Coatings  -  Chrome  and Plating
        Operation Parameters                               179

  48    Wastewater Treatment  Practices of Plants
        Visited in Study                                  192

  49    Water Effluent Treatment  Costs - Hot Forming
        Primary                                           199

  50    Water Effluent Treatment  Costs - Hot Forming
        Section                                           207

  51    Water Effluent Treatment  Costs - Hot Forming
        Flat

  52    Water Effluent Treatment  Costs - Pipe and
        Tubes                                             222

  53    Water Effluent Treatment  Costs - Pickling -
        Sulfuric Acid  -  Concentrates                       246
                            XXII

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                                                     DRAF
                       TABLES (Cont'd)

NUMBER                      TITLE                        PAGE

  54    Water Effluent Treatment Costs  -  Pickling  -
        Sulfuric Acid - Rinses                            247

  55    Water Effluent Treatment Costs  -  Pickling  -
        Continuous Sulfuric Acid                          255

  56    Water Effluent Treatment Costs  -  Pickling  -
        Hydrochloric Acid - Concentrates                   258

  57    Water Effluent Treatment Costs  -  Pickling  -
        Hydrochloric Acid - Rinses                         260

  58    Water Effluent Treatment Costs  -  Cold  Rolling      276

  59    Water Effluent Treatment Costs  -  Hot Coatings  -
        Galvanizing                                       282

  60    Water Effluent Treatment Costs  -  Hot Coatings  -
        Terne Plate                                       283

  61    Water Effluent Treatment Costs  -  Cold  Coatings -
        Tin                                               N/A

  62    Water Effluent Treatment Costs  -  Cold  Coatings -
        Chrome                                            N/A

  63    Control and Treatment Technology  -  Hot Forming
        Primary                                           331

  64    Control and Treatment Technology  -  Hot Forming
        Section                                           334

  65    Control and Treatment Technology  -  Hot Forming
        Flat                                              337

  66    Control and Treatment Technology  -  Pipe  and
        Tubes                                             341

  67    Control and Treatment Technology  -  Pickling  -
        Sulfuric Acid - Batch Concentrates                 344

  68    Control and Treatment Technology  -  Pickling  -
        Sulfuric Acid - Rinses                            347

  69    Control and Treatment Technology  -  Pickling  -
        Hydrochloric Acid - Concentrates  -  Alternate I    350
                            XXIII

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                                                      DRA
                       TABLES (Cont'd)

NUMBER                      TITLE                        PAGE

  70    Control and Treatment Technology - Pickling -     353
        Hydrochloric Acid - Rinses - Alternate I

  71    Control and Treatment Technology - Pickling -
        Hydrochloric Acid - Concentrates and Rinses -
        Alternate II                                      355

  72    Control and Treatment Technology - Cold Rolling -
        Recirculation                                     357

  73    Control and Treatment Technology - Cold Rolling -
        Combination                                       359

  74    Control and Treatment Technology - Cold Rolling -
        Direct Application                                361

  75    Control and Treatment Technology - Hot Coatings -
        Galvanizing                                       363

  76    Control and Treatment Technology - Hot Coatings -
        Terne                                             366

  77    Effluent Limitations Guidelines - Hot Forming
        Primary - BPCTCA                                  377

  78    Effluent Limitations Guidelines - Hot Forming
        Section - BPCTCA                                  38°

  79    Effluent Limitations Guidelines - Hot Forming
        Flat - Hot Strip and Sheet - BPCTCA               384

  80    Effluent Limitations Guidelines - Hot Forming
        Flat - Plate - BPCTCA                             386

  81    Effluent Limitations Guidelines - Pipe and
        Tubes - BPCTCA                                    390

  82    Effluent Limitations Guidelines - Pickling -
        Sulfuric Acid - Batch Concentrates - BPCTCA       393

  83    Effluent Limitations Guidelines - Pickling -
        Sulfuric Acid - Batch Rinses -  BPCTCA             397

  84    Effluent Limitations Guidelines - Pickling -
        Hydrochloric Acid - Concentrates - BPCTCA         400
                            XXIV

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                                                     DRAFT
                       TABLES (Cont'd)

NUMBER                      TITLE                         PAGE

  85    Effluent Limitations Guidelines  -  Pickling  -       404
        Hydrochloric Acid - Rinses  -  BPCTCA

  86    Effluent Limitations Guidelines  -  Pickling  -
        Hydrochloric Acid - Concentrates and  Rinses -
        BPCTCA                                            410

  87    Effluent Limitations Guidelines  -  Cold Rolling -
        Recirculation - BPCTCA                            405

  88    Effluent Limitations Guidelines  -  Cold Rolling -
        Combination - BPCTCA                              413

  89    Effluent Limitations Guidelines  -  Cold Rolling -
        Direct Application - BPCTCA                       416

  90    Effluent Limitations Guidelines  -  Hot Coatings -
        Galvanizing - BPCTCA                              419

  91    Effluent Limitations Guidelines  -  Hot Coatings -
        Terne - BPCTCA                                    422

  92    Effluent Limitations Guidelines  -  Hot Forming
        Primary - BATEA                                   426

  93    Effluent Limitations Guidelines  -  Hot Forming
        Section - BATEA                                   449

  94    Effluent Limitations Guidelines  -  Hot Forming
        Flat - Hot Strip and Sheet  -  BATEA                453

  95    Effluent Limitations Guidelines  -  Hot Forming
        Flat - Plate - BATEA                              458

  96    Effluent Limitations Guidelines  -  Pipe and
        Tubes - BATEA                                     461

  97    Effluent Limitations Guidelines  -  Pickling  -
        Sulfuric Acid - Batch Concentrates -  BATEA         466

  98    Effluent Limitations Guidelines  -  Pickling  -
        Sulfuric Acid - Batch Rinses  - BATEA               471

  99    Effluent Limitations Guidelines  -  Pickling  -
        Hydrochloric Acid - Concentrates - BATEA           474
                            XXV

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                                                        DRAFT
                        TABLES (Cont'd)

NUMBER                       TITLE                        PAGE

 100    Effluent Limitations Guidelines - Pickling -
        Hydrochloric Acid  -  Rinses - BATEA                479

 101    Effluent Limitations Guidelines - Pickling -
        Hydrochloric Acid  -  Concentrates and Rinses -
        BATEA                                              487

 102    Effluent Limitations Guidelines - Cold Rolling -
        Recirculation  - BATEA                             483

 103    Effluent Limitations Guidelines - Cold Rolling -
        Combination -  BATEA                                491

 104    Effluent Limitations Guidelines - Cold Rolling -
        Direct Application - BATEA                        494

 105    Effluent Limitations Guidelines - Hot Coatings -
        Galvanizing -  BATEA                                497

 106    Effluent Limitations Guidelines - Hot Coatings -
        Terne - BATEA                                      501

 107    Hot Forming and Cold Finishing Operations
        Projected Total Costs for Related Subcategories   506

 108    Non-Process Operations Projected Total Costs
        for Related Categories and Subcategories          522

 109    Non-Process Operations - Projected Total Costs For Related
        Categories and Subcategories                           523

 110    Hot Forming - Cold Finishing Operations - Projected Total
        Costs for Related  Categories and Subcategories            524

 111    Metric Units - Conversion Table                         555

 112    Classification by  Subcategory                          557
                            XXVI

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                          SECTION I

                         CONCLUSIONS

For the purpose  of  establishing  effluent  guidelines  and
standards  of  performance  for  the  hot  forming  and cold
finishing operations of the iron  and  steel  industry,  the
industry was divided into subcategories as follows:

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-Batch and Continuous
S.  Cold Rolling
T.  Hot Coat-Galvanizing
U.  Hot Coat-Terne
V.  Miscellaneous Runoffs
W.  Cooling Water Slowdown
X.  Utility Slowdown
Y.  Maintenance Department Wastes
Z.  Central Treatment

NOTE: Subcategories A through L relate to the Steelmaking
      Segment which was discussed in an earlier Development
      Document, EPA-440/l-74-024-a.

The selection of these subcategories was based upon distinct
differences  in  type  of products produced, production pro-
cesses, raw materials used,  wastewater  volumes  generated,
pollutants generated, and control and treatment technologies
employed.   Subsequent waste characterizations of individual
plants substantiated the validity of this subcategorization.

The waste characterizations  of  individual  plants  visited
during  this study, and the guidelines developed as a result
of the data collected, relate only to the aqueous discharges
from the facilities, excluding noncontact cooling waters.

The effluent guidelines established in this  study  are  not
dependent   upon   the   raw   water  intake  quality.   The
limitations were derived by determining the  minimum  flows,
in  volume  per unit weight of product, that can be achieved
by good water conservation techniques and by determining the
effluent concentrations of the pollutant parameters that can
be achieved by treatment technology.  The product  of  these
is the effluent limitations proposed.

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The plant raw wasteloads reflects  the pickup  of contaminants
across  a  production  process   in  a  single  pass.   It  was
necessary to establish the raw  waste load in  this  manner   in
order  to obtain a meaningful  comparison of wastes generated
during production from a range   of  plants  surveyed.    Some
plants  utilized  once-through   water  systems, while  many
others used varying degrees of  reuse and/or recycle.

As presented in this report, an initial   capital   investment
of  approximately  920.3  million  (August 1971 dollars)  with
annual capital  and operating costs of 144.1 million would be
required by the industry to comply with  the 1977  guidelines.
However, this is a net increase of only  68.2   million   above
current  (reference level) annual  expenditures since much of
the current costs for waste hauling can  be  discontinued  upon
installation  of  these  BPCTCA  treatment  facilities.    An
additional  capital investment of approximately 954.6 million
with added annual capital and operating  costs of  about 181.2
million  would be needed to comply with  the 1983  guidelines.
Costs may vary depending  upon   such  factors  as   location,
availability  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.

The subcategories listed above   together  with  this  report
represent  Phase  II  of  the  study  to  establish effluent
guidelines for the steel industry.

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                         SECTION II

                       RECOMMENDATIONS

The proposed effluent limitation guidelines for the  Forming
and  Finishing  Segment  of  the  Iron  and  Steel industry,
representing the effluent  quality  obtainable  through  the
application   of   the  appropriate  treatment  and  control
technology available  for  each  industry  subcategory,  are
summarized as follows:
Part I -   Best Practicable Control Technology Currently
           Available  (BPCTCA - 1977)
Part II -  Best Achievable Treatment Economically Achievable
           (BATEA - 1983)
Part III - Best Available Demonstrated Control Technology
           (BADCT - New Sources)
PART I - BEST PRACTICABLE CONTROL TECHNOLOGY CURRENTLY
AVAILABLE  (BPCTAC - 1977)
The  proposed  effluent  limitations guidelines representing
the effluent quality obtainable by  existing  point  sources
through  the  application  of  the  best practicable control
technology currently available (BPCTCA)  for  each  industry
subcategory are as follows:
    Hot Forming Primary

               BPCTCA Effluent Limitations
          Units:  kg pollutant per kkg of product
             or:  Ib pollutant per 1,000 Ib of product
Pollutant
Parameter
Maximum for any
One Day Period
Shall Not Exceed
 (a) Rolling Operation:

Suspended Solids         0.3753
Oil and Grease           0.1125
pH                            6.0

 (b) Hot Scarfing  (1) :
                 to
 Maximum Average of
Daily Values for any
   Period of 30
	Consecutive_DaYS	
     0.1250
     0.0375
   9.0

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Suspended Solids
Oil and Grease
pH
     0.1251
     0.0375
          6.0
to
  0.0417
  0.0125
9.0
(1)  Applies in addition to limitation stated immediately
above, if the primary hot forming operation has a hot
scarfer wet scrubber associated with the operation.
N   Hot Forming Section

               BPCTCA_Effluent Limitations
          Units:  kg pollutant per kkg of product
             or:  Ib pollutant per 1,000 Ib of product
Pollutant
Parameter

Suspended Solids
Oil and Grease
PH
Maximum for any
One Day Period
Shall Not Exceed

     1.8753
     0.5625
          6.0
    Maximum Average of
   Daily Values for any
      Period of 30
   	Consecutive Days	

        0.6251
        0.1875
to    9.0
O   Hot Forming Flat
               BPCTCA Effluent Limitations
          Units:  kg pollutant per kkg of product
             or:  Ib pollutant per 1,000 Ib of product
Pollutant
Parameter

 (a) Plate:

Suspended Solids
Oil and Grease
pH
Maximum for any
One Day Period
Shall Not Exceed
     2.5005
     0.7500
          6.0
 (b) Hot Strip and  Sheet:

 Suspended Solids          3.4383
 Oil and Grease            1.0314
 pH                             6.0
    Maximum Average of
   Daily Values for any
      Period of 30
   	Consecutive Days__
        0.8335
        0.2500
to    9.0
                         1.1461
                         0.3438
                 to    9.0

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         and Tubes
               BPCTCA Effluent Limitations
          Units:  kg pollutant per kkg of product
             or:  Ib pollutant per 1,000 Ib of product
Pollutant
Parameter

Suspended Solids
Oil and Grease
PH
  Maximum for any
  One Day Period
  Shall Not Exceed

       0.7815
       0.2343
            6.0
to
 Maximum Average of
Daily Values for any
   Period of 30
	Consecutive Days	

     0.2605
     0.0781
   9.0
    Pickling-Sulfuric^Acid-Batch
               BPCTCA Iffluent^Limitations
          Units:
             or:
kg pollutant per kkg of product
Ib pollutant per 1,000 Ib of product
Pollutant
Parameter

(a)  Concentrates:

Suspended Solids
Oil and Grease (1)
Dissolved Iron
PH
  Maximum for any
  One Day Period
  Shall Not Exceed
       0.0219
       0.0045
       0.00045
            6.0
to
    Maximum Average of
   Daily Values for any
      Period of 30
   	Consecutive_pay_s	
     0.0073
     0.0015
     0.00015
   9.0
(1)  This load is allowed only when these wastes are treated
in combination with cold rolling mill wastes.
(b)  Rinse Waters:

Suspended Solids
Oil and Grease(l)
Dissolved Iron
pH
       0.1251
       0.0250
       0.0025
            6.0
to
     0.0417
     0.0083
     0.00083
   9.0
(1) This load is allowed only when these wastes are treated
in combination with cold rolling mill wastes.
R   Pickling-Hydrochloric Acid-Batch and Continuous

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               BPCTCA Effluent Limitations
          Units:  kg pollutant per kkg of product
             or:  Ib pollutant per 1,000 Ib of product
Pollutant
Parameter

(a)  Concentrates:

Suspended Solids
Oil and Grease  (1)
Dissolved Iron
pH
Maximum for any
One Day Period
Shall Not Exceed
     0.0189
     0.0039
     0.00039
          6.0
    Maximum Average of
   Daily Values for any
      Period of 30
     Consecutive Days
        0.0063
        0.0013
        0.00013
to    9.0
(1)  This load is allowed only when these wastes are treated
in combination with cold rolling mill wastes.
(b)  Absorber Vent Scrubber (1):
Suspended Solids
Oil and Grease (2)
Dissolved Iron
pH
     0.1251
     0.0249
     0.00249
          6.0
to
  0.0417
  0.0083
  0.00083
9.0
(1)  This load allowed in place of Hydrochloric Acid
Pickling-Concentrate load as indicated in  (a) above
if the concentrate section has an acid regeneration unit
with an absorber vent scrubber.

(2)  This load is allowed only when these wastes are treated
in combination with cold rolling mill wastes.
 (c) Rinse Waters:

Suspended Solids
Oil and Grease (2)
Dissolved Iron
PH
     0.1251
     0.0249
     0.00249
          6.0
to
  0.0417
  0.0083
  0.00083
9.0
 (1) This load is allowed only when these wastes are treated
 in combination with cold rolling mill wastes.
 (d) Pickle Line Fume Scrubber Wastes  (1)
Suspended Solids
Oil and Grease(2)
Dissolved Iron
PH
     0.0312
     0.0063
     0.00063
          6.0
to
  0.0104
  0.0021
  0.00021
9.0

-------
(1) This limitation is allowed in addition to Hydrochloric
Acid Pickling-Rinse effluent limitations if the pickle line
has a fume hood scrubber.

(2) This load is allowed only when these wastes are treated
in combination with cold rolling mill wastes.
S   Cold Rolling
               BPCTCA Effluent Limitations
          Units:  kg pollutant per kkg of product
             or:  Ib pollutant per 1,000 Ib of product
Pollutant
Parameter

(a) Recirculation:

Suspended Solids
Oil and Grease
Dissolved Iron(l)
PH
Maximum for any
One Day Period
Shall Not Exceed
    Maximum Average of
   Daily Values for any
      Period of 30
   	Consecutive Days	
     0.0078
     0.00312
     0.000312
          6.0
        0.0026
        0.00104
        0.000104
to    9.0
 (1) This load is allowed only when these wastes are treated
in combination with pickle line wastewaters.
 (b) Combination:

Suspended Solids
Oil and Grease
Dissolved Iron  (1)
PH
     0.1251
     0.0502
     0.00501
          6.0
to
  0.0417
  0.0167
  0.00167
9.0
 (1) This load is allowed only when these wastes are treated
in combination with pickle line wastewaters.
 (c) Direct Application

Suspended Solids         0.3126
Oil and Grease           0.1251
Dissolved Iron(l)        0.0126
pH                            6.0
                 to
        0.1042
        0.0417
        0.0042
      9.0
 (1) This load is allowed only when these wastes are treated
 in combination with pickle line wastewaters.

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X   Hot_Cgatings-Galvanizing
               BPCTCA Effluent Limitations
          Units:  kg pollutant per kkg of product
             or:  Ib pollutant per 1,000 Ib of product
Pollutant
Parameter

(a) Rinse Waters:

Suspended Solids
Oil and Grease
Total Zinc
Hexavalent Chromium
Total Chromium
PH
Maximum for any
One Day Period
Shall Not Exceed
     0.3750
     0.1125
     0.0375
     0.00015
     0.0225
          6.0
 (b) Fume Hood Scrubber (1):

 Suspended Solids          0.3750
 Oil and Grease            0.1125
 Total Zinc                0.0375
 Hexavalent Chromium       0.00015
 Total Chromium            0.0225
 pH                            6.0
    Maximum Average of
   Daily Values for any
      Period of 30
     Consecutive Days
        0.1250
        0.0375
        0.0125
        0.00005
        0.0075
to    9.0
                         0.1250
                         0.0375
                         0.0125
                         0.00005
                         0.0075
                 to    9.0
 (1) Applies in addition to the limitations stated immedi-
 ately above, if the galvanizing line has a fume hood
 scrubber.
U   Hot Coatinqs-Terne
               BPCTCA  Effluent Limitations
          Units:   kg pollutant per kkg of product
             or:   Ib pollutant per 1,000 Ib of product
Pollutant
Parameter

 (a)  Rinse Waters:

Suspended Solids
Oil  and Grease
Total Lead
Maximum for any
One Day Period
Shall Not Exceed
      0.3750
      0.1125
      0.00375
    Maximum Average of
   Daily Values for any
      Period of 30
   	Consecutive Days	
        0.1250
        0.0375
        0.00125
                                   8

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Total Tin                0.0375              0.0125
pH                            6.0    to    9.0

(b)  Fume Hood Scrubber (1):

Suspended Solids         0.3750              0.1250
Oil and Grease           0.1125              0.0375
Total Lead               0.00375             0.00125
Total Tin                0.0375              0.0125
pH                            6.0    to    9.0

(1)  Applies in addition to the limitations stated immedi-
ately above, if the terne line has a fume hood
scrubber.
V   Miscellaneous Runoffs - Storage PilesL Casting and
    Slagging

 (a)  Discharges from Coal, Limestone and Ore Storage Piles:

No limitations are established for BPCTCA.

 (b)  Discharges from Casting or Slagging Operations:

There shall be no discharge of process  (i.e. contact)
wastewater pollutants to navigable waters.


W   Cooling_Water_Blowdgwn

Allowable load for discharge will be the loads determined by
multiplying the measured flow by the following concentrations:

                                         Maximum Average of
                    Maximum for any     Daily Values for any
Pollutant           One Day Period         Period of 30
Parameter           Shall Not Exceed    	Consecutive Days	
                         mg/1                 mg/1

Suspended Solids       150.0                50
Total Zinc              15.0                 5.0
Hexavalent Chromium      0.06                0.02
Total Chromium           9.0                 3.0
Phosphorus              24.0                 8.0
pH                            6.0    to    9.0


X   UtilityBlowdown

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Allowable load for discharge will be the loads determined
by multiplying the measured flow by the following
concentration:

                                         Maximum Average of
                    Maximum for any     Daily Values for any
Pollutant           One Day Period         Period of 30
Parameter           Shall_Not_Exceed    	QoJl§ecutive_Da.ys	
                        mg/1                    mg/1

Suspended Solids       150                  50
pH                         6.0    to    9.0
X   Maintenance Department Wastes

Allowable load for discharge will be the loads determined
by multiplying the measured flow by the following concen-
trations:

                                         Maximum Average of
                    Maximum for any     Daily Values for any
Pollutant           One Day Period         Period of 30
Parameter           Shall_Not_Exceed    	Qossecutive_Day.s	
                        mg/1                    mg/1

Suspended Solids           150                50
Oil and Grease              45                15
pH                            6.0    to    9.0
Z   Central_Treatment

Allowable  loads  for discharge will be the sum of the loads
from the regulated sources  (1) plus the loads from the semi-
regulated (2) and the unregulated sources  (3).   Loads  from
the  semi-regulated sources are determined from the measured
flow and the  concentrations  appropriate  to  that  source.
Loads  from  the unregulated sources are determined from the
flows  from  the  unregulated  sources  multiplied  by   the
following concentrations:
                                         Maximum Average of
                    Maximum for any     Daily Values for any
Pollutant           One Day Period         Period of 30
Parameter           §hall_Not_Exceed    	Consecutive_pay.s	
                         mg/1                 mg/1

Suspended Solids           150                  50
                                  10

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Oil and Grease
Total Zinc
Hexavalent Chromium
Total Chromium
Phosphorus
pH
45
15
 0
 9
24
                              06
                                6 . 0
                                       to
                                               15
                                                5
                                                0
                                                3
                                                8
                                             9 . 0
                                                  02
(1)   Regulated  sources  are those sources wherein the flows
are limited, eg., subparts A through V.  (2)  Semi-regulated
sources  are  those  sources  wherein the concentrations are
limited but the flows are not limited, i.e., subparts  W,  X
and  Y.   (3)    Unregulated  sources  such as cooling water,
etc., are sources for which no regulations apply.
PART II - BEST AVAILABLE TECHNOLOGY ECONOMICALLY
         (BATEA - 1983)
                                                  ACHIEVABLE
The  proposed  effluent guidelines representing the effluent
limitations quality obtainable  by  existing  point  sources
through  the  application  of  the best available technology
economically   achievable    (BATEA)   for   each    industry
subcategory are as follows:
    Hot Forming^ Primary

               BATEA Effluent Limitations (1)
          Units:  kg pollutant per kkg of product
             or:  Ib pollutant per 1,000 Ib of product
Pollutant
Parameter
                    Maximum for any
                    One Day Period
                     hall_NotExceed
(a)  Rolling Operation:

Suspended Solids         0.0312
Oil and Grease           0.0126
pH                            6.0
                                     to
                                         Maximum Average of
                                        Daily Values for any
                                           Period of 30
                                        _ Qossec.utive_pay.s __
                                             0.0104
                                             0.0042
                                           9.0
(b)  Hot Scarf ing (1):  included in  (a)
(1)  No additional load is allowed for hot scarfing since
scarfer scrubber water is part of the total primary mill
recycle system.
                                   11

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N   Hot Forming Section
               BATEA Iffluent Limitations
          Units:  kg pollutant per kkg of product
             or:  Ib pollutant per 1,000 Ib of product
Pollutant
Parameter

Suspended Solids
Oil and Grease
pH
Maximum for any
One Day Period
Shall Not Exceed

     0.0468
     0.0189
          6.0
    Maximum Average of
   Daily Values for any
      Period of 30
   	Consecutive Dayg	

        0.0156
        0.0063
to    9.0
Q   Hot Forming Flat
               BATEA Effluent Limitations
          Units:  kg pollutant per kkg of product
             or:  Ib pollutant per 1,000 Ib of product
Pollutant
Parameter

(a) Plate:

Suspended Solids
Oil and Grease
PH
Maximum for any
One Day Period
Shall Not Exceed
     0.0468
     0.0189
          6.0
 (b) Hot Strip and Sheet:

Suspended Solids         0.0468
Oil and Grease           0.0189
pH                            6.0
    Maximum Average of
   Daily Values for any
      Period of 30
   	Consecutive Days	
        0.0156
        0.0063
to    9.0
                         0.0156
                         0.0063
                 to    9.0
Z   Pipe and Tubes
               BATEA Effluent Limitations
          Units:  kg pollutant per kkg of product
             or:  Ib pollutant per 1,000 Ib of product
Pollutant
Parameter
Maximum for any
One Day Period
Shall Not Exceed
    Maximum Average of
   Daily Values for any
      Period of 30
   	Consecutiye_pays	
                                   12

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Suspended Solids
Oil and Grease
PH
       0.0468
       0.0189
            6.0
to
  0.0156
  0.0063
9.0
    Pickling-Sulfurjc Acid-Batch
               BATEA Effluent Limitations
          Units:
             or:
Pollutant
Parameter

(a) Concentrates:

Suspended Solids
Dissolved Iron
PH
kg pollutant per kkg of product
Ib pollutant per 1,000 Ib of product
  Maximum for any
  One Day Period
  Shall Not Exceed
    Maximum Average of
   Daily Values for any
      Period of 30
     Consecutive Days	
       No Discharge of Process
       Wastewater Pollutants
       to Navigable Waters(1)
 (1)  Vacuum eductor condenser water is considered noncontact
cooling water.
 (b) Rinse Waters:

Suspended Solids
Dissolved Iron
PH
       No Discharge of Process
       Wastewater Pollutants
       to Navigable Waters
E   Pickling-Hydrochloric Acid-Batch and Continuous

               BATEA Effluent Limitations
          Units:  kg pollutant per kkg of product
             or:  Ib pollutant per 1,000 Ib of product
Pollutant
Parameter

 (a) Concentrates:

Suspended Solids
Oil and Grease  (1)
Dissolved Iron
pH
  Maximum for any
  One Day Period
  Shall Not Exceed
       0.0093
       0.0039
       0.00039
            6.0
to
    Maximum Average of
   Daily Values for any
      Period of 30
   	Consecutiye_Da;y_s	
  0.0031
  0.0013
  0.00013
9.0
                                  13

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(1) This load is allowed
in combination with cold
only when these wastes  are treated
rolling mill  wastes.
(b) Absorber Vent Scrubber(l):
Suspended Solids
Oil and 6rease(2)
Dissolved Iron
PH
0.0093
0.0039
0.00039
     6.0
to
  0.0031
  0.0013
  0.00013
9.0
(1) These limitations are allowed in place  of  Hydrochloric
Acid  Pickling-Concentrate  Subcategory effluent limitations
if the concentrate section has  an  acid  regeneration  unit
equipped with an absorber vent scrubber.
(2)  This load is allowed only when these wastes
in combination with cold rolling mill  wastes.
                        are treated
(c) Rinse Waters:

Suspended Solids
Oil and Grease(l)
Dissolved Iron
PH
0.0156
0.0063
0.00063
     6.0
to
  0.0052
  0.0021
  0.00021
9.0
(1) This load is allowed only when these wastes are treated
in combination with cold rolling mill  wastes.
(d) Pickle Line Fume Scrubber Wastes(l):
Suspended Solids
Oil and Grease(2)
Dissolved Iron
PH
0.0156
0.0063
0.00063
     6.0
to
  0.0052
  0.0021
  0.00021
9.0
(1) This limitation is allowed in addition to Hydrochloric
Acid Pickling-Rinse effluent limitations if the pickle line
has a fume hood scrubber.

(2) This load is allowed only when these wastes are treated
in combination with cold rolling mill wastes.
1   Cold Rolling
               BATEA Effluent Limitations
          Units:  kg pollutant per kkg of product
             or:  Ib pollutant per 1,000 Ib of product

                                         Maximum Average of
                                  14

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Pollutant
Parameter

(a) Recirculation:

Suspended Solids
Oil and Grease
Dissolved Iron(l)
PH
Maximum for any
One Day Period
Shall Not Exceed
     0.0078
     0.00312
     0.000312
          6.0
   Daily Values for any
      Period of 30
   	Consecutive Days	
        0.0026
        0.00104
        0.000104
to    9.0
(1)  This load is allowed only when these wastes are treated
in combination with pickle line wastewaters.
(b)  Combination:

Suspended Solids
Oil and Grease
Dissolved Iron(l)
PH
     0.1251
     0.0510
     0.0051
          6.0
to
  0.0417
  0.0167
  0.0017
9.0
(1)  This load is allowed only when these wastes are treated
in combination with pickle line wastewaters.
(c)  Direct Application:

Suspended Solids         0.3126
Oil and Grease           0.1251
Dissolved Iron(l)        0.0126
pH                            6.0
                 to
        0.1042
        0.0417
        0.0042
      9.0
(1)  This load is allowed only when these wastes are treated
in combination with pickle line wastewaters.
T   Hot Coatings^Galvanizing
               BATEA Effluent Limitations
          Units:  kg pollutant per kkg of product
             or:  Ib pollutant per 1,000 Ib of product
Pollutant
Parameter

(a) Rinse Waters:

Suspended Solids
Oil and Grease
Maximum for any
One Day Period
Shall Not Exceed
     0.0312
     0.0126
    Maximum Average of
   Daily Values for any
      Period of 30
   	Consecutiye_Day_s	
        0.0104
        0.0042
                                  15

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Total Zinc
Hexavalent Chromium
Total Chromium
PH
     0.00249
     0.000024
     0.000252
          6.0
to
  0.00083
  0.000008
  0.000084
9.0
(b)  Fume Hood Scrubber (1):
Suspended Solids
Oil and Grease
Total Zinc
Hexavalent Chromium
Total Chromium
PH
     0.0468
     0.0189
     0.00375
     0.000039
     0.000378
          6.0
to
  0.
  0.
  0.
  0.
  0.
9.0
          0156
          0063
          00125
          000013
          000126
 (1) Applies in addition to the limitation stated
immediately above if the galvanizing line has a fume hood
scrubber.
U   Hot Coatings-Terne

               BATEA Effluent Limitations
          Units:  kg pollutant per kkg of product
             or:  Ib pollutant per 1,000 Ib of product
Pollutant(l)
Parameter

(a) Rinse Waters;

Suspended Solids
Oil and Grease
Total Tin
Total Lead
PH
Maximum for any
One Day Period
Shall Not Exceed
     0.0312
     0.0126
     0.00249
     0.000312
          6.0
to
    Maximum Average of
   Daily Values for any
      Period of 30
     Consecutive Days
  0.0104
  0.0042
  0.00083
  0.000104
9.0
 (b) Fume Hood Scrubber (1):

Suspended Solids         0.0468
Oil and Grease           0.0189
Total Tin                0.00375
Total Lead               0.000468
pH                            6.0
                         0.0156
                         0.0063
                         0.00125
                         0.000156
                 to
      9.0
 (1) This limitation applies in addition to the limitation
 stated immediately above if the terne  line has a fume hood
 scrubber.
                                 16

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V   Miscellaneous Runoffs — Storagg Piles, Casting and Slagging

 (a) Discharges from Coal, Limestone and Ore Storage Piles:

                                         Maximum Average of
                    Maximum for any     Daily Values for any
Pollutant           One Day Period         Period of 30
Parameter           Shall Not Exceed    ^Consecutive Days	
                         mg/1                 mg/1

Suspended Solids         75*                  25*
pH                          6.0    to    9.0

*This concentration applies only when the rainfall rate is
2.5 inches or less in any preceeding five day period.

 (b) Discharges from Casting or Slagging Operations:

There shall be no discharge of process  (i.e. contact)
wastewater pollutants to navigable waters.


W   Cooling Water Slowdown

Allowable load for discharge will be the loads determined by
multiplying the measured flow by the following concentrations:

                                         Maximum Average of
                    Maximum for any     Daily Values for any
Pollutant           One Day Period         Period of 30
Parameter           Shall Not Exceed    	Consecutive Days	
                         mg/1                 mg/1

Suspended Solids        75.0                25.0
Total Zinc               6.0                 2.0
Hexavalent Chromium      0.06                0.02
Total Chromium           0.6                 0.2
Phosphorus              24.0                 8.0
pH                            6.0    to    9.0


X   ytility_Blowdgwn

Allowable load for discharge will be the loads determined
by multiplying the measured flow by the following
concentration:

                                         Maximum Average of
                    Maximum for any     Daily Values for any
Pollutant           One Day Period         Period of 30
                                  17

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Parameter           Shall Not Exceed    	Consecutive Days
                        mg/1                    mg/1

Suspended Solids         75                      25
pH                         6.0    to    9.0
X   Maintenance Department^Wastes

Allowable load for discharge will be the loads determined by
multiplying the measured flow by the following concentrations:

                                         Maximum Average of
                    Maximum for any     Daily Values for any
Pollutant           One Day Period         Period of 30
Parameter           Shall Not Exceed      Consecutive Days	
                        mg/1                    mg/1

Suspended Solids            75                25
Oil and Grease              30                10
oH                            6.0    to    9.0
Z   Central^Treatment

Allowable loads for discharge will be the sum of  the  loads
from the regulated sources  (1) plus the loads from the semi-
regulated   (2)  and the unregulated sources  (3).  Loads from
the semi-regulated sources are determined from the  measured
flow  and  the  concentrations  appropriate  to that source.
Loads from the unregulated sources are determined  from  the
flows   from  the  unregulated  sources  multiplied  by  the
following concentrations:
                                         Maximum Average of
                    Maximum for any     Daily Values for any
Pollutant           One Day Period         Period of 30
Parameter           Shall Not Exceed    	Consecutive Days
                         mg/1                 mg/1

Suspended Solids           75                  25
Oil and Grease             30                  10
Total Zinc                  6                   2
Hexavalent Chromium         0.06                0.02
Total Chromium              0.6                 0.2
Phosphorus                 24                   8
pH                              6.0    to    9.0
                                  18

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(1)  Regulated sources are those sources  wherein  the  flows
are limited, eg., subparts A through V.   (2) Seimi-regulated
sources  are  those  sources  wherein the concentrations are
limited but the flows are not limited, i.e., subparts  W,  X
and  Y.   (3)   Unregulated  sources  such as cooling water,
etc., are sources for which no regulations apply.
PART III - BEST AVAILABLE  DEMONSTRATED  CONTROL  TECHNOLOGY
         (BADCT - New Sources)
The  proposed  effluent  limitations guidelines representing
the  effluent  quality  attainable  by  new  sources   (NSPS)
through  the  application of the best available demonstrated
control technology  (BADCT), processes, operating methods  or
other  alternatives  for  each  industry  subcategory are as
follows:
M   Hot Forming Primary

               NSPS^gffluent^Limitationg
          Units:  kg pollutant per kkg of product
             or:  Ib pollutant per 1,000 Ib of product

                                         Maximum Average of
                    Maximum for any     Daily Values for any
Pollutant           One Day Period         Period of 30
Parameter           Shall_Not_Exceed(1) 	Consecutive Days(1)

(a)  Rolling Operation:

Suspended Solids         0.0312              0.0104
Oil and Grease           0.0126              0.0042
pH                            6.0    to    9.0

(b)  Hot Scarf ing (1):   included in  (a)

(1)  No additional load is allowed for hot scarfing for NSPS,
since scarfer scrubber water is intended to be part  of  the
total primary mill recycle system.


N   Hot_]Forming^Section

               NSPS....Ef fluent ^Limitations
          Units:  kg pollutant per kkg of product
             or:  Ib pollutant per 1,000 Ib of product
                                  19

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Pollutant
Parameter

Suspended Solids
Oil and Grease
pH
Maximum for any
One Day Period
Shall Not Exceed

     0.0468
     0.0189
          6.0
    Maximum Average of
   Daily Values for any
      Period of 30
     Consecutive Days	

        0.0156
        0.0063
to    9.0
    Hot Forming Flat
               NSPS^Effluent Limitations
          Units:  kg pollutant per kkg of product
             or:  Ib pollutant per 1,000 Ib of product
Pollutant
Parameter

(a)  Plate:

Suspended Solids
Oil and Grease
PH
Maximum for any
One Day Period
Shall Not Exceed
     0.0468
     0.0189
          6.0
(b) Hot Strip and Sheet

Suspended Solids
Oil and Grease
PH

P   Pipe _and Tubes
     0.0468
     0.0189
          6.0
    Maximum Average of
   Daily Values for any
      Period of 30
   	Consecutive Days	
        0.0156
        0.0063
to    9.0
        0.0156
        0.0063
to    9.0
               NSPSm Effluent Limitations
          Units:  kg pollutant per kkg of product
             or:  Ib pollutant per 1,000 Ib of product
Pollutant
Parameter

Suspended Solids
Oil and Grease
PH
Maximum for any
One Day Period
Shall Not Exceed

     0.0468
     0.0189
          6.0
to
 Maximum Average of
Daily Values for any
   Period of 30
	Consecutive Days	

     0.0156
     0.0063
   9.0
    Pickling- Sul.fur.iq Acid-Batch
                                  20

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               NSPS Effluent Limitations
          Units:  kg pollutant per kkg of product
             or:  Ib pollutant per 1,000 Ib of product
Pollutant
Parameter

(a)  Concentrates:

Suspended Solids
Dissolved Iron
PH
Maximum for any
One Day Period
Shall^Ngt Exceed
    Maximum Average of
   Daily Values for any
      Period of 30
     Consecutive Days
     No Discharge of Process
     Wastewater Pollutants
     to Navigable Waters(1)
(1)  Vacuum eductor condenser water is considered noncontact
cooling water.
(b)  Rinse Waters:

Suspended Solids
Dissolved Iron
PH
     No Discharge of Process
     Wastewater Pollutants
     to Navigable Waters
R   Pickling-Hydrochloric Acid-Batch and Continuous

               NSPS JSffluent Limitation^
          Units:  kg pollutant per kkg of product
             or:  Ib pollutant per 1,000 Ib of product
Pollutant
Parameter

(a) Concentrates:

Suspended Solids
Oil and Grease  (1)
Dissolved Iron
PH
Maximum for any
One Day Period
Shall Not Exceed
     0.0093
     0.0039
     0.00039
          6.0
to
    Maximum Average of
   Daily Values for any
      Period of 30
     Consecutive
  0.0031
  0.0013
  0.00013
9.0
 (1)  This load is allowed only when these wastes are treated
in combination with cold rolling mill wastes.
 (b) Absorber Vent Scrubber  (1) :

Suspended Solids         0.0624
                         0.0208
                                  21

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Oil and Grease(2)
Dissolved Iron
pH
     0.0249
     0.00249
          6.0
to
  0.0083
  0.00083
9.0
(1) These limitations are allowed in place of Hydrochloric
Acid Pickling-Concentrate Subcategory effluent limitations
if the concentrate section has an acid regeneration unit
equipped with an absorber vent scrubber.

(2) This load is allowed only when these  wastes are treated
in combination with cold rolling mill wastes.
(c) Rinse Waters:

Suspended Solids
Oil and Grease(l)
Dissolved Iron
pH
     0.0156
     0.0063
     0.00063
          6.0
to
  0.0052
  0.0021
  0.00021
9.0
(1) This load is allowed only when these wastes are treated
in combination with cold rolling mill wastes.
(d) Pickle Line Fume Scrubber Wastes:
Suspended Solids
Oil and Grease(l)
Dissolved Iron
pH
     0.0156
     0.0063
     0.00063
          6.0
to
  0.0052
  0.0021
  0.00021
9.0
(1) This load is allowed only when these wastes are treated
in combination with cold rolling mill wastes.
S^   Cold Rolling
               NSPS Effluent Limitations
          Units!kg pollutant per kkg of product
             or:  Ib pollutant per 1,000 Ib of product
Pollutant
Parameter

(a) Recirculation:

Suspended Solids
Oil and Grease
Dissolved Iron(l)
pH
Maximum for any
One Day Period
Shall Not Exceed
     0.0078
     0.00312
     0.000312
          6.0
to
    Maximum Average of
   Daily Values for any
      Period of 30
     Consecutive Days
  0.0026
  0.00104
  0.000104
9.0
                                  22

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(1)  This load is allowed only when these wastes are treated
in combination with pickle line wastewaters.
(b)  Combi nat i on:

Suspended Solids
Oil and Grease
Dissolved Iron(l)
pH
     0.1251
     0.0501
     0.0051
          6.0
to
  0.0417
  0.0167
  0.0017
9.0
(1)  This load is allowed only when these wastes are treated
in combination with pickle line wastewaters.
(c)  Direct Application:

Suspended Solids         0.3126
Oil and Grease           0.1251
Dissolved Iron(l)        0.00126
pH                            6.0
                 to
        0.1042
        0.0417
        0.0042
      9.0
(1)  This load is allowed only when these wastes are treated
in combination with pickle line wastewaters.
T   Hot Coatings-Galvanizing
               NSPS^Effluent Limitations
          Units:  kg pollutant per kkg of product
             or:  Ib pollutant per 1,000 Ib of product
Pollutant
Parameter

(a)  Rinse Waters:

Suspended Solids
Oil and Grease
Total Zinc
Hexavalent Chromium
Total Chromium
PH
Maximum for any
One Day Period
Shall Not Exceed
     0.1875
     0.0750
     0.0150
     0.00015
     0.00150
          6.0
(b) Fume Hood scrubber

Suspended Solids         0.1875
Oil and Grease           0.0750
Total Zinc               0.0150
    Maximum Average of
   Daily Values for any
      Period of 30
     Consecutive Days	
        0.0625
        0.0250
        0.0050
        0.00005
        0.00050
to    9.0
                         0.0625
                         0.0250
                         0.0050
                                  23

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Hexavalent Chromium
Total Chromium
PH
     0.00015
     0.00150
          6.0
  to
     0.00005
     0.00050
   9.0
U   Hot Coatjngg^Terne
               NSPS Effluent Limitations
          Units:  kg pollutant per kkg of product
             or:  Ib pollutant per 1,000 Ib of product
Pollutant
Parameter

(a)  Rinse Waters:

Suspended Solids
Oil and Grease
Total Tin
Total Lead
PH
Maximum for any
One Day Period
Shall Not Exceed
     0.1875
     0.0750
     0.0150
     0.00189
          6.0
 (b)  Fume Hood Scrubber

Suspended Solids         0.1875
Oil and Grease           0.0750
Total Tin                0.0150
Total Lead               0.00189
pH                            6.0
      Maximum Average of
     Daily Values for any
        Period of 30
     	Consecutive Days
          0.0625
          0.0250
          0.0050
          0.00063
  to    9.0
                         0.0625
                         0.0250
                         0.0050
                         0.00063
                 to    9.0
V   Miscellaneous Runoffs - Storage^Piles, Casting and Slagging

 (a) Discharges from Coal, Limestone and Ore Storage Piles:
Pollutant
Parameter
Suspended Solids
PH
Maximum for any
One Day Period
Shall Not Exceed
     mg/1
     75*
        6.0
to
 Maximum Average of
Daily Values for any
   Period of 30
	Consecutive Days
      mg/1

      25*
 9.0
*This concentration applies only when the rainfall rate is
2.5 inches or less in any preceeding five day period.

 (b) Discharges from Casting or Slagging Operations:
                                  24

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There shall be no discharge of process (i.e.
wastewater pollutants to navigable waters.
                         contact)
H   Cooling Water Slowdown

Allowable load for discharge will be the loads determined by
multiplying   the   measured   flow   by    the    following
concentrations:
Pollutant
Parameter
Suspended Solids
Total Zinc
Hexavalent Chromium
Total Chromium
Phosphorus
PH
Maximum for any
One Day Period
Shall^Not .Exceed
     mg/1

    75.0
     6.0
     0.06
     0.6
    24.0
          6.0
     Maximum Average of
    Daily Values for any
       Period of 30
    	Consecutive Days	
          mg/1

        25.0
         2.0
         0.02
         0.2
         8.0
 to    9.0
X   Utility Slowdown

Allowable load for discharge will be the loads determined by
multiplying    the    measured   flow   by   the   following
concentration:
Pollutant
Parameter
Suspended Solids
PH
Maximum for any
One Day Period
§hall_Not_Exceed
    mg/1
       75
         6.0
to
     Maximum Average of
    Daily Values for any
       Period of 30
      Consecutive^DaYS	
            mg/1
           25
9.0
Y   Maintenance Department Wastes

Allowable load for discharge will be the loads determined by
multiplying   the   measured   flow   by    the    following
concentrations:
Pollutant
Parameter
Maximum for any
One Day Period
Shall Not Exceed
     Maximum Average of
    Daily Values for any
       Period of 30
    	Consecutive Days	
                                 25

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                        mg/1                    mg/1

Suspended Solids            75                25
Oil and Grease              30                10
pH                            6.0    to    9.0
Z   Central Treatment

Central treatment only applies to existing sources.
                                  26

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                        SECTION III

                        INTRODUCTION
Purpose and Authority

Section  301(b)   of  the Act requires the achievement by not
later than July 1, 1977, of effluent limitations  for  point
sources,  other  than  publicly owned treatment works, which
are based on the application of the best practicable control
technology   currently   available   as   defined   by   the
Administrator   pursuant  to  Section  304 (b)   of  the  Act.
Section 301(b)  also requires the achievement  by  not  later
than  July  1,   1983,  of  effluent  limitations  for  point
sources, other than publicly owned  treatment  works,  which
are   based   on  the  application  of  the  best  available
technology economically  achievable  which  will  result  in
reasonable  further  progress  toward  the  national goal of
eliminating the discharge of all pollutants,  as  determined
in  accordance  with regulations issued by the Administrator
pursuant to Section 304(b)  to the Act.  Section 306  of  the
Act  requires  the  achievement  by new sources of a Federal
standard of performance providing for  the  control  of  the
discharge  of  pollutants which reflects the greatest degree
of effluent reduction which the Administrator determines  to
be  achievable through the application of the best available
demonstrated  control   technology,   processes,   operating
methods,    or    other   alternatives,   including,   where
practicable,  a  standard   permitting   no   discharge   of
pollutants.

Section  304(b)   of  the  Act  requires the Administrator to
publish within one year of enactment of the Act, regulations
providing guidelines for effluent limitations setting  forth
the  degree  of  practicable  control  technology  currently
available and the degree of  effluent  reduction  attainable
through  the  application  of  the best control measures and
practices achievable including treatment techniques, process
and  procedure  innovations,  operation  methods  and  other
alternatives.

Section  306  of  the Act requires the Administrator, within
one year after a category of sources is included in  a  list
published  pursuant  to  Section 306 (b) (1) (A)  of the Act, to
propose  regulations  establishing  Federal   standards   of
performances  for  new  sources within such categories.  The
Administrator published in the Federal Register  of  January
16,  1973,  a  list of 27 source categories.  Publication of
the list constituted  announcement  of  the  Administrator's
                                  27

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intention  of  establishing, under Section 306, standards of
performance applicable to new sources within  the  iron  and
steel  industry which was included within the list published
January 16, 1973.
Summary of Methods^Used for Development of the Effluent
Limitations Guidej.ines_and Standards of Performance

The  effluent  limitations  guidelines  and   standards   of
performance  proposed herein were developed in the following
manner.  The point source category was first studied for the
purpose of  determining  whether  separate  limitations  and
standards  would be required for different segments within a
point source category.  The  analysis  was  based  upon  raw
material   used,  product  produced,  manufacturing  process
employed, and other factors.  The raw waste  characteristics
for each subcategory were then identified.  This included an
analyses  of  (1) the source and volume of water used in the
process employed and the sources of waste and wastewaters in
the plant; and  (2) the constituents  (including  thermal)  of
all  wastewaters  including  toxic  constituents  and  other
constituents which result  in  taste,  odor,  and  color  in
water.   The  constituents  of  wastewaters  which should be
subject to effluent limitations guidelines and standards  of
performance were identified.

The   full  range  of  control  and  treatment  technologies
existing  within  each  subcategory  was  identified.   This
included  an  identification  of  each  distinct control and
treatment technology, including  both  inplant  and  end-of-
process technologies, which are existent or capable of being
designed   for   each  subcategory.   It  also  included  an
identification  in terms of the amount  of  constituents  and
the  chemical,  physical,  and biological characteristics of
pollutants,  of  the  effluent  level  resulting  from   the
application   of   each   of   the   treatment  and  control
technologies.   The problems, limitations and reliability  of
each  treatment  and  control  technology  and  the required
implementation  time was also identified.  In  addition,  the
nonwater  quality  environmental impact, such as the effects
of the application of such technologies upon other pollution
problems, including air, solid waste,  noise  and  radiation
were  also  identified.   The energy requirements of each of
the control and treatment technologies  were  identified  as
well as the cost of the application of such technologies.

The  information,  as  outlined above, was then evaluated in
order to  determine what levels of technology constituted the
"best practicable  control technology  currently  available,"
                                  28

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"best  available technology economically achievable" and the
"best available demonstrated control technology,  processes,
operating  methods,  or other alternatives."  In identifying
such technologies, various factors were  considered.   These
included  the  total  cost  of  application of technology in
relation to the effluent reduction benefits to  be  achieved
from  such  application, the age of equipment and facilities
involved, the process employed, the engineering  aspects  of
the  application  of  various  types  of control techniques,
process  changes,  nonwater  quality  environmental   impact
(including energy requirements) and other factors.

The data for identification and analyses were derived from a
number  of  sources.   These  sources  included EPA research
information, EPA and State  environmental  personnel,  trade
associations,   published  literature,  qualified  technical
consultation, and on-site visits including sampling programs
and interviews at steel plants throughout the United  States
which  were  known  to  have  above  average waste treatment
facilities.   All  references   used   in   developing   the
guidelines   for   effluent  limitations  and  standards  of
performance for new sources reported herein  are  listed  in
Section XIII of this document.

Operating  plants  were  visited and information and samples
were obtained from as high as seven plants in  each  of  the
subcategories.   Both  in-process  and end-of-pipe data were
obtained as a basis for  determining  water  use  rates  and
capabilities  and  effluent  loads.   The permit application
data was of limited value for the  purposes  of  this  study
since most of this data is on outfalls serving more than one
operation and frequently was deficient in one or more of the
components  needed  to  correlate  the  data.  The following
capital and operating cost data sheet and test data  sheets,
e.g.  EPA  Form  B,  for  raw  waste,  treated effluent, and
service water were given to the plants, at the time  of  the
sampling  visit, for completion relative to the operation or
operations studied  at  a  given  plant.   The  plants  were
requested   to   return   this  information,  together  with
production data to the study contractor.

General Description^Qf_the_Industry

Although the making of steel  appears  to  be  simple,  many
problems  are  encountered  when  a  great  quantity  of raw
materials and resources are brought together  to  ultimately
produce  steel.   Steel  mills  may range from comparatively
small plants to completely integrated steel complexes.  Even
the smallest of plants will generally represent a fair sized
industrial complex.  Because of the wide product range,  the
                                  29

-------
operations will vary with each facility.  The steel oriented
may  fail  to  realize  that those unfamiliar with the steel
industry may find it difficult to comprehend the  complexity
of this giant operation.

It  was not until the mid-fifties that the industry began to
look  at  iron  and  steelmaking  as  unit  operations  that
required  a  better  knowledge  of the kinetics of competing
reactions.  Since  this  initial  change  in  thinking,  the
adoption of advanced technology has become a way of life for
the steel industry.

Approximately  92%  of  the  1972 total United States annual
steel ingot  production  was  produced  by  15  major  steel
corporations.  This total also represents 22.5% of the world
total  of  566,875,000 metric tons (625,000,000 ingot tons).
Table 1 presents the breakdown by corporation.  The year  of
record  for steel ingot production was 1969 with 127,887,000
kkg (141,000,000 ingot tons) being produced.

Prgduct^Classification

The  U.  S.  Bureau  of  Census,  Census  of  Manufacturers,
classifies the steel industry under Major Group 33 - Primary
Metal  Industries.   This  phase  of  study  covers  the hot
forming and cold finishing  segments  of  SIC  Industry  No.
3312,   3315,  3316,  and 3317 as it pertains to the iron and
carbon  steel  industry.   This  includes   all   processes,
subprocesses,   and  alternate  processes  involved  in  the
manufacture of intermediate  or  finished  products  in  the
above  categories.   A detailed list of product codes within
the industry classification code 3312, 3315, 3316, and  3317
is included in Tables 2, 3, 4, and 5 respectively.

Anticipated Industry growth

Steel  in  the  United  States  is  a  $22.47 billion a year
business.  The industry is third in the nation,  behind  the
automotive  and  petroleum  industries,  in the value of its
total shipments and, with 487,000 employees, is second  only
to  the automotive industry in the number of people who work
for it.  Over the decade since 1962, the steel industry  has
grown 60% from sales of $14.0 to $22.HI billion.

In  1972  steel climbed back from its worst market in over a
decade showing a steady improvement in the early part of the
year.  Both raw steel production and finished  mill  product
shipments  were  up  substantially from 12 year lows reached
late summer of 1971.  As steel demand improved, so did steel
employment.  The  number  of  persons  carried  on  domestic
                                  30

-------
                           TABLE 1

       United States Annual Steel Ingot Ton Production
                       Manor Producers
                            1972
                           Metric Tons/Year  Ingot Tons/Year
United States Steel
Bethlehem Steel
Republic Steel
National Steel
Armco Steel
Jones & Laughlin Steel
Inland Steel
Youngstown Sheet & Tube
Wheeling Pittsburgh
Kaiser
McLoutI:
Colorado Fuel & Iron
Sharon
Interlake
Alan Woc-a
31,750
19,°60
 9,980
 97520
 7,710
 7,280
 6,800
 5,440
 3,540
 2,720
 1,819
 1,360
 1,360
   907
   907
,000
,000
,000
,000
,000
,000
,000
,000
,000
,000
,000
;ooo
,000
,000
,000
35,000
22,000
11,000
10,500
 8,500
 8,000
 7,500
• 6,000
 3,900
 3,000
 2,000
 1,500
 1,500
 1,000
 1,000
,000
,000
,000
,000
,000
,000
,000
,000
,000
,000
,000
,000
,000
,000
,000
                           31

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33

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                            TABLE 3
PRODUCT CLASSIFICATION BY SIC CODE (3315)
FOR THE IRON AND STFEL INDUSTRY
STEEL WIRE DRAWING AND STEEL NAILS AND SPIKES



Establishments primarily engaged in drawing wire from pur-

chased iron or steel rods, bars, or wire and which may be

engaged in the further manufacture of products made from wire;
                                     /

establishments primarily engaged in manufacturing steel nails

and spikes from purchased materials are also included in this

industry.  Rolling mills engaged in the production of ferrous

wire from wire rods or hot rolled bars produced in the same

establishment are classified in Industry 3312.  Establishments

primarily engaged in drawing nonferrous wire are classified in

Group 335.
     Brads, steel: wire or cut

     Cable, steel: insulated or
                   armored

     Horseshoe nails

     Nails, steel: wire or cut

     Spikes, steel: wire or cut

     Staples, steel: wire or cut
Tacks, steel: wire or cut

Wire, ferrous

Wire products, ferrous:
made in wire drawing plants

Wire, steel: insulated or
             armored
                             34

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                            TABLE 4
PRODUCT CLASSIFICATION BY GIG CODE  (3316)
FOR THE IRON AMD STEEL INDUSTRY
COLD ROLLED STEEl, SHEET, STRIP, AND BARS



Establishments primarily engaged in (1) cold rolling steel

sheets and strip from purchased hot rolled sheets; (2)  cold

drawing steel bars and steel shapes from purchased hot rolled

steel bars; and (3)  producing other cold finished steel.

Establishments primarily engaged in the production of steel,

including hot rolled steel sheets, and further cold rolling

such sheets are classified in Industry 3312.
     Cold finished steel bars

     Cold rolled steel strip,
     sheet, and bars: not made
     in hot rolling mills

     Corrugated iron and steel,
     cold rolled
Flat bright steel strip,
cold rolled: not made in
hot rolling mills

Razor blade strip steel,
cold rolled: not made in
hot rolling mills

Sheet steel, cold rolled:
not made in hot rolling
mills

Wire, flat: cold rolled
strip
                           35

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                            TABLE 5
PRODUCT CLASSIFICATION BY SIC CODE (3317)
FOR THE IRON 7iND STEEL INDUSTRY
STEEL PIPES AND TUBES



Establishments primarily engaged in the production of welded

or seamless steel pipe and tubes and heavy riveted steel pipe

from purchased materials.  Establishments primarily engaged

in the production of steel, including-steel skelp or steel

blanks, tube rounds, or pierced billets, are classified in

Industry 3312.
     Boiler tubes, wrought:
     welded, lock joint, and
     heavy riveted - not made
     in rolling mills

     Conduit: welded, lock joint,
     and heavy riveted - not made
     in rolling mills

     Pipe, seamless steel: not
     made in rolling mills

     Pipe, wrought: welded, lock
     joint, and heavy riveted -
     not made in rolling mills
 Tubes,  seamless  steel:  not
•made  in rolling  mills

 Tubing,  mechanical  and
 hypodermic  sizes: not made
 in  rolling  mills

 Well  casing, wrought:
 welded,  lock joint,  and
 heavy riveted  -  not made
 in  rolling  mills

 Wrought pipe and tubes:
 welded,  lock joint,  and
 heavy riveted  -  not made
 in  rolling  mills
                            36

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steelmaker  payrolls  increased  steadily  during  the fir'st
quarter, after hitting a 32  year  low  in  November,  1971.
Just  how  fast  the economic position of the nation's steel
industry improves, however, depends to a large extent on one
important imponderable:  imports.  In the first  two  months
of  1972,  for  instance,  foreign  steel accounted for one-
seventh of the nation's apparent steel consumption.

General Description gf ^the_Operations

The hot forming and cold finishing  operations  exist  in  a
variety  that  makes  simple  classification and description
difficult.  In general, the hot forming primary mills reduce
ingots to slabs or blooms whereas the secondary mills reduce
slabs or blooms to billets, plates, shapes, strip, etc.  The
steel finishing operations involve  a  number  of  processes
that  do  little  to  alter the dimensions of the hot rolled
product, but which impart desirable  surface  or  mechanical
characteristics  to  the product.  The product flow of these
typical steel mill operations is shown in Figure 1.

It  is  possible,  and  often  economical,  to  roll  ingots
directly through the bloom, slab, or billet stages into more
refined  and  even  finished steel products in one mill in a
continuous  operation,  frequently  without  any  reheating.
Large  tonnages  of  standard  rails,  beams, and plates are
produced regularly by this practice from ingots of medium to
large size.  Most of the ingot tonnage, however,  is  rolled
into  blooms, slabs, or billets in one mill, following which
they are cooled, stored,  and  eventually  rolled  in  other
mills or forged.

The  basic  operation  in  a  primary  mill  is  the gradual
compression of the steel ingot between the surfaces  of  two
rotating rolls, and the progression of the ingot through the
space  between  the  rolls.   The physical properties of the
ingot prohibit making the total required deformation of  the
steel  in  one pass through the rolls, so a number of passes
in sequence are always necessary.  As the ingot  enters  the
rolls,  high  pressure water jets remove surface scale.  The
ingot is passed back and forth between  the  horizontal  and
vertical  rolls  while manipulators turn the ingot from time
to time so that it is well worked on all  sides.   When  the
desired  shape  has  been achieved in the rolling operation,
the end pieces or crops are removed by electric or hydraulic
shears.  The semi-finished pieces  are  stored  or  sent  to
reheating furnaces for subsequent rolling operations.

Ever   increasing   attention   is   being  devoted  to  the
conditioning of semi-finished products  as  the  requirement
                                   37

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for  high  qualities  of  steel  products  increases.  Major
elements in this area involve the need for removing  surface
defects from blooms, billets, and slabs prior to shaping, as
by  rolling  into a product for the market.  Such defects as
rolled seams, light scabs, checks,  etc.,  generally  retain
their  identity  during  subsequent  forming  processes  and
result in products of inferior quality.

These surface defects  may  be  removed  by  hand  chipping,
machine chipping, scarfing, grinding, milling, and hot steel
scarfing.    The   various   mechanical   means  of  surface
preparation are  those  common  in  all  metal  working  amd
machine shop operations.  Scarfing is a process of supplying
streams  of  oxygen  as  jets  to  the  surface of the steel
product under  treatment,  while  maintaining  high  surface
temperatures  that  result  in rapid oxidation and localized
melting of a thin layer of the metal.  The process may be  a
manual  one  consisting  of  the  continuous  motion  of  an
oxyacetylene torch along the length of the piece  undergoing
treatment.   In  recent  years  the  so-called  hot scarfing
machine has come  into  wide  use.   This  is  a  production
machine  adapted to remove a thin layer  (1/8 in. or less) of
metal from all steel passed through the machine in a  manner
analogous to the motion through rolling mills.

Reheating  is  necessary  throughout  the  rolling operation
whenever the temperature of the  metal  being  worked  falls
below  that  necessary  to  retain  the required plasticity.
Reheating furnaces are of two  general  classes,  batch  and
continuous  types.   Batch  furnaces  are those in which the
charged material remains in a fixed position on  the  hearth
until  heated  to  rolling temperature.  Continuous furnaces
are those in which the charged material  moves  through  the
furnace   and   is  heated  to  rolling  temperature  as  it
progresses toward the exit.  One unique  type  of  reheating
furnace  is  the  rotary  hearth  type  used  frequently for
heating rounds in tube mills and for heating  short  lengths
of  blooms  or  billets for forging.  The rotary hearth type
permits external walls and roof to remain  stationary  while
the  hearth section of the furnace revolves.  Batch furnaces
vary in size from those with hearths  of  only  a  few  feet
square  to  those  20 ft in depth by 50 ft long; some modern
continuous furnaces have hearths 80 to 90 ft long.

Plates are classified, by definition, according  to  certain
size  limitations to distinguish them from sheet, strip, and
flat bars.  According to  this  classification,  plates  are
generally  considered  to  be those flat hot-rolled finished
products that are more than 8 in. wide  and  generally  0.23
in.   or  more  thick, or over 48 in. wide and at least 0.18
                                  39

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in.  thick.  Sequence  of  operations  for  plate  mills  is
heating of slabs, descaling, rolling, leveling, cooling, and
shearing.   Most  plate  mills  use  continuous type heating
furnaces.  Descaling in modern plate mills  is  accomplished
by  hydraulic  sprays  impinging  on  both  top  and  bottom
surfaces and operating at pressures up to 1,500 Ibs per  sq.
in.   Temperature  variation  in the plate from the front to
the back is a problem of particular  importance  in  rolling
plates, as is the care that must be exercised in cooling the
rolled  product  so  as  to avoid distortion.  Plate rolling
mills are generally considered  in  two  very  broad  design
classifications.   One  type  includes  the  universal mills
which are characterized  by  vertical  rolls  preceding  and
following  the  horizontal  rolls;  such  a  mill produces a
product of a width which conforms to narrow tolerances.  The
second type of mill is the sheared plate mill which  may  or
may not include edge working equipment.

A wide variety of steel shapes are rolled from blooms; these
shapes   include   structural   sections  such  as  I-beams,
channels, angles, wide flanged beams, H-beams, sheet piling,
rails, and numerous special sections.  The  heating  of  the
bloom  for  large  sections  is  usually  done in batch type
furnace, although some newer mills use continuous  furnaces.
A  typical  mill  consists of a two high reversing breakdown
stand in which initial shaping is accomplished, followed  by
a  group  of  three  roll  stands in train where the rolling
process is completed; these  mills  are  known  as  roughing
stands,  intermediate stands, and finishing stands.  Several
passes of the material are made back and forth  through  the
breakdown, roughing and intermediate mills; a single pass is
usually  made  through the finishing stand.  The sequence of
operations then consists of heating bloom, rolling to proper
contour dimensions, cutting while hot to lengths that can be
handled,  cooling  to  ambient  temperature,  straightening,
cutting to ordered lengths, and shipping.

Merchant-bar,  rod, and wire mills produce a wide variety of
products in continuous operations  ranging  from  shapes  of
small  size  through bars and rods.  The designations of the
various  mills  as  well  as  the  classification  of  their
products  are  not very well defined within the industry; in
general,  the  small  cross-sectional  area  and  very  long
lengths  distinguish  the  products  of  these  mills.   Raw
materials for these mills are reheated billets.  Many  older
mills  use  hand looping operations in which the material is
passed from mill stand to mill stand by  hand;  newer  mills
use  mechanical  methods  of  transferring the material from
stand to stand.  As with other rolling operations the billet
is progressively squeezed and shaped to the desired  product
                                   40

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dimensions  in  a  series  of  rolls.  Water sprays are used
throughout the operation to remove scale.

The continuous hot  strip  mill  utilizes  slabs  which  are
brought  to  rolling  temperatures  in  continuous reheating
furnaces; the conditioned slabs pass through scale  breakers
and  high  pressure water sprays which dislodge the loosened
scale.  A. series of roughing stands and a rotary crop  shear
produce  a  section  that  can  be finished to a coil of the
proper weight and gauge.  The second scale breaker and  high
pressure  water  sprays precede the finishing stand train in
which the final size reductions are made.  Cooling water  is
applied  through  sprays  on  the  run-out  table,  and  the
finished strip is coiled.  Such a mill can turn a thick 6 ft
slab of steel into a thin strip or sheet a quarter of a mile
long in three minutes or less.  The modern  hot  strip  mill
produces  a product which may be up to 96 in. wide, although
the most common width in newer mills is 80 in.  The  product
of  the  hot  strip  mill  may  be sold as produced, or used
within the mill for further  processing  in  cold  reduction
mills, and for plated or coated products.

Welded  tubular products are made from hot-rolled skelp with
square or slightly beveled edges, the width and thickness of
the skelp being selected to suit the various sizes and  wall
thicknesses  to  be  made.   The  coiled  skelp is uncoiled,
heated, and fed through forming and welding rolls where  the
edges  are  pressed  together  at high temperature to form a
weld,  welded pipe or tube can also be made by the  electric
weld  process,  where  the  weld is made by either fusion or
resistance welding.

Seamless tubular products are made by rotary piercing  of  a
solid  round  bar  or  billet,  followed  by various forming
operations to produce the required size and wall thickness.

Correct  surface  preparation  is  the  primary   and   most
important   requirement   for  satisfactory  application  of
protective coatings to steel.  Without  a  properly  cleaned
surface,  even  the  most  expensive  coatings  will fail to
adhere or to prevent rusting of the steel base.   A  variety
of  cleaning  methods  are  utilized  to insure good surface
preparation for subsequent coating.  The steel surface  must
also  be  cleaned  at  various  stages  during production to
insure that oxides formed on the surface are not worked into
the finished product causing  marring,  staining,  or  other
surface imperfections.

Pickling  is  the  process of chemically removing oxides and
scale from the surface of the steel by the action  of  water
                                  41

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solutions of inorganic acids.  While pickling is only one of
several methods of removing undesirable surface oxides, this
method  is  the  most  widely  used  in  the  manufacture of
finished steel products, due to comparatively low  operating
cost and ease of operation.

Some  products  such  as tubes and wire are pickled in batch
oper~.cions; that is, the product  is  immersed  in  an  acid
solution  and  allowed  to remain in this solution until the
scale or oxide film is removed.  The material is lifted from
the  bath,  allowed  to  drain,  and  rinsed  by  sequential
immersion in rinse tanks.

Pickling  lines for hot-rolled strip operate continuously on
coils that are welded together, passed through the  pickler,
then  sheared  and  recoiled.   The steel passes through the
pickler countercurrently to the flow of the  acid  solution.
Most   plant  carbon  steel  is  pickled  with  sulfuric  or
hydrochloric  acid;  stainless  steels  are   pickled   with
hydrochloric,   nitric,  and  hydrofluoric  acids.   Various
organic chemicals are  used  in  pickling  to  inhibit  acid
attack  on  the  base  metal,  while permitting preferential
attack on the oxides; wetting agents are used to improve the
effective contact  of  the  acid  solution  with  the  metal
surface.   As  in  the batch operation the steel passes from
the pickling bath through a series of rinse tanks.

Solvents clean metal surfaces  by  dissolving  and  diluting
foreign  matter  such  as oil, grease, soil, and drawing and
cutting compounds.  Oil or grease may be removed  by  wiping
or  scrubbing  the  surface  with  solvent and clean rags or
brushes.  The steel may also be completely immersed  in  the
solvent,  or solvent sprays may be used, or the steel may be
subject to vapor degreasing in equipment in which  vaporized
solvent  condenses  on the surfaces to be cleaned.  Solvents
used  include  mineral   spirits,   naphthenes,   and   some
chlorinated hydrocarbons.

Alkaline cleaners are used where mineral and animal fats and
oils  must be removed.  Mere dipping in solutions of various
compositions,  concentrations,  and  temperatures  is  often
satisfactory.   The  use  of  electrolytic  cleaning  may be
advisable for large scale production, or where this  methodd
yields  a cleaner product.  Caustic soda, soda ash, alkaline
silicates  and  phosphates  are  common  alkaline   cleaning
agents.   Sometimes  the  addition  of wetting agents to the
cleaning bath will facilitate cleaning.

Blast cleaning utilizes abrasives such as sand, steel,  iron
grit,  or  shot  which  impinges at high velocity against the
                                  42

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surfaces to be cleaned, either by compressed air in a nozzle
type blast cleaning apparatus, or by  centrifugal  force  in
rotary   type  blasting  cleaning  machines.   Such  methods
usually result in a roughened  surface  and  the  degree  of
roughness  must  be  regulated  to  be  satisfactory for the
intended use.  Newer methods of blast cleaning are  said  to
produce  smooth finishes and, as such, promise to substitute
for pickling as a cleaning method.

Steel finishing operations involve  a  number  of  processes
which  do  little  to alter the dimensions of the hot-rolled
product, but which impart desirable  surface  or  mechanical
characteristics to the product.  Such processes include cold
rolling,   cold   reduction,   cold   drawing,  tin-plating,
galvanizing, coating with other metals, coating with organic
compounds as well as inorganic compounds, and tempering.

Cold reduced, flat rolled products are made by  cold-rolling
pickled  strip;  the thickness is reduced 25% to 99% in this
operation and a smooth,  dense  surface  is  produced.    The
product  may  be  sold  as cold reduced, but is usually heat
treated.

Cold reduction generates heat that is  dissipated  by  flood
lubrication   in  which  palm  oil  or  synthetic  oils  are
emulsified in water and directed in jets against  the  rolls
and the steel surface during rolling.  Cold reduced strip is
cleaned  with  alkaline  detergent  solutions  to remove the
rolling oils prior to coating operations.   Electrolysis  is
frequently  used  in such cleaning operations.  Cold-rolling
mills are used to give steel  products  a  smooth,  lustrous
finish, with little reduction in thickness.

Tin-plate  is  made  from cleaned, and pickled, cold reduced
strip by either the electrolytic  or  hot-dip  process.   In
this  country  more than 80% of the tin-plate is produced by
the electrolytic process; the  hot-dip  process  is  rapidly
becoming  obsolete  as a major tin-plating method.  The hot-
dip process consists of passing the steel  through  a  light
pickling  solution  and  then  through  the  tin  pot  which
consists of a flux, molten tin, and  a  bath  of  palm  oil.
Electroloytic  processes  will  be  included  in  the  final
Development Document for the electroplating  of  common  and
precious  metals  segment of the Electroplating Point Source
Category 40 CFR 413 to be published on a future date.

Hot-dipped galvanized sheets are produced on either sheet or
continuous lines.  The process  consists  essentially  of  a
light  pickle  in  hydrochloric  acid and application of the
zinc coating by dipping through the  pot  containing  molten
                                  43

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zinc.   Variations in continuous operations include alkaline
cleaning,  continuous  annealing  in  controlled  atmosphere
furnaces/ and several fluxing techniques.

In   recent   years,  steel  products  coated  with  various
synthetic resins have become commercially important.   Other
steel  products are produced with coatings of various metals
and   inorganic   materials.    Several   major    tin-plate
manufacturers  are  currently  substituting chromium plating
for tin-plating for the container industry.
                                  44

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                         SECTION IV

                 INDUSTRY SUBCATEGORIZATION


An  evaluation  of  the  hot  forming  and  cold   finishing
operations  was  necessary to determine if subcategorization
would be required in order to  prepare  effluent  guidelines
which would be broadly applicable and yet representative and
appropriate   for   the  operations  and  conditions  to  be
controlled.  From this evaluation  it  was  determined  that
fourteen subcategories would be required in order to develop
an  adequate  set of guidelines for the hot forming and cold
finishing segment of the Iron  and  Steel  Industry.   These
subcategories are as follows:

    M. Hot Forming Primary

    N. Hot Forming Section

    O. Hot Forming Flat

    P. Pipe and Tubes

    Q. Pickling-Sulfuric Acid-Batch

    R. Picling-Hydrochloric Acid-Batch and Continuous

    S. Cold Rolling

    T. Hot Coat-Galvanizing

    U. Hot Coat-Terne

    V. Miscellaneous Runnoffs

    W. Cooling Water Slowdown

    X. Utility Slowdown

    Y. Maintenance Department Wastes

    Z. Central Treatment

In  formulating  these  subcategories  a  knowledge  of  the
various operations was required.

Dsscrip.ti.on of Operations to Hot Form and Cold Finish Steel

Hot Forming
                                  45

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Hot forming defines the initial  stages  in  forming  useful
products  from  steel  ingots  by  hot rolling.  The initial
stages consist of a series  of  hot  rolling  operations  in
which  the  steel ingot cross-section is reduced to either a
square, oblong, or  rectangular  cross-sectional  shape  and
proportionately  increased  in  length.   Steel  ingots  are
originally tapered and 2 to 3 ft in cross-section and 5 to 9
ft in height.

The first rolling mill stages of the hot forming  operations
are identified as primary breakdown mills called blooming or
slabbing  mills.   The cross-section of final rolled product
determines whether the mill is identified as a  blooming  or
slabbing mill.  Generally slabbing mills produce rectangular
slab  shapes  2 in. to 6 in. thick and 24 in. to 60 in. wide
and blooming mills in the range of 6 in. x 6 in. to 12 in. x
12  in.  square  blooms  in  cross-section  and  lengths  of
products  may  be  up  to  90 ft.  The primary mills furnish
steel slabs or blooms either directly or  through  reheating
furnaces  to  secondary  finishing  or  section  mills.  The
slabbing mills furnish slabs to flat rolling mills, such  as
hot  strip  mills or plate mills; and blooming mills furnish
blooms for billet mills, bar and rod mills,  structural  and
rail  mills,  narrow  strip mills, and beam mills.  Products
from the bar, rod, and narrow strip  (sometimes  referred  to
as  skelp)  mills,  can be further rolled to produce pipe or
tubing.

Many of the primary mills are presently  being  replaced  by
the continuous casting process referred to as billet, bloom,
or slab casting machines.  The casting machines then in turn
furnish the steel slabs or blooms to the section mills.  For
description  and effluent guidelines for continuous casting,
see Phase I Report.

The steel products from the section and flat  rolling  mills
are  sometimes  further  cold  rolled,  cleaned  in pickling
operations and special coatings added such  as  galvanizing,
terne  plate,  etc.   These  operations  and  prcoesses  are
described under steel finishing.

Hot Forming - Primary  (Blooming and  Slabbing Mills);

The basic operation of a primary mill is the gradual  cross-
sectional  reduction  of  a  hot  steel  ingot  between  the
surfaces of two rotating steel rollers and  the  progression
of the ingot through the space between the rolls.

The  hot  steel  ingots are transferred to the primary mills
for rolling from soaking  pit  furnaces  which  provide  for
                                  46

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uniform  heating  of the steel ingots to the desired rolling
temperature, usually 1,180° to 1,340°C (2,156°  to  2,444°F)
and also acts as a storage area to compensate for production
variations   in   the  flow  of  steel  ingots  between  the
steelmaking  facilities  and  primary  rolling  mills.   The
soaking  pit  furnaces  consist  of  square, rectangular, or
circular, fuelfired (oil, gas, etc.)  refractory  lined  pits
constructed  with  the top of pits several feet above ground
level and  installed  usually  in  rows  under  cover  of  a
building  adjacent  or within the primary mill to be served.
The ingots are placed into the soaking pits  in  an  upright
position  through  openings  in  the  top.  Removable covers
close the pit openings.

The soaking pit furnace bottoms are made up using a  12  in.
to  16 in. thick bed of coke breeze and when the bed becomes
burned and contaminated with iron  oxide  scale,  and  other
alien  material,  it  is removed through cinder holes in the
furnace pit bottoms  and  new  12  in.  to  16  in.  bed  is
installed.

The  pits  are  spanned  by one or more cranes equipped with
ingot lifting tongs  for  placing  and  removing  the  steel
ingots  as  required.  The crane removes the properly heated
steel ingots and places  them  into  an  electrically-driven
ingot  transfer  car which automatically delivers the ingots
to the primary rolling mill.

After the steel ingot is delivered to the primary  mill,  it
is  generally  weighed  on  a scale and,  if required, turned
180° on a turntable so the top of  the  ingot  is  the  last
section  to  enter  the  rolling  mill.   The  ingot is then
delivered from the weigh  scale  table  across  motor-driven
table  rolls  to  the  rolling mill stand.  The rolling mill
stand housing contains the rolls for reduction  of  the  hot
steel  ingot.   Mills are generally classed according to the
number of rolls, and the diameter and length of rolls in the
first mill stand.  Also, the  mills  can  be  identified  as
reversing,  tandem, etc.  The term "two high reversing mill"
refers to two rolls in the mill stand, and in  reducing  the
steel  ingot,  it is passed back and forth through the rolls
(reversing) and is defined by the number  of  passes,  which
may  number as many as five to reach the proper size of slab
or bloom.

Tandem refers to a single pass through a multiple of  single
roll  stands,  thus  eliminating  the need for reversing the
ingots.  Mills can be two high, three high, four high, etc.
                                  47

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During the rolling  operations,  cooling  water  is  sprayed
externally  over the table and mill stand rolls.  This water
is  discharged  to  trenches  beneath   the   rolling   mill
equipment.   When  the  steel  ingot enters the rolling mill
stands, high pressure  (2,000 psi) descaling water is sprayed
over the hot steel ingot to flush away any iron oxide  scale
that  forms.   Generally,  about  4X  of  this cooling water
evaporates, and the balance is discharged to an  iron  oxide
scale   and  water  collection  system.   Iron  oxide  scale
generation may amount  to  8-10%  of  the  throughput  steel
production.

Primary  mills  are  generally rated on the tons of finished
rolled product the mill produces on an  hourly  basis.   For
example,  one  slabbing mill producing 14 in. x 82 in. slabs
is rated at 630 tons/hour, and a blooming mill producing  9-
1/2 in. x 11 in. size is rated at 125 tons/hour.

After the product has been reduced to the proper size in the
rolling  mill stand, it is transferred via motor-driven mill
table rolls to the shear  where  the  product  is  cut  into
proper  lengths  for the section or flat rolling mills.  The
last portion of the rolled product is sheared off and wasted
to a  scrap  bin  for  recycling  back  to  the  steelmaking
facilities.   This  section  contains impurities, etc., from
the original steel ingot and is referred to  as  the  "crop"
ends.

When  the product is sent to the secondary mills for further
rolling, any imperfections  in  the  surface  of  the  steel
product  will  produce  a poor finish in the section or flat
mills  product.   Therefore,  the  steel  product  from  the
primary  mills  is  generally  hand  scarfed,  automatically
scarfed, machine ground or chipped or hand or machine gouged
to remove these surface imperfections before rolling in  the
section  mills.   Many primary mills have automatic scarfing
facilities for  the  surface  finishing  and  are  installed
between  the  rolling  mill  stands and shear.  The scarfing
operation consists of passing the hot steel product  through
natural  gas-fired  preheat  burners  and then applying high
pressure, pure oxygen through nozzles to the  steel  surface
which  removes  from  3/32  in. to 3/16 in. thickness of the
steel slab.  High pressure water sprays  (150 psig) flush the
slag from the steel surface as it  is  generated.   All  the
slag  and water is discharged into a pit beneath the scarfer
machine.  Low pressure  (HO psig) mill water is also used  to
spray  exposed  scarfer  equipment  to protect the equipment
from heat and flying slag particles.  The hot steel scarfing
results in the generation of appreciable quantities of smoke
and fume, the quantity  and  density  depending  upon  steel
                                  48

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analyses,  oxygen pressure, etc.  It is necessary to collect
and discharge the smoke and fume  by  means  of  a  suitable
exhaust  system  consisting  of a hood over the roll tables,
exhaust duct system, dust collector, and fan.  Older systems
discharged the smoke and fume directly to the atmosphere but
the newer scarfer systems  are  installing  dust  collection
systems  with either wet electrostatic precipitators or high
energy scrubbers.  The smoke solids generated are  submicron
iron  oxide  particles,  yellowish-brownish  in  color.  The
scarfing operation produces about 5 grams per KKG (35 grains
of smoke solids per pound)  of steel removed.

The exhaust system volumes may vary between 9,400 to  47,000
I/sec  (20,000  to  100,000  cfm)  consisting  mainly of air
(nitrogen and oxygen)  and small percentages  of  CO2   (1.5%)
and  CO  (0.6%).   Resulphurized  steels, when scarfed, will
produce acidic water discharges.

After the product is sheared to length, it is transferred to
cooling beds and allowed to cool.  Some  installations  will
couple a billet mill directly to the blooming mill, and then
the  product  is transferred directly without cooling and is
rolled into a consumer product such as hot-rolled rounds and
bars.

More specific details of the blooming  and  slabbing  opera-
tions are shown in Figure 2.

Hot Forming - Section

Billets

Blooms  from  the  primary mill are conveyed directly to the
billet mill without  reheating.   The  billets  are  further
processed  to produce materials with small sections, such as
tube rounds, bar and rod, wire, small sections, and  special
products.

Modern  billet  mills  utilize  continuous  lines which have
alternate horizontal and vertical stands.   The  blooms  are
normally  passed through hot-scarfing machines after leaving
the bloom shears.  The scarfing head of the machine contains
oxyacetylene burner  nozzles  to  remove  defects  from  the
surface  of the blooms.  Fume control equipment is required,
and water sprays carry the iron oxide waste through a trench
under the mills to a collection system. Metal  loss  in  the
scarfing  operation  is  generally  2% to 3X of the product.
The bloom is now conveyed  to  the  continuous  billet  mill
stands.   The  continuous  mill consists of a series of roll
stands, arranged one after the other so that the piece to be
                                  49

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rolled enters the first stand and travels through the  mill,
taking but one pass in each stand of rolls and emerging from
the  last  set  as  a finished product.  Descaling water and
cooling water are sprayed at the stands and rolls  with  the
discharge going to trenches under the mills.

After  the  billet  mills  the product is cut to the desired
finish  piece  length.   The  cutting  is  accomplished   by
stationary  shears, movable gang shears, flying shear, flame
cutting, or saws.  Shears are  faster  but  distort  product
ends.   Flying shears are used on small billets to eliminate
long tables and transfers.  Saws and flame cutting eliminate
distorted ends but are slower and  require  maintenance  and
expensive fuels.

After   cutting,   the   billets   are  stamped  for  proper
identification of heat number so the product may be properly
routed.  The billets are cooled on cooling beds, or hot beds
and then pushed into cradles, from which they can be  loaded
into   cars   for   shipment   or  transferred  for  further
processing.

Billets are transferred to the bar mill or merchant mill for
processing into finished products.  The billets  are  heated
to  rolling temperature in a continuous reheat furnace.  The
billets are fed into one end and moved through  the  furnace
by  a  billet  pusher.   A walking beam furnace is sometimes
utilized to eliminate the slide marks on  the  underside  of
the  billets.  A billet ejector, normally a pusher bar type,
pushes the end billet out of the side  of  the  furnace.   A
shear  cuts  the heated billets to size or removes b*=>"t ends
prior to conveying the billet to the bar mill.

Modern bar mills are normally arranged  in  a  cross-country
design  or  continuous  design.   Both  types  have  in-line
roughing stands but the cross-country mill has side by  side
intermediate  and finishing stands where the continuous mill
has  all  stands  in-line.   The  continuous  mill  is  more
efficient  for  production  runs but requires more space and
individual motors on  each  stand.   Descaling  and  cooling
water  sprays  are  employed  at  the  irill  stands with the
discharge going into trenches under the mill  to  collection
systems.

Various products are rolled in the bar mills such as angles,
channels,  flats,  other small sections, rebar, window sash,
fence posts, rounds, wire, and  flat  narrow  strip.   These
various  products  are  conveyed  to  a  cooling bed.  After
cooling the product is sheared to proper length, marked  for
                                  51

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identification,  sometimes  straightened, bundled or coiled,
and weighed for shipment or further processing.

Blooms from the primary mill are further  processed  into  a
variety of products.  The products are rails and joint bars,
structural and other sections, and billets which are further
processed  to  tube  rounds,  bar and rod, wire, and special
products.
Rails  are  formed  from  heated  blooms  in  various   mill
arrangements,  but the formation may be considered as taking
place in three steps or stages.   The  first  stage  is  the
roughing   where   the  bloom  is  reduced  in  section  and
elongated.  High pressure sprays are used at  the  discharge
of  the  roughing  stands for scale removal.  The second, or
intermediate stage, proceeds with the forming  of  the  rail
and involves a combination of slabber, dummy, former, edger,
and  leader passes, depending on the mill layout.  The third
stage is the finishing pass which completes the formation of
the desired rail section.

The rails are conveyed from the finishing stand on a  runout
table  to  hot  saws  which  cut  the  product to the normal
standard 39 ft rail length.   After  sawing  the  rails  are
stamped,  cambered,  and weighed before they are advanced to
cooling beds.  Rails intended for railroad service  must  be
control  cooled  in  containers  to prevent the formation of
internal thermal ruptures  or  cracks.   After  cooling  the
rails   are  conveyed  to  the  finishing  operations.   The
finishing consists of  inspection,  removal  of  saw  burrs,
straightening,   drilling,   grinding   of  ends,  leveling,
inspection, classification, and  painting.   The  rails  are
then ready for storage and shipment.

Rail-Joint Bars

Joint  bars are rolled from heated blooms or billets similar
to rails.  Additional passes are required if the  joint  bar
has   a  depending  flange,  or  long  toe.   The  finishing
operation consists  of  hot-working  and  oil-quenching  the
joint  bars.   In this operation the product is cold sheared
to length and then reheated for hot-working  which  consists
of  punching,  slotting,  straightening, and quenching in an
oil tank.

Structural and Other Sections
                                   52

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Structural sections include standard items, such as I-beams,
channels,  angles,  and  wide-flange  beams,   and   special
sections  such  as zees, tees, bulb angles, and car-building
center sills.  Other  sections  include  such  miscellaneous
shapes  as  sheet  piling, tie plates, cross ties, and those
for special purposes.

Blooms are heated in a continuous reheat  furnace  and  then
conveyed   to  the  roughing,  intermediate,  and  finishing
stands.  Passes in actual use range  from  fifteen  roughing
and  nine  intermediate  on sections requiring heavy overall
work, to two fine roughing, and three  intermediate  on  the
sections  requiring  a  minimum  of work.  In all cases, the
intermediate passes are followed by a single finishing pass.
In rolling wide-flange beams it is customary to roll a bloom
which has, as nearly as possible, the  same  proportions  as
the finished beam.

Rolled  material  from  the structural mills is delivered by
roller table to the hot saw.  This equipment consists  of  a
circular  saw  with  large  quantities  of  cooling water to
maintain the cutting edges.  Cuts are usually  made  at  the
hot saw to remove the crop ends, to part the usable material
into lengths that can be handled for further processing, and
to provide short test pieces.  The shapes are then cooled on
a cooling bed.  After cooling the shapes are conveyed to the
finishing  area where they are straightened, cold sheared or
cold sawed, and inspected prior to separating and  assembled
for shipment.

More  specific details of sectional type mill operations are
shown on Figures 3 and 3a.

Hot Forming - Flat

Plate Mills

The basic operation of a plate mill is the  reduction  of  a
heated  slab  to  the  weight  and  dimensional  limitations
defining plates.  This is accomplished by heating the slabs,
descaling,  rolling  to  plate,  leveling   or   flattening,
cooling, and shearing to desired size.

Slabs  are  received from the slabbing mill or roller tables
or removed from storage by overhead cranes and placed  on  a
charging  table  at  the  entry end of reheat furnaces.  The
slabs are removed through a continuous type  reheat  furnace
by  pushing  the  last  piece  charged  with a pusher at the
charging or entry end of the furnace.   The  reheat  furnace
heats  the  slabs to rolling temperature up to approximately
                                  53

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STEE INDUS
OT FO
TYPE
OCESS FLO
54

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                                                                             W
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                     55

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1,230°C (2,250°F).  As each cold slab  is  pushed  into  the
furnace  against  the  continuous line of material,  a heated
piece is removed.  The heated slab is  discharged  from  the
furnace by gravity upon a roller table which feeds the mill.

Heated  slabs  are  conveyed  on  a roller table to a scale-
breaker stand.  As the slab exits  from  the  scale-breaker,
primary  descaling  is completed on the delivery side of the
mill as the slab is  passed  through  top  and  bottom  high
pressure  hydraulic  sprays  operating at 1,000 psi to 1,500
psi.  The scale-breaker and sprays  flush  away  iron  oxide
scale   that   forms  on  the  surface  of  the  hot  slabs.
Generally, about 4X of the spray water  evaporates  and  the
balance is discharged through a trench under the mills to an
iron  oxide  and  water collection system.  Iron oxide scale
generation may amount  to  8-10X  of  the  throughput  steel
production.  During the rolling operations, cooling water is
sprayed  externally  over  the  table  and mill stand rolls.
Additional lubrication of mill stand rolls  is  provided  at
intervals by shots of water-soluble oil.

The  descaled  slabs  are  conveyed  on roller tables to the
plate mill.  There are various types of plate mills such  as
three-high  mills,  four-high reversing mills, tandem mills,
semi-continuous  and  continuous  mills.   In  each  of  the
various  plate  mills  the  heated  slab  is  reduced to the
desired plate size.  Cooling water, spray water, and  water-
soluble oil is sprayed externally over the mill stand rolls.
Hydraulic sprays on both sides of the mill stands, operating
at  high pressure, are utilized for top and bottom secondary
scale removal.

The plates are conveyed on a runout table to a  leveler.   A
portion  of  the  runout  table is equipped with a series of
cooling sprays.   After  leveling,  the  plates  are  cooled
uniformly  to  avoid  localized  stresses which would set up
permanent  distortions.   After  cooling,  the  plates   are
conveyed to end and side shears to be cut to proper size and
then into a shipping or storage building.

More   specific  details  of  a  plate  mill  operation  are
presented on Figure 4.

Hot Strip Mills

The basic operation of a hot strip mill is the reduction  of
slabs to flat strip steel in thicknesses of O.OU in. to 1.25
in., widths of 24 in. to 96 in., and lengths up to 2,000 ft.
A  modern wide hot strip mill will heat slabs in two or more
continuous reheating furnaces and convey the heated slabs to
                                   56

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a rolling train.  A typical rolling train will consist of  a
roughing scale-breaker, and six four-high finishing stands.

Slabs  are  received from the slabbing mill on roller tables
or removed from storage by overhead cranes and placed  on  a
charging  table  at  the  entry end of reheat furnaces.  The
slabs are moved through a continuous type reheat furnace  by
pushing the last piece charged with a pusher at the charging
or  entry  end of the furnace.  The reheat furnace heats the
slabs to rolling temperature up to approximately  1,100°  to
1,300°C  (2,010°  to  2,370°F).  As each cold slab is pushed
into the furnace against the continuous line of material,  a
heated piece is removed.  The heated slab is discharged from
the  furnace  by gravity upon a roller table which feeds the
mill.

Heated slabs are conveyed on a roller table to the  roughing
scale-breaker stand for primary descaling.

Descaling water sprays, operating at approximately 1,300 psi
pressure  after the stand, remove iron oxide from the slabs.
Generally,  about U% of the spray water  evaporates  and  the
balance is discharged through a trench under the mills to an
iron  oxide  and  water collection system.  Iron oxide scale
generation may amount  to  8-10%  of  the  throughput  steel
production.  During the rolling operations cooling water and
water-soluble  oil  is sprayed externally over the table and
mill stand rolls.

The slabs are conveyed from the  roughing  scale-breaker  to
the  four  four-high  roughing  stands.   The first roughing
stand is normally a broadside mill used  to  produce  widths
greater  than  the  original  slab.   Slab  turnarounds  are
provided before and after this mill to rotate the slabs  90°
when the stand is used for broadsiding.  Following the mill,
a  slab squeezer serves to true up edges and widths.  A slab
shear  is  located  between  the  squeezer  and  the  second
roughing  stand.   Sheared waste is fed into a scrap bin for
recycling back to the steelmaking facilities as scrap.   The
second,  third, and fourth roughing stands are equipped with
vertical edging rolls mounted on  the  entry  side  of  each
mill.   After  the  roughing  stands,  the rolled product is
cooled on a holding table, if necessary,  to  attain  proper
finishing  temperature  to meet requirements.  A rotary crop
shear is installed at the end of the table, so that both the
front and back ends of  the  material  can  be  squared  off
before  finishing.   A second scale-breaker followed by high
pressure sprays  is  utilized  to  perform  secondary  scale
removal prior to entering the finishing stands.
                                  58

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Material  is fed into the finishing train, which consists of
six four-high mill stands, and is  continuously  reduced  to
strip  product.   Product  speed  leaving the last finishing
stand reaches approximately 600 meters/minute  (1,970  fpm).
Loopers  are provided between the finishing stands and steam
sprays are provided on the delivery side of each stand.

Strip product is conveyed from the  finishing  stands  on  a
runout   table   to   automatic  coolers.   Cooling  sprays,
sometimes referred to as laminar sprays,  continuously  cool
the product on the runout table.  Similar to the mill stands
and  tables,  the spray water is discharged through a trench
under the mill to a water  collection  system.   The  coiled
strip  product  is  then conveyed to storage for shipping or
further processing.

More specific details of a hot strip mill operation are also
presented on Figure 4.

Skelp_Mills

Skelp is a hot rolled strip used to make butt-weld  pipe  or
tube.   The  skelp is rolled with square or slightly beveled
edges, the width of which corresponds to  the  circumference
of  the pipe, and the gauge to the thickness of the wall.  A
bloom is heated and rolled to produce skelp of  the  desired
size.

The  bloom  which  is rectangular in shape and of the proper
dimensions to produce skelp of the desired size,  is  heated
in  a continuous reheat furnace to rolling temperature.  The
bloom is then conveyed on a roller table to the mill stands.

The first two to four stands in the mill,  corresponding  to
roughing  stands  in other mills, are used to spellerize the
bloom.  This means  the  working  surfaces  of  the  stands,
called  knobbling  rolls, are provided with regularly shaped
projections and depressions, while the surface of the  other
passes  are  plain.   When  the  bloom  passes through these
rolls, the  kneading  process  to  which  its  surfaces  are
subjected  is  said  to  give  a pipe surface that is better
adapted  to  resist  corrosion.   Descaling  water   sprays,
operating  at  high  pressure  after the stands, remove iron
oxide scale from the blooms.  Generally,  about  4%  of  the
spray water evaporates and the balance is discharged through
a  trench  under  the  mills  to  an  iron  oxide  and water
collection system.  Iron oxide scale generation  may  amount
to  8-10%  of  the  throughput steel production.  During the
rolling operations, cooling water and water-soluble  oil  is
sprayed externally over the table and mill stand rolls.
                                   59

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The  bloom,  now  much  reduced  in thickness, is edged by a
twisting guide in the  next  group  of  rolls  in  order  to
control  the width.  Next, the bloom is cut into two or more
pieces by a hot shear, to adjust the length of the  finished
strip  to the cooling bed.  These pieces then pass flatwise,
or flat and edgewise, through the next fine  stands  to  the
vertical  rolls.  The vertical rolls are grooved to roll the
edges of the skelp, which must be slightly beveled, so that,
when skelp is bent to form the pipe, they will fit  squarely
together and form a perfect joint.

From  the finishing rolls, the skelp passes over the cooling
bed to the shears, where the crop ends are cut off, and  the
remainder  of  the  skelp  strip  is  cut  into  the lengths
desired.  The skelp is then passed to the clipper, a machine
that performs the double function of a shear  and  a  press.
It shears two small triangular-shaped pieces from one end of
the skelp to start the curve for welding the pipe, and bends
the end of the skelp to facilitate handling with the welding
tongs.   The  skelp  is stacked and transported to the butt-
welding furnaces.

More specific details of a typical skelp mill operation  are
shown on Figure 5.

Pipe and Tubes

Steel  tubular  products  have  many uses to which they have
been applied and  this  has  led  to  descriptive  terms  in
designating   the  products  used  for  different  purposes.
Typical products are standard pipe, conduit pipe, line pipe,
pressure pipe, structural pipe, oil-country  tubular  goods,
pressure  tubes,  mechanical tubes, and stainless steel pipe
and tubes.  Another classification is based on  the  methods
of  manufacture, to which we will refer.  On this basis, all
steel tubular products may be classified under the two  main
headings of welded and seamless.

Welded Tubular Products

Welded  tubular  products  are classified as butt-weld, lap-
weld, or electric-weld.  Butt-weld pipe or tube is made from
a hot rolled strip, with square or  slightly  beveled  edges
called   skelp,  the  width  of  which  corresponds  to  the
circumference of the pipe, and the gauge to the thickness of
the wall.  By heating this skelp to the welding  temperature
and drawing it through a die or roll pass, the skelp is bent
into cylindrical shape and its edges pressed firmly together
into  a  buttweld, thus forming a pipe.  Lap-weld  is similar
except the edges are lapped.  In the electric-weld  process,
                                  60

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hot  rolled  strip  or plate of a gauge corresponding to the
thickness of the wall of the pipe desired, but of an overall
width slightly greater  than  its  circumference,  is  first
edge-trimmed  to insure parallelism and accurate width.  For
large diameter pipe fusion-welding is used.   The  plate  is
bent  into cylindrical shape with the beveled edges abutting
to form a "V" into which the electrode is melted.  For small
diameter pipe electric-resistance welding is  used,  whereby
the  union  of  the  seam  is affected by the application of
pressure  and  heat,  the  heat  being  generated   by   the
resistance to current flow across the seam during welding.

Butt-Welded Pipe

The  butt-welded process is used in the manufacture of pipe,
1/8 in. to 4 in., nominal diameter.  Skelp is conveyed  from
storage  and  charged  into a reheating furnace, welded in a
welding stand, and finished on finishing machines.

The skelp is  charged  into  a  continuous  reheat  furnace.
Modern  mills used skelp strip in coils to feed a continuous
butt-welding mill.   The  skelp  is  fed  into  a  threading
machine  which  feeds  it  through  the  furnace.   Once the
leading end is in the forming and welding unit the threading
rolls release the skelp.  The leading end of the next  skelp
strip  is welded to the trailing arm of the first strip by a
flash-type skelp welder, prior  to  the  entry  end  of  the
reheat furnace.  The skelp strip exits from the furnace into
a  continuous  forming  and welding mill.  The forming stand
rolls force the skelp into an arc of about  270°.   Then  it
goes  through a welding horn and into a welding stand, where
the edges are pressed firmly together.  The last  stands  of
the  mill contain reducing rolls which provide for reduction
of diameter and  resultant  change  in  wall  thickness.   A
rotary  flying  saw  cuts  the continuous pipe into lengths.
The cut lengths are reduced to the required hot  size  on  a
sizing mill.  The hot pipe is delivered to a cooling bed and
then   passes  to  a  water  bosh  tank  for  fast  cooling.
Conveyors feed the pipe to straighteners  in  the  finishing
bay.

Seamless Tubular Products

Seamless   tubular  products  are  made  by  two  processes;
piercing and cupping.  In  the  piercing  process,  a  solid
round bar or billet is heated, pierced and afterwards shaped
to the desired diameter and thickness of wall.  This process
is  used  today for most of the seamless pipe products.  The
cupping process is used primarily  for  the  manufacture  of
special  tubes and gas cylinders.  A circular sheet or plate
                                  63

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	f
       is  forced by successive operations through several pairs  of
       conical  dies  until  the plate takes the form of a tube,  or
       cylinder with one end closed.

       Seamless^gipe Mills

       The production of seamless pipe and the  mills  required  in
       the  operation  will  vary  depending on the diameter of the
       pipe product.  The steps required to produce pipe  up  to  H
       in.   diameter  consist  of heating a solid billet, piercing,
       plug rolling, reeling, reheating  and  reducing  or  sizing.
       Pipe  up  to  16  in.  diameter  is  similar except a second
       piercing and reheating operation is required.   Pipe up to 26
       in.  diameter is similar to the preceding  16  in.  operation
       except for the addition of a rotary rolling mill and a third
       reheating operation.

       A  solid  bar or billet of the proper length and diameter to
       make the size and  weight  of  tube  desired  is  heated  to
       rolling temperature of approximately 1,230°C (2,250°F).  The
       heated  billet  is transferred in a horizontal trough to the
       piercing mill.  The piercing mill consists of two  contoured
       horizontal  rolls and a piercing mandrel.  The roll surfaces
       are contoured so that, in the horizontal plane  through  the
       centerline  of  the  pass,  the space between the rolls con-
       verges toward the delivery side and then  diverges  to  form
       the  pass  outlet.   The  elevation of the centerline of the
       pass is determined by guides mounted  above  and  below  the
       center  of the mill in the space between the rolls.  Between
       these guides in the pass outlet a projectile shaped piercing
       mandrel is held in position on the  end  of  a  water-cooled
       mandrel  support  bar,  located  on the delivery side of the
       mill.  As the billet, which is in a  plastic  state,  enters
       the  mill,  the  rolls  grab  it  at  opposite points on its
       circumference.  As the billet is drawn  and  compressed  the
       spreading  of  the  metal sets up a lateral tension that may
       cause its particles to be drawn away from the  center.   The
       nose  of  the mandrel is at a point preceding the forming of
       the cavity to insure a smooth inner  surface.   The  pierced
       billet  is  drawn  out  by the rolls and in passing over the
       mandrel produces the hollow  shell.   The  initial  piercing
       produces a hollow tube with a comparatively heavy wall.  The
       second  piercing mill further reduces the wall thickness and
       increases the diameter and length of the piece  required  in
       producing large diameter product.

       In the plug mill, a plug on a support bar is rammed into the
       end  of  the  shell.   The  shell  is drawn over the plug by
       revolving rolls, slightly reducing the  wall  thickness  and
       increasing the diameter and length.  The rotary rolling mill
                                         64

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is  used  for  large  diameter pipe.  Conical rolls grip and
spin the pipe, feeding  it  forward  over  a  large  tapered
mandrel,  thereby affecting a decrease in the wall thickness
of the pipe and an increase in the diameter.  The length  of
the tube is substantially unchanged by this operation.

The  reeling machine consists of rolls and a mandrel similar
to the piercing mill.  A slight reduction in  the  thickness
of  the wall is affected during the reeling operation.  This
slight reduction has the effect of burnishing the inside and
outside surfaces of the tube  and  slightly  increasing  its
diameter.   After  reeling the tube is reheated and conveyed
to the sizing mill.  The sizing mill consists of a series of
stands of sizing rolls, the grooves of  which  are  slightly
smaller  than  the  reeled  tube.   The  diameter  reduction
affected is to insure uniform size and roundness  throughout
the  length  of  the  tube.   After  sizing  the  product is
straightened,  end  cropped,  inspected,  and  finished   as
required for its eventual use.

Electric-Resistance-Welded Tubing

Electric-resistance-welded  tubing  is  referred  to  as ERW
tubing.  Strip sheet or plate in coil  form  is  used  as  a
starting  material  for  ERW  tubing.  The steps used in the
manufacture of ERW tubing are:   forming,  welding,  sizing,
cutting, and finishing.

Tubing  is  produced  from  single width strip, the width of
which will equal the perimeter of the tubing to  be  welded.
If extra wide strip is used it is passed through a slitting-
line  for  cutting  to  proper width and then recoiled.  The
proper width strip is fed into forming rolls.   The  forming
rolls  consist  of  an  edge trimmer to smooth and clean the
edge of the strip for good welding and forming, closing  and
fin pass rolls.  After the fin rolls the strip is in perfect
guidance to enter the welding section to provide the precise
circumference  of the required tube.  In the welding section
of the mill the tube is held in squeeze rolls at the correct
pressure to provide the desired weld as the edges are heated
at this point to welding temperature.  The heat for  welding
is  provided by low-frequency power through electrode wheels
or radio-frequency power through sliding  contacts  or  coil
induction.  Typical power for welding is supplied at 450,000
cycles  per  second.   The  welded  tube then passes under a
cutting tool which removes  the  flash  resulting  from  the
pressure  during welding.  The welded seam or entire tube is
then  annealed  or  normalized  depending  on  the  required
metallurgy.   After  cooling the tube is sized on horizontal
and vertical sizing rolls to obtain a round finished product
                                  65

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of the desired diameter.  After sizing the tube  is  cut  to
length,  straightened,  and  end  finished if required.   The
tubes are inspected and packed for shipment.

Electric-welded Pipe

The electric-weld process or fusion weld is used to  produce
pipe  in  unlimited diameters.  If the circumference exceeds
the plate width, two or more plates may be  welded  together
to  provide the necessary width.  The steps required to make
plates into pipe by the electric-weld process are  shearing,
planing,   crimping,   bending,   welding,   expanding,   and
finishing.

Plate is transferred to the edge-planing machine where it is
aligned so that the two edges will be  parallel  and  square
with  the  ends  after planing.  Forming plate into circular
pipe  is  usually  performed  in  three  operations   called
crimping,   "U"-ing,  and  "O"-ing.   The  first  operation,
crimping, consists of bending the edges in a press so as  to
avoid a flat surface near the longitudinal seam of the pipe.
The crimped plate is then conveyed to a "U"-ing machine.  In
this  operation  the  plate  is  centered  over  a series of
parallel rocker-type dies which lie along the  axis  of  the
plate.   A  large "U"shaped die operated by a press, as long
as the longest length of plate, is moved down on the  plate,
forcing  it  between  the  dies  which automatically conform
themselves to the operation and assist in forming the  plate
into  the  "U" shape.  The plate is then transferred to what
is called the "O"-ing machine.  The machine consists of  two
semicircular  dies  which are as long as the plate.  Rollers
mounted on vertical spindles prevent the plate from  falling
and  keep  it  in correct alignment as it enters the "0"-ing
machine.  The "U"-shaped plate rests in the bottom die,  and
the  top  die is forced down by a press, deforming the plate
until it is the shape of an almost closed  circle  which  is
then  ready  for  welding.  The pipe is held in position for
welding by a longitudinal rod which maintains the proper gap
for welding.  A specially  designed  welding  head  deposits
flux  along  the joint, feeds metal electrode, and transmits
welding current to the  joint and electrode.   Molten  filler
metal  is deposited from the metal electrode to the work and
replaces the fluid flux and forms the weld.  After the  pipe
is  welded  on  the outside it is welded on the inside by an
automatic welding machine mounted  on  the  end  of  a  long
cantilever  arm  and  the  pipe  is drawn over this arm by a
carriage.  After welding the scaly  deposit  left  from  the
flux is removed by a  cantilevered tube device.
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The  final pipe diameter is obtained by either hydraulically
expanding  the  shell  against   a   retaining   jacket   or
mechanically  expanding  it  over  an  inside  mandrel.   In
hydraulic  expansion,  tne  ends  are  expanded  to   proper
diameter  by  mandrels.  Retainer rings encircle the body of
the pipe  which  is  filled  with  water  and  hydraulically
expanded  to the limits of the bands.  This also serves as a
hydraulic test.   The  expansion  by  either  method  sizes,
rounds, and straightens the pipe and provides a good test of
the  weld.  Attention is given to non-destructive inspection
of the weld quality, by x-ray examination of the weld.   The
pipe  is then placed in special machines which face the ends
to ensure they are smooth  and  at  right  angles.    If  the
joints  are  to  be  welded,  the  ends  are beveled in this
operation prior to shipment.

More specific details of typical pipe  mill  operations  are
also presented on Figures 5 and 5a.

Scale Removal

Heat  is  used  in  the  production  and finishing of steel.
Exposure to the atmosphere causes oxide scale to form on the
surface of the hot steel.  This scale must be removed  prior
to further processing.  This operation can be done in one of
the following ways:

1.  Acid Pickling
2.  Mechanical Action

Acjd gickling

The  traditional  method  of   scale   removal   is   called
"pickling".   Pickling  is  the  chemical removal of surface
oxides (scale) from metal by immersion in a heated solution.
Carbon steel pickling is almost universally accomplished  by
using  either  hydrochloric acid or sulfuric acid.   The acid
conditions vary with the type material to  be  pickled.   In
addition the bath temperature, use of inhibitors, and source
of  agitation  are  also  varied dependent on material to be
pickled.  Pickling is accomplished  by  either  one  or  two
general  processes  dependent  upon  the type material to be
pickled.

A.  Continuous Strip Pickling

Continuous strip pickling lines use  principally  horizontal
pickling  tanks.    (However,  in a few cases, vertical spray
tanks are being employed.)
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The fresh acid solution is added to the  last  tank  section
and cascades through the tanks to an overflow located in the
first section.  Acid solution flow is opposite the direction
of  the  strip travel.  More specific details of the process
are shown on Figures 6 and 6a.

B.  Batch Type Pickling

Large, open tanks of a wide range  of  sizes  are  used  for
batch  type  pickling,  principally  for  rod  coils,  bars,
billets, sheet, strip, wire, and tubing.  Pickling  is  also
applicable  to  many types of forgings, castings, structural
parts, and other sundry-shaped items.  Tanks  are  generally
rubber  lined  and brick sheathed and hold a large volume of
heated acid solution.   (Most often sulfuric acid  is  used.)
After   a   certain   iron  buildup  due  to  scale  removal
(pickling), the acid solution is considered spent and dumped
as a batch.  A typical flow sheet  illustrating  details  of
the process are shown on Figure 7.

There  are  three  separate  operations  involved  with  the
pickling  operation.   They  are  as  follows  and  directly
related to one another:

A.  Pickling
B.  Rinsing
C.  Fume Scrubbing

Pickling

If pickling is to be done efficiently, it must  be  regarded
as  what  it  really  is...a  chemical process, not merely a
method of cleaning, using hot acid.  When  this  concept  is
accepted,  then  the  conditions necessary for any efficient
chemical reaction can be stated and defined.   In  pickling,
those    conditions    are   temperature,   agitation,   and
concentration.

Temperature.    Temperature   is   critical    because    it
dramatically  affects  the  rate  of reaction.  However, the
method of heating is also important.   When  live  steam  is
injected  directly  into  the acid tank, it dilutes the acid
strength by increasing the volume of acid solution since the
steam condenses into water.  To avoid dilution, internal  or
external  heat exchangers should be employed.  These devices
transfer heat from steam to  pickle  liquor  but  allow  the
condensate to be discharged externally.
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Agitation.   Agitation  is  probably the most ignored aid to
good pickling.  The  speed  of  pickling  can  be  increased
significantly by properly agitating the acid pickle bath.

Sulfuric.  A proven answer is an effective, custom-designed,
air-operated,  agitation  system  suited  to  the  type  and
configuration of the steel being pickled.  An added  benefit
is   that   the   evaporation   (caused  by  air  agitation)
concentrates, rather than dilutes, the acid  bath.   Induced
evaporation  requires  the addition of more pickling liquids
to maintain optimum tank level.

Hydrochloric»  In the case  of  hydrochloric  acid  pickling
(which  is  usually  the  case  in continuous strip pickling
lines), the agitation can be achieved  by  recirculation  of
the  pickle  liquor  from  the pickling tanks, into external
heat exchangers, and back into  the  pickling  tanks.   This
agitation  is  supplemented  by  the  movement  of the strip
itself through the pickling solution.

In either case, however, any additional vapors or acid mists
caused by the agitation system need not be a problem because
they can  be  collected  in  a  proper  exhaust  system  and
returned to the pickle tank for reuse.

Concentrations   of  acid  and  ferrous  salts  are  related
directly to the rate of reaction  and  subsequently  to  the
rate  of  cleaning.   Yet,  most pickling plants do not have
facilities that would justify  maintaining  consistent  acid
strengths.   To  reduce  waste when pickle liquor is dumped,
the acid content is allowed to become weaker and weaker, and
thus the pickling process takes longer and longer.

On the other hand, use of an acid recycling plant allows the
acid to be maintained consistently  at  its  most  effective
strength  without  the possibility of waste, because no acid
can leave the system.
Rinse

The rinse operation may vary  from a  one-step  dunk  to  more
sophisticated  multi-stage  rinsing.   The primary purpose of
the rinse is to  remove contaminants  prior to moving  to  the
next   sequence   in the process.  The first  rinse removes the
bulk of the contaminants  from the pickled product.
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The next rinse section can be of conventional nature, either
"dunk" rinse or spray.  It  removes  the  remainder  of  the
contaminants  from the work.  The water from this section is
used to replenish the first-stage rinse section.

The last stage of rinsing uses clean,  fresh  water  as  the
final  washing medium to insure a clean product.  This final
stage water is pumped to the previous stage rinse section.

Again, it may be possible  to  use  the  contaminated  rinse
water  as  input  water  to  the fume scrubber, prior to its
final disposition as pickle recycling system makeup water.

Most continuous strip pickling lines employ the  traditional
approach  to  rinsing;  flooding  the strip with hundreds of
gallons of water per minute to wash away the few gallons  of
acid  that  are  dragged  out of the pickling tanks.  In the
past, this was a practical approach to the  problem  because
it  effectively  cleaned  the  strip  and  diluted  the acid
content  of  the   rinse   water   to   an   extremely   low
concentration,   for   it  was  usually  discharged  without
treatment.

Instead of introducing a high volume flow of water into  the
rinsing  section  and  releasing  it  to the drain after one
contact  with  the  strip,  the  multi-stage  spray   system
compartmentalizes  the  rinse  water  and reuses it over and
over.  The net effect is that the amount of water  impinging
upon  the  strip  is  actually  greater than the amount in a
traditional spray-dunk system.

The dilution rate from one tank section to the next  follows
a  geometric progression, so the number of stages determines
how much clean water must be fed into the system to  achieve
a  given  degree  of  cleanliness.  For instance, a typical,
large, high-speed pickle line with a five-stage system could
operate at about 20 gpm.

Disposal of the rinse water at such a low rate of flow  (and
with  the  higher  acid  concentration) becomes a relatively
simple matter.  It can be further concentrated and piped  to
the  waste  pickle liquor acid regeneration system or it may
even be used as makeup for  the  solution  in  the  pickling
tanks.

Multi-stage spray rinsing systems can easily be incorporated
into  new  continuous  strip pickling lines, and they can be
installed in existing lines in place of the present  rinsing
sections.
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Fume Scrubbing

Acid fumes are prevalent in the pickling process and must be
removed  in  order  to  provide  a good working environment.
Many existing exhaust  systems  discharge  directly  to  the
atmosphere,  causing air pollution.  To remove the acid from
the exhaust stream, washing or  filtration  methods  may  be
applied.  In scrubbers, the acid droplets are contacted with
water,  trapped,  and  then  flushed  away.   This, however,
merely trades air pollution for water pollution because  the
acid has contaminated the scrubber water.

Sulfuric.    Acid   mist   filters  use  specially  designed
synthetic fibers in a filter box which is installed  in  the
discharge  end  of  an  exhaust  system.  This unit releases
water vapor to the atmosphere while  it  collects  the  acid
droplets and returns them to the pickle tank.  The acid mist
filter  controls  air  pollution and simultaneously recovers
acid  for  reuse.   No  water  is  used  in  its  operation;
therefore, no liquid effluent is discharged.

Hydrochloric.   The  wet-type  scrubber  works  and, in most
cases, works well.  Its biggest deterrence, however, is that
it usually requires and thereby contaminates  large  volumes
of  water  (typically,  50  to 200 gallons per minute).  The
logical solution, therefore, is to (1)  minimize  the  volume
of  water  used;  (2) instead of fresh water use contaminated
water (such as rinse water);  (3) use  all  of  the  scrubber
water  as  makeup  water  in the pickling operation, thereby
eliminating the discharge of acidified waters.

Mechanical Action

A second method for removal  of  unwanted  matter  from  the
metal surface can be accomplished through mechanical action.
However,  pickling  and  mechanical  action are not mutually
exclusive  and  are  generally  used  in  combination.   The
following  operations  are  included  under  the  mechanical
action processes:

1.  Shot Blast Descaling
2.  Shot Blast and Pickling
3.  Grinding
4.  Abrasive Cleaning
5.  Mass Finishing
6.  Miscellaneous Methods
    a.   Hand Tool Cleaning
    b.   Power Tool Cleaning
    c.   Flame Cleaning
    d.   Sand Blasting
                                  74

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Shot_Blast Descaling.  Shot blasting or mechanical descaling
is done in special cabinets using an airless principle where
"shot"  is  hurled  at  high  velocity  upon  the  work   by
centrifugal force from the blasting units.  There are bladed
wheels  which  rotate  at  more  than  2,000  rpm  and throw
abradants under  directional  control  without  the  use  of
compressed air.

A  typical  shot  blast  machine may be installed in a steel
strip cleaning line depending on the end product use or  can
be  used  in  conjunction  with  an operating pickling line,
particularly where extremely tough scale is encountered; for
example, hot rolled nickel-alloy steel.

Initial claims for shot blast  cleaning  were  to  eliminate
"pickling;"  however,  this  has happened in only a very few
special cases where embedded scale or  "rolled-in"  soil  or
dirt  could  be  tolerated  in  the end product.  "Smut" and
surface dirt has required the  addition  of  pickling  tanks
where  a  chemically clean surface is required for the strip
or product.
               «
A number of large fabricators for  the  automobile  industry
are  using  shot  blast  cleaning  in combination with other
finishing type lines.

In practically all cases, we can  reasonably  conclude  that
mechanical  blast  cleaning  will  not replace pickling as a
method for scale removal where the material is to be further
cold reduced or must be chemically clean.

Pickling with acid produces  a  cleaner  product  at  higher
production rates and at lower operating costs, especially in
high speed, continuous strip pickling lines.

Shot Blast and Pickling.   Since  the  initial  use  of shot
blast cleaning equipment, it  was  found  necessary  to  add
pickling  tanks  to  remove surface dust and hidden scale so
that  the  strip  would  be  chemically  clean  for  further
processing.

In  a  few cases where extremely tough scale is encountered,
for example,  special  grades  of  hot  rolled  nickel-alloy
steel,  the  use  of shot blast descaling units speed up the
pickling operation.

Some users considered mechanical blast cleaning to eliminate
the pollution problems  associated  with  the  spent  pickle
liquor  developed  from  pickling.  Generally, this goal was
not achieved.  As a result  of  this,  we  find  combination
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mechanical shot blast cleaning and pickling lines in several
plants in the steel and metal working industries.

Grinding.   Grinding  of  bars,  billets,  and  narrow heavy
plates has been used  successfully  to  remove  oxide  scale
instead of batch pickling.

Grinding serves a twofold purpose; (1) it removes the scale,
and   (2)  it  performs  a salvage and machining operation by
eliminating  surface  defects,  embedded  scale,  etc.,  and
producing  a  flat, smooth surface which aids the subsequent
mechanical working.

It is noted that this is a special case, usually applied  to
products  like  alloy  bars  and stainless plates, and is an
expensive, time-consuming operation.

Abrasive Cleaning.   Abrasive  blasting  is  a  process  for
cleaning and finishing of materials by forceful direction of
an  abrasive  grain,  applied  either  dry or suspended in a
liquid medium, against the surface of  a  workpiece.   As  a
material  finishing  tool, abrasive blasting is used for (a)
removal of mold sand, heat treat scale, rust, paint,  carbon
deposits,  and  other  dry soils;  (b) roughening of surfaces
for the application of paint, adhesive  for  the  subsequent
bonding  of  an  overlay,  or  for  the application of other
protective   coating   types;    (c)   removal   of   surface
irregularities  to improve surface finish, as exemplified by
the  elimination  of  directional  grinding  lines,   burrs,
feather edges, and metal fuzz; and  (d) improvement of micro-
finish, or the development of a mat finish.

Hand Tool Cleaning.    This   category   consists   of  hand
scrapers, chippers, and wire brushes.  It is  expensive  and
an  acceptable method with obvious limitations.  It will not
remove all mill scale and rust  residues,  particularly  the
tightly adhering scale.

Power Tool Cleaning.   This  is  a  more efficient method of
using the tools mentioned in  hand  cleaning  but  with  the
application  of  power.   Thus, power tools such as sanders,
wire  brushes, chipping  hammers,  grinders,  etc.,  will  be
included.   It is far less expensive than hand cleaning, and
the surfaces so  prepared  with  usually  have  very  little
remaining  mill scale or rust.  Excessive power cleaning may
produce a burnishing effect  which  produces  a  surface  to
which  paint  may  not  adhere,  resulting  in a detrimental
effect on the entire subsequent paint system.
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Flame Cleaning.  The application  of  direct  flame  to  the
surface  causes  heavily  rusted  areas and mill scale to be
cleaned off by the action of heat.   While  mill  scale  may
flake  and  crack  off,  heavy  rust which has been loosened
should be removed with subsequent wire brushing  (preferably
power).   Thin  sections  of metal subject to warping should
not be flame cleaned.

Sand Blasting.  This method provides  a  means  of  removing
rust and mill scale by propelling fine sand or grit by means
of  compressed  air onto the surface to be cleaned.  It is a
very efficient method of removing rust and mill  scale,  and
provides a surface free from oil, grease, scale, oxides, and
other corrosion products.

Cold Rolling

Cold  rolling  is  that  operation  where  unheated metal is
passed through a pair of rolls for the purpose  of  reducing
its  thickness,  of  producing a smooth dense surface and of
developing controlled mechanical properties  in  the  metal.
Any  one of a combination may be the reason for cold rolling
the material.  Cold  rolling  generally  implies  a  rolling
operation  in which the thickness of the material is reduced
a relatively small amount to produce a superior  surface  or
impart  the  desired  mechanical  properties  to  the rolled
material.

Cold reduction is a special form of cold  rolling  in  which
the  thickness  of  the  starting  material  is  reduced  by
relatively large amounts in each pass through the rolls.  In
the production of  most  cold  rolled  materials,  the  cold
reduction process is used to reduce the thickness of the hot
rolled  breakdown  between  25% and 9055.  After cleaning and
annealing, a large percentage of material is  subject  to  a
cold  rolling operation called tempering.  In tempering, the
thickness of the material is reduced only a few  percent  to
impart   the   desired  mechanical  properties  and  surface
characteristics to the final product.

Cold rolled strip, cold rolled sheet, black plate  and  cold
rolled flat bar are the principal products from cold reduced
flat  rolling  mills.   Carbon, alloy or stainless steel are
used depending on the end use of the products.  The greatest
percentage of the products rolled are from carbon  steel  in
sheet  form  and  are  used as base material for such coated
products as long terne sheets, galvanized  sheets,  aluminum
coated  sheets,  tin-plate,  or  tin-free steel.  Hot rolled
coils called "breakdowns" are the base material used in  the
cold  rolling  operation.   Prior  to rolling, however, they
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must be  descaled  and  pickled,  usually  in  a  continuous
pickling operation.

There  are  several types of cold reduction mills varying in
design from single stand reversing mills to continuous mills
with up to six  stands  in  tandem.   In  the  single  stand
reversing mill, the product is rolled back and forth between
the   work   rolls   until   the   desired   thickness   and
characteristics are  reached.   In  the  single  stand  non-
reversing  mill the material makes a single pass through the
rolls and is recoiled.  If additional  rolling  is  required
the  coil  is  returned  to  the  head  end  of the mill and
reworked.  The single stand non-reversing mill is  generally
used for tempering operations.

The  bulk  of  the  cold  reduced  flat  steel  is rolled on
continuous three, four, or  five  stand  tandem  mills.   In
these  mills  the  material  continually passes from roll to
roll, to be further reduced and leaves the final roll at the
desired thickness.  The continuous rolling  mills  represent
modern  technology  and  would  be  the  type  of  equipment
installed in new mills.

A  typical  modern  cold  rolling  shop  would   contain   a
continuous  pickling  operation   (sulfuric  or  hydrochloric
acid) for the removal of scale and rust from the hot  rolled
breakdown coil.  As it leaves the pickler the strip is oiled
to  prevent  rusting  and  to act as a lubricant in the cold
rolling mill.  The coil is then fed into a  continuous  cold
rolling  reducing  mill  that  can contain up to six rolling
stands in tandem  (in series).  Each stand contributes to the
reduction  in  thickness  of   the   material;   the   first
contributing  the  greatest  reduction  while the last stand
acts  as  a  straightening,  finishing,  and  gauging  roll.
Unlike   hot   forming,  no  scale  is  formed  during  this
operation.

During rolling the steel becomes quite hard  and  unsuitable
for  most uses.  As a result, the  strip must usually undergo
an annealing operation to return its ductility and to effect
other  changes  in  mechanical  properties  to  render   the
material  suitable  for  its  intended use.  This is done in
either a batch or continuous annealing operation.

In batch or box annealing a large  stationary mass  of  steel
is  subject  to  a  long  heat treating cycle and allowed to
slowly cool.  In continuous annealing a single strip of cold
reduced product passes through a   furnace  in  a  relatively
short  period  of time.  The heat  treating and cooling cycle
in the furnace is determined  by   the  temperature  gradient
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within  the  furnace  as  well as the dimensions and rate of
travel of the steel.  To prevent oxidation and the formation
of scale, inert atmospheres are maintained in these furnaces
at all times.

Prior to annealing the material must be cleaned of all  dirt
and  oil  from the pickler to prevent surface blemishes.   In
the case of the continuous annealing furnaces  the  material
is   uncoiled  and  passes  through  a  continuous  cleaning
operation prior to entering the  furnace.   On  leaving  the
furnace  the material is oiled, recoiled, and is ready to be
tempered.

The temper mill is a single stand cold  rolling  mill  whose
prime  purpose is to produce a slight reduction in thickness
of the steel in order to develop  the  proper  stiffness  or
temper  by cold working the steel at a controlled rate.  The
end use of the material dictates the degree of tempering  to
be performed.

An  oil-water  emulsion lubricant is sprayed on the material
prior to its entering the rolls of a cold rolling  mill  and
the  material  is  coated with oil prior to recoiling.  This
oil prevents rust while the material is  in  transit  or  in
storage  and  must  be  removed  before  the material can be
further processed or formed.

More specific  details  of  the  cold  rolling  process  are
presented on Figure 8.

Coatings

The  simplest,  yet  most  useful  definition  of  the  term
"coating" is the application of a layer of one substance  to
completely  cover  another.  In the iron and steel industry,
coatings are applied for a variety of reasons.  Most  often,
a  relatively  thin layer of a metallic element such as tin,
zinc, chromium or  aluminum  is  applied  to  carbon  steel,
giving desirable qualities, such as resistance to corrosion,
safety  from  contamination, or decorative appearance, for a
fraction of the cost of product made from the coating  metal
alone.  The finished materials retain the strength of steel,
while  gaining  the  high  surface  quality  of the coating.
Figure 9 presents a schematic of the material transfer  from
slab to the various coating processes.

There  are  many  different  types  of  coating materials in
addition to metallic elements.   These  include  non-metals,
like oxides, sulfides, phosphates, and silicates; simple and
complex  organic  compounds,  like  synthetic  alkyd resins.
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varnishes,  and  bituminous  coatings;   and   miscellaneous
inorganic  coatings,  like vitreous enamel (a layer of glass
fused to a steel base); and  metallic  powders  in  silicate
paints.   But the great bulk of coatings associated with the
iron and steel industry are the metallic coatings,  so  they
will be emphasized in the following discussions.

All  methods  for  applying  protective  coatings  to  steel
surfaces require careful attention to proper surface prepar-
ation - the primary and most important step in  the  coating
process.  Without such surface preparation, good adhesion of
the  protective  coating  is  impossible,  and  without good
adhesion, the coating can hardly be considered "protective."
The type of surface preparation will vary somewhat with  the
nature  of  the coating to be applied, but it always aims at
cleanliness and uniformity of surface.   Commonly  used  are
alkaline  or  solvent  cleaning  for  grease  removal;  acid
pickling  for  removing  scale   or   rust;   and   physical
desurfacing abrasives or brushes.

Following  the  preparation  of  suitable surfaces, metallic
coatings may be applied to those  surfaces  by  one  of  the
following methods:

Hot_Dip^Process.   The steel is immersed in a molten bath of
the coating metal, then removed from the bath in such a  way
that  the  coating  is  uniformly distributed over the metal
surface as free of discontinuities as possible.   Most  zinc
coatings,  and  all   aluminum  and  terne  (a lead/tin alloy)
coatings are applied  in this manner.  In the past,  tin  was
also  applied  as a hot-dipped coating, but the electrolytic
tin plate process  has  almost  completely  supplanted  this
practice.

Metal Spraying.   The coating metal is drawn into wire, then
fed into a specially-built spray gun  using  compressed  air
and  a  gaseous  fuel.   The  wire  is melted, and projected
against  the  steel   surface  being  coated.    The   molten
particles cool quickly and adhere to the steel.

Metal_Cementation.    The  coating  metal is alloyed into the
surface of the base metal at elevated temperature and  often
in  a reducing atmosphere.  The coated metal, when cool, may
be considered to be a solid solution of that metal in iron.

Fusing Welding.  Using an electrical current  of  sufficient
density,  the  surfaces  of  the coating metal and the steel
base metal are fused  together.
                                  82

-------
Metal Cladding.  This process for coating steel is practiced
in any of several variations.  In one method, the steel core
is mounted  in  a  covered  mold  and  heated  in  an  inert
atmosphere  to  a temperature greater than the melting point
of the coating metal, which is then carefully cast about  it
while  the  core  remains  in  the  mold.   Cladding is also
accomplished by rolling flat steel, then placing it  between
two  sheets  of  the  coating  metal,  not  unlike  a simple
sandwich.  The stack is then cold rolled into one mass using
high pressures, or heated and hot rolled together to form  a
tight  bond  between  the  coating metal and the steel core.
Another method of metal cladding  ideally  suited  for  wire
drawing consists of forcing a solid steel rod into a coating
metal  tube  of  very  slightly larger inside diameter.  The
action of drawing this pair into wire results in  a  product
with a uniform metal coat around a steel core.

After  application  of  the  coating by one of the foregoing
methods, the coated product may still be subject to  a  wide
variety  of  treatment  steps.   It may be rinsed, dried and
oiled to improve handling and protect against  oxidation  of
the  coating.  It may require additional remelting to insure
smooth, even deposition  of  the  metallic  coating.   Or  a
chemical  treatment  may  be  provided following the coating
operation to passivate the  coated  surface  or  to  provide
certain  desirable  characteristics  to  enhance  subsequent
processing steps.   For  example,  galvanized  (zinc-coated)
strip  may  be  treated  with  zinc  phosphate  to produce a
surface with  excellent  paint-adherence  properties.   More
specific  discussion  of  these processes is included in the
descriptions of  the  individual  coating  operations  which
follows.

The  principal  metallic coating operations practiced in the
iron and steel  industry  can  be  divided  into  two  major
classes,  hot  coating  and  cold coating.  Zinc, terne, and
aluminum coatings are most often applied hot, while tin  and
chromium   are  most  often  applied  electrolytically  from
plating solutions maintained between 20-90°C  (68-19U°P), not
actually "cold," but relatively so when compared with molten
metal temperatures encountered in the hot dip processes.

Hot Coating

Hot dipped coating using baths of molten metal is  practiced
in  the iron and steel industry as a batch-dip operation for
sheet, plate, pipe or other pre-formed  products,  or  on  a
continuous  basis  using  coiled  strip  as  the  base metal
source.  Mill processes vary, depending on the coating being
applied.
                                 83

-------
Zinc.  The batch-dip operation normally follows hot rolling,
batch annealing, cold rolling, and pre-forming or cutting to
size.  Rolling lubricants are removed by alkaline  cleaning,
and  final  surface  preparation  requires  acid pickling in
stationary tubs provided with slight  agitation.   Following
pickling,  residual  acid  and iron salts are removed either
via an alkaline dip; thorough water  rinsing;  or  prolonged
immersion  in  boiling  water.   The latter practice has the
added advantage of minimizing hydrogen embrittlement.  Clean
base metal forms then are conveyed, by hand or via  conveyor
belt,  through  the flux box section of the coating pot, and
immersed in the molten metal.  Coated products are withdrawn
from the bath and subjected to drying with a warm air blast,
or  chemical  treatment  with  ammonium   chloride,   sulfur
dioxide,  chromate or phosphate solutions to produce special
galvanized finishes and surface  characteristics.   A  final
water rinse may be used, with subsequent drying, after which
the product is ready for shipment.

Continuous hot-dip galvanizing, which accounts for about 60%
of  total  galvanizing  production, is practiced via several
different arrangements of processing  steps.   The  simplest
version  starts  with  annealed  and  tempered  strip  which
receives a light muriatic acid  (HCl) pickle and rinse,  then
proceeds  directly  through  a layer of fluxing agent to the
molten zinc bath.  The coated strip is dried  and  recoiled,
or  cut  to  size  for  shipment.  More elaborate continuous
galvanizing lines utilize additional stages  leading  up  to
the  hot-dip  step.   At  least  one  plant  incorporates  a
sequence of pickling  in  hot  sulfuric  acid;  rinsing  and
scrubbing  with  brushes; a hot alkaline dip into a cleaning
solution; scrubbing in alkaline solutions;  an  electrolytic
hot  alkaline  cleaning  step;  rinsing  and  scrubbing with
brushes; a light pickle in hot sulfuric  acid;  rinsing  and
scrubbing  with  brushes; a dip into a hot zinc sulfate flux
bath; the hot dip into  molten  zinc;  dip  and  spray  with
chromate or phosphate solutions; a final water rinse; drying
with hot air; and recoiling.

Other  producers  use  a  so-called  "furnace line" to treat
their strip prior to coating with zinc.  The incoming  coils
are  very  hard  following  the cold reduction step unless a
separate  annealing  step  is   practiced.    Furnace   line
operators  include this step in their continuous galvanizing
sequence, as follows.  Cold rolled coils  are  given  a  hot
alkaline  cleaning,  rinsing,  and  scrubbing  and  a  light
pickling in hot  acid followed by water rinses.   Strip  then
enters  a  controlled  atmosphere heating chamber  (annealing
furnace) up to  60 meters  (200 ft) in length with a series of
independently controlled heat zones to provide  temperatures
                                  84

-------
required for annealing, yet sufficient cooling so that strip
exits  the furnace at temperatures slightly above the molten
bath  temperature.   A  mixture  of  NX   gas   (principally
nitrogen,   with   controlled  amounts  of  methane,  carbon
monoxide, and carbon dioxide)  and cracked ammonia is used in
some   annealing   furnaces   to   prevent   oxidation   and
decarburization  during the treatment process.  The exit end
of the furnace discharges strip below  the  surface  of  the
molten  zinc bath.  A sinker roll submerged near the surface
of the molten zinc, is used for  controlling  the  thickness
and distribution of the coating.  Forced air blasts are used
to  cool  the  exiting  strip  and to help solidify the zinc
coating.  A dip or  spray  chromate  or  phosphate  chemical
treatment  may be provided at this point to retard formation
of white corrosion products on the coating.  A  final  rinse
and  drying  step may also follow.  Finished coated strip is
recoiled or cut to sizes ready for shipment.

Another type of furnace line subjects cold rolled strip to a
complex furnace gas  containing  hydrogen  chloride.   After
annealing and cooling, a light pickling in hydrochloric acid
is  done immediately prior to entering the flux section of a
conventional molten zinc pot.   In place of  the  usual  exit
rolls  for controlling coating thickness, asbestos wipes are
used  to  yield  very  thin,  but  extremely  adherent  zinc
coatings.

More  specific  details  of  the  hot coating operations are
shown on Figures 10, 11, and 12.

Terne Metal.  Terne (from a French word meaning  "dull")  is
an   inexpensive,   corrosion-resistant  hot-dipped  coating
consisting of lead and tin in a ratio typically near four to
one.  Lead alone does not alloy with iron, but does  form  a
solid  solution  with tin, which in turn alloys readily with
iron, although requiring higher temperatures  than  for  tin
alone.

A  major portion of all terne coated material is used in the
auto industry to manufacture  gasoline  tanks,  with  lesser
amounts  going  into  the production of automotive mufflers,
oil pans, air  cleaners,  and  radiator  parts.   Other  end
products  made  of  terne  metal  include roofing materials,
portable fire extinguishers, and burial caskets.

As  in  the  case  of  hot-dipped  galvanizing,  batch   and
continuous terne coating operations both exist, although the
continuous  process  is  used  to  produce by far the larger
portion of the market.  Both metals used  in  terne  coating
are  very  corrosionresistant, as is their combination.  But
                                  85

-------
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since both lead  and  tin  are  cathodic  to  iron  in  most
environments,  corrosion  is  actually  accelerated  if  any
portion of the base metal  is  exposed.   For  this  reason,
terne  coatings  are  usually  thicker  than  other metallic
coatings, and for maximum  corrosion  resistance,  even  the
thickest  terne  coatings  benefit  from  painting  or other
protective finishing.

The batch-dip terne coating operation normally is  performed
on cold reduced, batch annealed, and temper rolled coils cut
into  sheets.   Oils and greases are removed via alkaline or
solvent   (mineral  spirits)   cleaning,  and  final   surface
preparation  requires  an  HCl  dip  just  prior to coating.
Excess acid is squeezed from the sheets by rubber rolls, and
the sheets are conveyed through a flux box containing a  hot
solution  of zinc chloride in hydrochloric acid, or a molten
zinc chloride salt bath, to remove any residual iron oxides,
and leave a dry steel surface.  The sheets are  then  passed
downward  through  a  molten  terne metal bath maintained at
325° to 360°C  (617° to 680°F), where the coating is applied,
then upward through an oil bath floating atop the terne pot.
This oil tends to maintain the high temperature long  enough
for  oil  rolls  to control deposition and coating thickness
evenly over the sheet surfaces.  Although most  batch-dipped
terne  coatings  utilize a single unit as described above, a
wider range of coating weights sometimes necessitates a pass
through a second  unit  of  the  same  type,  but  including
another oil bath instead of the zinc chloride flux box prior
to application of the second coat.

The  steel strip fed to a continuous terne coating operation
receives  the  same  preliminary  treatment  as  the   steel
processed  on  the batch-dip line, except that it remains in
the coil form, and the cleaning procedure prior to  pickling
is most often done electrolytically.  The normal sequence is
oil  and  grease  removal  in an electrolytic alkaline unit;
rinsing and scrubbing with brushes; pickling; terne coating;
and oiling via a  bath  similar  to  batch  dipping.   After
cooling,  residual  oils  are  removed  in  a branner, which
consists of tandem sets of cleaning rolls made of  thousands
of  tightly  compressed flannel discs.  Middlings from grain
milling, called bran, are fed to the first set of  rolls  to
absorb  moisture  and  excess oil, while the remaining rolls
distribute a light oil film evenly over  the  entire  coated
surface.   The  final  product  is  then recoiled, or cut to
sizes for shipment as terne  coated  flats.   More  specific
details of the terne line are shown on Figure 13.

Aluminum.   The  third  major metallic coating applied using
the hot-dipped technique  is  aluminum.   Products  made  of
                                  89

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aluminum  coated  steel  include  bright  and matte finished
sheets and strip  used  as  building  materials  in  marine,
industrial,  or  other  environments  where  high degrees of
resistance to corrosion are required; aluminum  coated  wire
for  chain-link  and  field  fencing, barbed wire, telephone
wire, and screening; and batch  treated  small  parts  where
decorative finishes are required.

The  batch  treatment  process  is  done  either  by using a
conventional molten metal bath, as in zinc or terne coating,
or by  a  special  cementation  process  called  calorizing.
Thoroughly  cleaned, degreased, and dried steel articles are
packed in a rotating drum, along with a mixture of  aluminum
powder,  aluminum oxide, and ammonium chloride.  As the drum
rotates inside a furnace at  940°-955°C  (1,724°-1,751°F)  a
reducing  gas  is  passed  into the drum, and the mixture is
tumbled for 4-5 hours.  A  solid  solution  of  aluminum  in
iron,  richest  in  aluminum  near  the  surface,  forms the
coating.  This type of coating is  especially  effective  in
protecting  steel from oxidation at high temperatures, hence
its use in pyrometer and superheater tubes, and in a variety
of oil refinery applications.

The continuous aluminum coating process is  performed  using
cold  rolled steel strip or steel wire.  The strip lines are
usually furnace lines, with an annealing step just prior  to
the  hot dip into molten aluminum.  The sequence is much the
same as zinc coating on a furnace  line.   The  cold  rolled
steel  coils are cleaned in a hot alkaline solution, rinsed,
and given a light pickling in hot acid, followed by a  final
rinse.   An  annealing  furnace  softens  the otherwise hard
carbon  steel,  and  the  coating  is  applied   immediately
following  the furnace.  The strip exiting the aluminum bath
is cooled, oiled if required, and recoiled or  cut  to  size
for  shipment.   There  is  usually no chemical treatment or
final rinse following the aluminizing dip.

In making aluminum coated wire products  by  the  hot-dipped
process,  clean,  cold-drawn  carbon-steel  wire  is  passed
through the  molten  aluminum  bath  at  660°-680°C   (1,220-
1,256°F).   This  temperature  is  high enough to soften the
carbon-steel wire sufficiently that an annealing furnace  is
not  required,  but  the  tensile  strength  of  the wire is
reduced, rendering it  unsuited  for  certain  applications.
This  problem  is readily corrected by cold-drawing the wire
coating, which not only raises  the  tensile  strength,  but
also provides a very bright final finish to the coating.

More  specific  details of the aluminizing line are shown on
Figure 14.
                                  91

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Rationale^for Categorization - Factors Considered

With  respect  to   identifying   any   relevant,   discrete
categories  for  the  iron and steel industry, the following
factors   were   considered    in    determining    industry
subcategories for the purpose of the application of effluent
limitation guidelines and standards of performance:

1.  Manufacturing processes
2.  Products
3.  Wastewater constituents
4.  Gas cleaning equipment
5.  Waste treatability
6.  Size and age
7.  Land availability
8.  Aqueous waste loads
9.  Process water usage

After  considering  all  of  these factors, it was concluded
that the iron and steel industry is  comprised  of  separate
and  distinct  processes  with enough variability in product
and waste to require categorizing into more than  one  giant
unit operation.  The individual processes, products, and the
wastewater   constituents   comprise  the  most  significant
factors in the categorization of this most complex industry.
Process descriptions are provided in  this  section  of  the
report  delineating  the detailed processes along with their
products and sources of wastewaters.  Waste treatability  in
itself  is  of  such  magnitude  that  in  some  industries,
categorization  might  be  based  strictly  on   the   waste
treatment  process.   However, with the categorization based
primarily on the process with its products and wastes, it is
more reasonable to treat each process waste treatment system
under  the  individual  category  or   subcategory.    Waste
treatability  is  discussed  at  length  under  Section VII,
Control and Treatment Technology.

Size and age of the plants has  no  direct  bearing  on  the
categorization.   The  processes  and  treatment systems are
similar regardless of the age and size of the plant.  Tables
6 through 16 provide, in addition to  the  plant  size,  the
geographic  location  of the plant along with the age of the
plant and the treatment plant.  It can be noted that neither
the wastes nor the treatment will vary with respect  to  the
age or size factor.  Therefore, age 'and size in itself would
not     substantiate     industry    categorization.     The
aforementioned tables should be tied back to the  discussion
in  Sections  VII  and  VIII,  related  to  raw waste loads,
treatment system, and plant effluents.
                                  93

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                                                   104

-------
The number and type of pollutant parameters of  significance
varies  with  the  operation  being  conducted  and  the raw
materials used.  The waste volumes and waste loads also vary
with the operation.  In order to prepare effluent limitation
guidelines that would adequately reflect these variations in
significant parameters and waste volumes, the  industry  was
subcategorized   primarily   along  operational  lines  with
permutations where necessary, as indicated in Table 17.

Selection of Candidate Plants for Visits

A  survey  of  existing  treatment  facilities   and   their
performance  was undertaken to develop a list of best plants
for  consideration  for  plant  visits.    Information   was
obtained from:

a.  The Study Contractor's Personnel
b.  State Environmental Agencies
c.  EPA Personnel
d.  Personal Contact
e.  Literature Search
f.  Industry Sources
g.  Permit Applications
h.  Perimits

Since the steel industry is primarily situated in 15 states,
greatest  contribution  was  obtained  from  state  and  EPA
personnel located in the following  states:    (a.)  Alabama,
(b.) California, (c.)  Colorado,  (d.) Illinois, (e.)  Indiana,
(f.)  Kentucky, (g.) Maryland, (h.) Michigan,  (i.) Missouri,
(j.) New York,  (k.) Ohio,   (1.)  Pennsylvania,   (m.)  Texas,
(n.) Utah, and  (o.) West Virginia.

Personal   experiences  and  contacts  provided  information
required to assess plant processes and treatment technology.
Although an extensive literature search was  conducted,  the
information  was  generally  sketchy and could not be relied
upon solely without considerable further investigation.

Upon completion of this  plant  survey,  the  findings  were
compiled  and  preliminary  candidate lists were prepared on
those plants that were considered by more than one source to
be providing the best waste  treatment.   These  lists  were
submitted to the EPA by the study contractor for concurrence
on  sites to be visited.  The rationale for plant selections
in all the sutcategories  is  presented  in  Table  18.   In
several  instances, last minute substitutions had to be made
because of the non-availability of the  plant.   In  several
other   instances,   while   at   the  plant  an  additional
subcategory was sampled  to  provide  a  complete  study  of
                                  105

-------
                           TABLE 17

                   SUBCATEGORIZAT10N OF THE
           HOT FORMING AND COLD FINISHING OPERATIONS
   I.  Hot Forming - Primary

  II.  Hot Forming - Section

 III.  Hot Forming - Flat

  IV.  Pipe and Tubes

   V.  Pickling - Sulfuric Acid - Batch

  VI.  Pickling - Hydrochloric Acid -,Batch and Continuous

 VII.  Cold Rolling

VIII.  Hot Coatings - Galvanizing

  IX.  Hot Coatings - Terne

   X.  Miscellaneous Runoffs - Storage -Piles, Casting  & Slagging

  XI.  Cooling Water Blowdown

 XII.  Utility Blowdown - Water Treatment

XIII.  Maintenance Department Wastes

 XIV.  Central Treatment
                            106

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          TABLE 18
Rationale £• r Flint Selections
         Hot Forming
PRODUCTION
FACILITIES
Blooming
Billets
Bar
Rod

C-2
Blooming
Billet
Rod


Blooming
Slabbing
Billet
Bar
Structural
Plate
Sheet
F-2
Blooming &
Slabbinq
Billets"
Bar
Hot strip

N-2
_





V.'ASTEWATER TREATMENT
scale pit
scale pit
scale pit
scale pit


scale pit
scale pit
scale pit


scalr. pit
scale pit
scale pit •
scale pit
scale pit
scale pit
scale pit


scale pit
scale pit
scale pit
scale pit


_





BASIS FOR SELSC7IOM
The use of rapid rate
mixed media polishing
filters following some
of the secondary hot
rolling scale pits.

The use of rapid rate
mixed media polishing
filters following some
of the secondary hot
rolling scale pits.
Use ol hydromation
polishing filters
following some of the
secondary hot rolling
scale pits.




The use of rapid rate
mixed media polishing
filters following some
of the secondary hot
rolling scale pits.

The use of rapid rate
mixed media polishing
filters following some
of the secondary hot
rolling scale pits.
           107

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  TABLE 18



Hot Forming
PRODUCTION
FACILITIES
Blooming
Slabbing
Billet
Bar
Strip-sheet-
plate
Strip-sheet
plate


K-2
Slabbing
Billets
Bar
Plate
Rail
Hot strip
J-2
Blooming
Slabbing
Billet
Bar
Structural
A-2
Blooming
Slabs
Billet &
Sheet Bar
Rod & Bar
Plate
Hot strip

WASTEV7ATER TREATMENT
scale pit
scale pit
scale pit
scale pit
scale pit

scale pit
*

*•

scale pit
scale pit
scale pit
scale pit
scale pit
scale pit

scale pit
scale pit
scale pit
scale pit
scale pit

scale pit
scale pit

scale pit
scale pit
scale pit
scale pit

BASIS FOR SELECTION
The USP of rapid rate
mixed media polishing
filters following some
of the secondary hot
rolling scale pits.
.
The use of rapid rate
mixed media polishing
filters following sc.ne
of the secondary hot
rolling scale pits.
The use of rapid rate_
jnixed media polishing
filters following some
of the secondary hot
rolling scale pits.


The use of rapid rate
mixed media polishing
filters following some
of the secondary hot
rolling scale pits.

The use of rapid rate
mixed media polishing
filters following some
of the secondary hot
rolling scale pits.


   108

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                              TABLE 18

                              Pickling
 PRODUCTION
 FACILITIES
   .•7ASTEWATER TREATMENT
   BASIS FOR SELECTION
Wire Mill

Q-2   •
Batch type - H-SO. acid
regeneration
Zero discharge of pro
cess wastewater pollu
tants.
Strip Mill

T-2
Continuous type - H-SO.
acid regeneration
Zero discharge of proces
wastewater pollutants.
Wire Mill
0-2
Batch type - H-SO. acid
regeneration
Zero discharge of proces
wastewater pollutants*
Wire Mill
Batch type - H2SO. acid
regeneration
Zero discharge of proces
wastewater pollutants.
Bars, shapes,
tubing

P-2
Batch type.- H-SO. acid
regeneration
Vacuum crystallization
utilized for cooling and
producing heptahydrate.
Oxide removal by non
acid technique.
Strip Mill
Continuous type - H_SO.

acid regeneration
Utilizes combination
shot blasting and pickl-
ing for oxide removal.
Continuous
strip


Y-2
Acid regeneration -
HC1 - Woodall - Duckham
(Spray roaster)
Process has been in use
for several years.
                              Ill

-------
                         TABLE 18

                         Pickling
 PRODUCTION
 FACILITIES
   WASTEWATER TREATMENT
  BASIS FOR SELECTION
Continuous
strip

W-2
Acid regeneration HC1 -
Lurgi  (fluid bed)
Process has been in use
for several years.
Continuous
strip
Acid regeneration - HC1
Woodall - Duckham (spray
roaster)
Process has been in use
for several years.
Continuous
ptrip

X-2
Acid regeneration - HC1
Woodall - Duckham (spray
roaster)
New system - start up
mid 1973.
Continuous
str:p
Acid regeneration - HC1
Lurgi - (fluid bed)
New system - start up
late 19/3 - or early
1974.
Continuous
Strip

BB-2
Continuous type - HC1
acid - lime neutralizatior
of rinse water
Reported as good by
steel industry repre-
sentatives
Continuous
wire pick-
ling batch
rod pickling
Rinses to central treat-
ment lagoon
Reported as good by
Vendor
Batch pick-
ling tubes

R-2
Lime slurry treatment of
rinse waters
Reported as good by
literature reference
                            112

-------
                            TABLE 18

                            Pickling
 PRODUCTION
 FACILITIES
Batch HC1
wire picklin
V-2	
WASTEWATER TREATMENT
BASTS FOR SELECTION
                        Recommended by  equipment
                        vendor
Batch HC1
wire picklinc
U-2
                        Recommended  by equipment
                        vendor
                              113

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                         TABLE  18

                       Cold  Rolling
 PRODUCTION
 FACILITIES
   WASTEWATER TREATMENT
   BASIS  FOR SELECTION'
 5-stand
 tandem cold
 mill. Cold
 rolled
 sheet and
 tin plate.
 FF-2	
 4  -  flat bed  filters
 6000 gpm coolant  system,
 recireulati ig water,  re-
 circulating detergent,
 and  waste  treatment
 reservoirs.
Reported as good by stee]
industry representative
 5-stand
 tandem cold
 mill.  Cold
 rolled
 sheet.
 1  -  flat bed  filter
 1500  gom detergent
 solution system.
Reported as good by
vendor
 5-fccand
 tandem cold
 rolled
 sheet and-
 tin plate.
 DD-k	
 2  -  flat bed filters
 6000 gpm oil and water
 coolant system.
 1  -  special skimmer for
 direct application oil.
Reported as good by
vendor
5-stand
tandem -
tin plate
and cold
rolled
sheet.
2 stand
temper.
 1  -  5500  gpm solution
 system.
 1  -  1500  gpm detergent
 recirculating system.
 1  -  25000  gallon waste
 treatment system.
 1  —  tramp oil skimmer.
 4  -  flat  bed filters.
Reported as good by
vendor
3 - stand
tandem cold
rolled
sheets.
3500 gpm soluble oil and
water system.
1 - tramp oil skimmer.
1 - flat bed filter.
Reported as good by
vendor
3 - stand
tandem tin
plate and
cold rolled
steel.
2 - flat bed filters
3000 gpm-combination
direct application and
solution system.
Reported as good by
vendor
2 - stand
tandem tin
plate.
1 - 1000 gpm solution
system.
1 - 1500 gpm solution
Reported as good by
vendor
             system.
             i_> y . i_.^,in •
             1 - tramp oil skimmer.
             2 -.flat bed filters.
                             114

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                           TABLE  18

                        Cold  Rolling
 PRODUCTION
 FACILITIES
   WASTEWATER TREATMENT
   BASIS  FOP SELECTIO::
5-stand
tandem cold
rolled steel
2-stand
tandem tin
plate.
EE-2	
4 - flat her! filters
9600 gpm solution system.
3000 gpm solution system

1 - flat bed filter.
Reported as good by
steel industry
representative
6-stand
tandem tin
plate
4 - flat bed filters
12000 gpm solution system
Reported as good by
vendor
5-bcand
tandem cold
rolled
steel.
X-2
2 flat bed filters
6000 gpm solution system.
Reported as good by
steel industry re-
presentative
4-stand
tandem cold
rolled
steel.
5-stand
tandem cold
rolled
sheets.
1 - flat bed filter
2500 gpm solution system.
2 - flat bed filters -
flotation reservoir.
9400 gpm soluble oil and
water coolant system.
Reported as good by
steel IndusL-y repre-
sentative
5-stand
tandem.
2 - tramp oil skimmers
2 - flat bed filters.
Reported as good by
steel industry repre-
sentative
5-stand
tandem.
4 - flat bed filters.
8000 gpm coolant system.
3000 gpm detergent system.
Reported as good by
steel industry repre-
sentative
                             115

-------
                          TABLE 18

                Hot Coatings  -  Galvanizing
PRODUCTION
FACILITIES
   WASTEWATER TREATMENT
  B.'SIS FOR S"LECTIO::
            Combined treatment
OO-2
                           One type of three
                           distinct processes.
                           Recommended by equipment
                           manufacturer
            Combined treatment
                          Process used only at
                          USS plants
180,OOOT/yr

MM-2
Combined treatment for
hot and cold coatings
Process used only at
USS plants
                                      Process used only at
                                      USS plan-s
NN-2
                          Third type process used
                          at Wheeling-Pittsburgh
                          plants.  Reported as
                          good treatment by indus-
                          try representative
                            116

-------
                                                           :-• .•••  rr
                           TABLE 18

                 Hot  Coatings - Terne Line
 PRODUCTION
 FACILITIES
   WASTEWATER TREATMENT
  BASIS FOR SELECTION
115,OOOT/yr
PP-2
Combined treatment
Reported as  good  by
industry representative
and mill builder
150,OOOT/yr


00-2
Combined treatment
Reported as good  by
industry representative
and mill builder
             Combined  treatment
                          Reported by mill builder
                             117

-------
                        TABLE 18

              Hot Coatings - Aluminizing
PRODUCTION
FACILITIES
WASTEWATER TREATMENT
BASIS FOR SELECTION
           Combined treatment for hot
           and cold coatings
                       Reported by equipment
                       manufacturer
                            118

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several  systems that were tied together, i.e., cold rolling
- pickling; coating - pickling.  Table 19 presents a summary
of the requirements for the study.
                                  119

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                         SECTION V

            WATER USE AND WASTE CHARACTERIZATION
GENERAL

The  wastewater  streams  for  the  industry  are  described
individually in their respective subcategories.  Waste loads
were developed by actual plant sampling programs at selected
better  plants  on which EPA concurred.  Raw waste loads are
defined as the contaminants attributable to the  process  of
concern.   The  basis  for  plant selection was primarily on
their  waste  treatment   practices.    Therefore,   further
rationale  for  selection  of  the  plant sites is presented
under Section VII  Control and Treatment Technology.

HOT FORMING OPERATIONS

Wastewater results from the hot forming operation because of
the large amount of direct  contact  cooling  and  descaling
waters  required  between the hot steel and the rolling mill
equipment.  Approximately H% of the water sprayed on the hot
steel evaporates and the balance is discharged  beneath  the
rolling mill equipment to trenches called flumes.

When the hot steel product is being rolled, iron oxide scale
keeps forming on the surface of the hot steel and this scale
is  continuously  removed  by  direct  contact high pressure
(1,000-2,000 psig)  spray water before each roll pass of  the
product.   In  case  of  a  reversing mill, descaling sprays
would be mounted on both sides  of  the  mill  stands.   Low
pressure  spray  cooling water is also used to keep the mill
stand and table rolls cool as the hot steel passes  over  or
in between them.

Due to the many different types of hydraulic and lubrication
systems required to maintain the rolling mill equipment, the
direct  contact cooling and descaling waters pick up oil and
greases when being sprayed over the mill  equipment.   Also,
water soluble oil solutions are sometimes used for mill roll
spray coolant waters.

When  automatic hot scarfing machines are used for the final
surface finishing of the blooms or slabs, fume,  smoke,  and
slag is produced.

The  scarfing operation on hot steel results in a continuous
production of molten slag ahead of the reaction zone.   This
slag  is directed and driven to a slag pit or trench beneath
                                  123

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the scarfer machine and water is used to break-up and  flush
the  slag being generated by the scarfing process.  Water is
also used to spray exposed equipment items in  the  vicinity
of  the  scarfing  reaction  to  protect  them from heat and
flying slag particles.  High pressure water   (150  psig)  is
used  for flushing the slag from the steel surface while (40
psig) low pressure water  is  used  for  the  spray  cooling
water.

The   hot  scarfing  process  also  results  in  appreciable
quantities of fume  and  smoke,  the  quantity  and  density
depending upon steel analysis, scarfing oxygen pressure, and
efficiency  of the slag water jets.  The smoke contains some
solids in addition to  steam  and  gases.   The  solids  are
mainly oxides of iron with traces of alloying elements found
in the scarfed steel.  The oxides are submicron in size and,
therefore,  it  is  necessary  to  collect  this  smoke  and
discharge outside  of  the  mill  building  by  means  of  a
suitable exhaust system.

Wastewater results when wet type dust collectors are used to
contain  and  clean the exhaust gases from the scarfer.  Dry
collectors cannot be used due to the saturated nature of the
exhaust gases.

HOT FORMING -_ PRIMARY

Blooming and Slabbinc^Mills

General process and water flow schematic of typical blooming
and slabbing mills are presented on Figure 2.

The blooming and slabbing mills  have  generally  four  main
plant water systems.

a.  Descaling Water Sprays
b.  Table Roll Cooling Sprays
c.  Scarfer Water Spray System
d.  Mill Stand Cooling Sprays

All  the water cooling and descaling systems  are generally a
once-through water system discharged into a scale pit  where
the  scale  is settled out, oil is trapped by means of weirs
and the overflow water is pumped to a sewer.  Some mills  do
not  have  scale  pits but use mechanical means  such as drag
scrapers or clam buckets for the  scale  removal  while  the
water  is  collected  in a sump and pumped to  a central  plant
water treatment system.
                                  124

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The wet collecting systems used for the  scarfing  fume  are
generally recycle systems with a system blowdown to maintain
cycles of concentration.  The system's blowdown is generally
pumped backed to the mill scale pit.

Table 20 summarizes the plant raw waste loads for the plants
studied.

HOT FORMING - SECTION

General  process  and water flow schematic of a typical mill
is presented on Figure 3.

Section  mills  generally  have  water  systems  similar  to
primary mills as discussed above.

Table 21 summarizes the plant raw waste loads for the plants
studied.

HOT FORMING; - FLAT

General  process  and  water flow schematic of typical plate
and hot strip mills are presented on Figure H.

Plate Mills

The plate mills have generally  four  types  of  mill  water
systems.

a.  Descaling water sprays - Direct Contact
b.  Table roll and plate cooling water sprays - Direct
    Contact
c.  Mill stand roll cooling sprays - Direct Contact
d.  Reheat slab furnace skid cooling water - Noncontact

The slab reheat furnace noncontact cooling waters can either
be  once-through  or  recycled  water systems depending upon
mill water availability.  Flows up to 315 I/sec  (5,000  gpm)
are required to cool the furnace skids but discharged waters
are  noncontact  cooling  and  will  only pick up heat.  The
descaling sprays, table roll, and plate cooling  sprays  and
mill  stand rolling cooling sprays are generally oncethrough
systems where the waters are discharged to flumes  or  sumps
beneath  the  plate  mill  stands.  The scale and oilbearing
waters are flushed into scale pits where the majority  (up to
90*) of scale is settled out, oil is  removed  by  means  of
weirs  and  skimmers  and  scale  pit overflow water is dis-
charged to sewers.  Removal of scale  is  generally  through
mechanical  means  such  as cranes with clam buckets or drag
scraper conveyors beneath the mill stands.  About H% of  the
                                 125

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                                                        u
                          TABLE 20

                     Characteristics of
              Hot Forming Primary Plant Wastes
                  Net Plant Raw Waste Loads
Characteristics

                          A-2       B-2     C-2     D-2      L-2

Flow, 1/KKg              2,890     2,131   3,248   3,732    2,560
Suspended Solids, mg/1      86        57      21 -     91       11
Oil and Grease, mg/1        13.9     150       2       5.1      4.3
                            TABLE 21

                       Characteristics  of
                Hot Forming Section Plant Wastes
                    Net Plant Raw Waste Loads
 Characteristics

                         A-2     D-2-a    D-2-b    D-2-c    E-2-a

 Flow,  1/KKg            2,485    51,891    51,258    35,045   36,796
 Suspended Solids,  mg/1     86        38        20        33       71
 Oil and Grease, mg/1       14        11        11        13       14

                        E-2-b     F-2      G-2      H-2      1-2

 Flow,  1/KKg          13,198     9,312    16,859    28,969   20,904
 Suspended Solids, mg/1     29        12        21        33      125
 Oil and Grease,  mg/1       5         0         0.4      14        1.4
                              126

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spray cooling waters evaporate and the balance is discharged
to the scale pits.

Hot Strip Mills

The  hot strip mills have generally five types of mill water
systems:

a.  Slab reheat furnace cooling water - Noncontact
b.  High pressure descaling water - Direct Contact
c.  Low pressure roll coolant water - Direct Contact
d.  Table roll and shear cooling waters - Direct Contact
e.  Strip spray cooling waters - Direct Contact

The slab reheat furnace noncontact cooling waters can either
be  once-through  or  recycled  depending  upon  mill  water
availability.   Flows  up  to  315  I/sec  (5,000  gpm)   are
required to cool the furnace skids but the discharged waters
are noncontact cooling and will only pick up heat.

The descaling sprays, table roll, and shear  cooling  waters
and  roll coolant waters are generally once-through systems,
where the cooling waters are discharged to flumes  or  sumps
beneath the hot strip mill stands.

The scale and oil-bearing waters are flushed into scale pits
where  the majority  (up to 90%) of scale is settled out, oil
is removed by means of weirs  and  skimmers  and  scale  pit
overflow water is discharged to sewers.  Removal of scale is
generally  through mechanical means such as cranes with clam
buckets or drag scraper conveyors beneath the mill stands.

The strip spray cooling waters are sprayed to cool the strip
after it has been rolled on the final mill finishing stands.
This water system may be once-through if good quality  water
is  available, but because of the great quantities required,
(up to 4,400 I/sec ±70,000 gpml  on  new  hot  strip  mills)
recycle  systems  are  installed.   Approximately  856 of the
strip cooling waters evaporate and  the  balance  is  either
discharged to sewers or recycled.

Table  22 summarizes the plant raw waste load for the plants
studied.

PIPE AND TUBE MILLS

General process and water flow schematic of  pipe  and  tube
mills are presented on Figure 5.
                                  127

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                          TABLE 22

                     Characteristics of
                Hot Forming Flat Plant Wastes
                  Net Plant Rav; Waste Loads
Characteristics
Flow, 1/KKg
Suspended
Solids, rag/1
Oil and
Grease, mg/1
          Plants
J-2
32,142
1C
5
K-2
23,073
57
4.3
L-2
34,215
11
4.3
M-2
35,182
25
2
N-2
30,328
14
10
                          TABLE 23

                     Characteristics of •
          Pipe and Tubes - hot Worked Plant Wastes
                  Net Plant Raw Waste Loads
Characteristics
Flow, 1/KKg
Suspended Solids, mg/1
Oil and Grease, mg/1
                          E-2
        GG-2
              Plants
II-2   JJ-2
KK-2
53,255* 7,089  15,371* 9,562* 2,148
    27     40      50    103     61
     17       06-3
*Includes non-contact cooling water flows.
                             128

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The  pipe  and tube mills can be classed into three types of
hot forming production methods.

1.  Butt welded pipe
2.  Electric-resistance welded tubing
3.  Seamless tubes

Butt welded pipe mills can either be unit type  mills  which
produce  a  definitive  length of pipe, or a continuous butt
welded mill where the production is continuous and  pipe  is
cut  to suitable lengths by hot saws.  Skelp or narrow steel
strip is used for the production of butt welded pipe.

The butt welded pipe mills generally  have  three  types  of
water systems.

1.  Noncontact cooling waters in skelp  heating  furnaces
    water cooled skids, water cooled welding bell, etc.

2.  Roll cooling spray waters

3.  Pipe cooling bed water bosh

The skelp heating  furnace  noncontact  cooling  waters  can
either  be  once-through or recycled water systems depending
upon mill  water  availability.   The  effluent  waters  are
noncontact  cooling  waters  and  will only increase in heat
content.

The roll cooling spray  waters  are  generally  once-through
water  systems  where  the  scale and oil-bearing waters are
discharged to flumes or trenches beneath the pipe mill  roll
stands  and  in  turn flushed into scale pits where scale is
settled out and oils removed by means of weirs and skimmers.
Removal of scale is generally through mechanical means  such
as  drag  scraper  conveyors,  clam buckets hung on overhead
cranes, etc.  About 4J6 of the spray waters evaporate and the
balance is discharged to the scale pits.

The pipe cooling bed water bosh is sometimes used to provide
adequate cooling  capacity  without  excessively  long  pipe
cooling beds.  The waters are generally once-through systems
providing  direct  control cooling and waters are discharged
into the roll cooling water systems.

The electric-resistance welded tubing mills  have  only  two
types of water systems.

1.  Noncontact cooling water for equipment welders, etc.
2.  Water soluble oil spray cooling systems
                                  129

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Electric-resistance  welded tubing is formed by cold rolling
and then is heated by the electric welder as the  tube  seam
is welded.  The tube is cooled by passing through a spray of
water  soluble  oils.   These  waters  are generally recycle
systems and makeup is required.

The seamless tube mills generally have three types of  water
systems:

1.  Noncontact  cooling  waters  -  reheat  furnaces,  water
    cooled, piercing mandrels, etc.

2.  Roll spray coolant waters

3.  Spray water quench

Seamless tube is produced by piercing a solid hot billet  or
round,  and  then  finished  through  further working of the
seamless tube product through steel rolls and over  internal
water  cooled  mandrels  until  the proper tube diameter and
length is achieved.

The noncontact cooling waters can either be once-through  or
recycled   depending  upon  mill  water  availability.   The
noncontact effluent waters will  only  increase  in  temper-
ature.

The  roll  spray  coolant  waters are generally once-through
systems where the spray water is discharged  to  scale  pits
via flumes and trenches beneath the tube mill stands.  Scale
is  settled  out  and oil is trapped and removed by means of
weirs and skimmers.

The spray quench water system  is  used  to  produce  higher
strength tubes than  just hot working the tubing.  The tubing
is  quenched,  reheated,  and  quenched  by  means  of water
sprays.  These waters are once-through systems.

Tables 23 and 24 summarize the plant raw waste loads for the
plants studied.

PICKLING

General process and water flow schematics of the  continuous
and batch pickling operations are presented on Figures 6 and
7.   The  three  major  wastewater  sources  associated with
carbon steel pickling  are  inseparable  from  the  process.
They  include:
                                  130

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                           TABLE 24

                      Characteristics of
           Pipe and Tube - Cold Worked Plant Wastes
                   Net Plant Raw Waste Loads
 Characteristics                            Plants

                                             HPT-2

 Flow,  1/KKg                                24,019
 Suspended Solids,  mg/1                         19
 Oil and Grease, mg/1                           ol
                           TABLE 25

                      Characteristics of-
        Pickling - Sulfuric Acid - Batch Plant Wastes
     Net Plant Raw Waste Loads from Spent Pickle Liquor
Characteristics                        Plants

                        1-2    0-2    P-2    Q-2    R-2    S-2

Flow, 1/KKg             151    104     60    101     23    132
Dissolved Iron, %       N/A      8.6    6.2    8.0    6.8  N/A
Suspended Solids, mg/1  N/A     48    260    N/A     70    N/A
                             131

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Spent. Pickle Liquor.   The  pickling  solution  becomes pro-
gressively saturated with ferrous salts.  When  the  ferrous
salt  content  reaches  a  certain  level,  the acid becomes
ineffective and has to be dumped.

Rinse Water.  Rinse water is pickle liquor in  dilute  form.
Disposal  of  large quantities of rinse water poses a dif „ j.-
cult and serious problem.

Acid Vapors and Mists.   The   emission   of   pungent   and
corrosive  mist  and  vapor from the pickling tanks presents
serious hazards, both indoors from a health and  maintenance
standpoint and outdoors as air pollution.

The primary function of a pickling facility is to chemically
remove  iron  scale  from steel.  The amount of iron removed
depends upon  the  type  of  steel  being  pickled  and  the
specific condition of the product.  As an example, heavy and
bulky  steel  shapes,  such  as  billets,  bars,  etc.,  may
experience an iron weight loss  (due to  pickling)  of  1/4%.
This  would  amount  to  5 Ib Fe loss per ton being pickled.
Steel strip or sheet is more typically 1/2%  (10  Ib  Fe  per
ton  pickled).   Rod   (for  manufacture of wire) ranges from
1/2% to 2%  (10 Ib to 40 Ib per ton).

In addition to the free acid and ferrous salt  content,  the
spent  liquor could also contain relatively small amounts of
other metal  sulfates,  chlorides,  lubricants,  inhibitors,
hydrocarbons, and other impurities.

SPENT PICKLE LIQUOR

Sulfuric Acid.    Typical   spent   sulfuric  pickle  liquor
averages about 8% free acid and  8X dissolved iron   (Fe).   A
gallon of this spent acid solution weighs about 10 Ib.

On  this basis, each ton of steel  pickled  (at 1% loss) would
generate about 25 gal. of spent  pickle liquor.

Therefore,  assuming  16,000,000   tons  of   steel   pickled
annually  with sulfuric, the yearly volume of spent sulfuric
pickle liquor would be 400,000,000 gal.  This  volume  would
contain  about  320,000,000  Ib  of  free  sulfuric acid and
essentially the same amount of dissolved iron  (as Fe).  This
amount of iron would  appear  as   about  870,000,000  Ib  of
ferrous sulfate  (or 435,000 tons of FeSO4).

Hydrochlgric Acid.  Typical spent  hydrochloric pickle liquor
average  about  1/2%  to 1% free acid and  10% dissolved iron
 (Fe) .  A gallon of  this  spent acid solution weighs  about  10
                                   132

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Ib.   On  this basis, each ton of steel pickled (at 1% loss)
would generate about 20 gal. of spent pickle liquor.

Therefore,  assuming  40,000,000  tons  of   steel   pickled
annually  with  hydrochloric,  the  yearly  volume  of spent
hydrochloric pickle liquor would be 800,000,000  gal.   This
volume   would   contain   about   80,000,000   Ib  of  free
hydrochloric acid and 800,000,000 Ib of dissolved  iron  (as
Fe).    This   amount   of   iron   would  appear  as  about
1,800,000,000 Ib of ferrous chloride  (or  900,000  tons  of
FeCl2).

RINSE WATERS

After pickling is achieved in the acid bath, the material is
subjected  to a water rinse to remove the acid/iron solution
prior to further  processing.   The  traditional  method  of
rinsing  calls  for high volumes of fresh water for dilution
purposes.  Pickling facilities vary; however, typical  rinse
water  volumes  range  from  1.5  to  65  I/sec (25 to 1,000
gal./minute)  flow  rate.   The  larger   continuous   strip
pickling  lines  use  6 to 65 I/sec (100 to 1,000 gpm), most
often closer to  20-25  I/sec  (300-400  gpm).   Batch  type
pickling  facilities  average  about 1.5-20 I/sec  (25 to 300
gpm) .

The problem with rinse water is not so  much  the  acid/iron
concentrations  present,  but rather the very high volume of
liquid to be treated.  Treatment  systems  for  these  large
flows are costly to build and operate.

ACID VAPORS AND MISTS

All  pickling  facilities,  large  or  small,  continuous or
batch, produce acid vapors or mists at  the  pickling  tank.
If  the  tank  itself  is  not  equipped  with  a  means  of
collecting and transporting these emissions  away  from  the
pickling  line,  an  indoor  health  and maintenance problem
occurs.  If the tank is so equipped and the  acid  emissions
are  properly  withdrawn from the line, the vapors and mists
are transferred  outdoors  and  may  create  a  serious  air
pollution problem.

Many  pickling facilities are properly equipped to include a
scrubbing device which uses water to collect the acid  mist.
This  then  transfers the air pollution problem into a water
pollution problem.
                                  133

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Studies by some steel mills indicate that about 10%  to  15%
of  the acid from a pickling line is lost in the rinse water
(as dragout)  and in the fume exhaust system.

Tables 25-32 summarize the plant raw  waste  loads  for  the
plants studied.

COLD ROLLING OPERATIONS

General  process  and water flow schematic of a typical cold
rolling operation is presented on Figure 8.

The major water use on cold reduction mills is  for  cooling
the   rolls   and   the  material  being  rolled.   This  is
accomplished by using a flooded lubrication system to supply
both lubrication  and  cooling.   A  water-oil  emulsion  is
sprayed  directly  on the material and rolls as the material
enters the rolls.  Each stand has its own sprays  and  where
recycle  is used, its own recycle system.  Past practice has
been the direct sewering of the emulsion.  However, the high
cost of rolling oils  and  the  expense  of  complying  with
pollution  control  regulations are modifying this practice,
and recycle and recovery systems  are  currently  in  common
use.

The  water used in a cold rolling mill must be a fairly good
quality water,  free  of  suspended  matter.   High  quality
rolling  oils  are  added  to  form the emulsion.  Since the
material being rolled is clean and free from rust, and since
no  scale  is  generated  during  the   rolling,   oil   and
temperature are the basic pollutants in this discharge.

Those  mills  still using once-through solution systems have
installed  oil  recovery  plants.   The  recovered  oil   is
returned  for  processing  or  otherwise disposed of.  Those
mills operating recirculation systems  on  all  mill  stands
have no continuous discharge of wastewaters.  However, means
must  be  provided  for  the  treatment or disposal of batch
discharges of spent  rolling  solutions.   The  majority  of
plants  operate  as  combinations  of bath systems, and will
have   significant   volumes   of    continuously    running
wastewaters.

Regardless of what systems are used, miscellaneous oil leaks
and spills can be troublesome and means must be provided for
their  control.   One  area associated with the cold rolling
operation but separate from the rolling mill itself  is  the
maintenance and roll finishing shop.  Oil-bearing wastewater
originating  in  these  areas  is  a  major  contributor  to
wastewater discharges from a cold rolling mill  using  total
                                  134

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                              TABLE 26

                         Characteristics oi:
            Pickling - Sulfuric Acid - Batch Plant Wastes
          Net Plant Raw Waste Loads from Rinsing Operations
    Characteristics                         Planes

                           1-2        0-2      P-2    Q-2    R-2    S-2
                        (a)    (b)
Flow,  1/KKg             872   1935    N/A       70     33    151    826
Dissolved Iron, mg/1    380     33   46,000  7,500  4,700    460  2,600
Suspended Solids, mg/1   70     21       18    155     20  2,100  1,720
                                135

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                          TABLE 27

                     Characteristics of
      Pickling - Hydrochloric Acid - Batch Plant Wast-s
      Net Plant Raw Waste Load from Spent Pickle Liquor
Characteristics                 Plants

                            U-2       V-2

Flow, 1/KKg                 27        17
Dissolved Iron, %            7.7      10.7
Suspended Solids, mg/1      N/A       N/A
                          TABLE 28

                     Characteristics of
      Pickling - Hydrochloric Acid - Batch Plant Wastes
      Net Plant Raw Waste Load from Rinsing Operations
Characteristics                 Plants

                            U-2       V-2

Flow, 1/KKg                 387       696
Dissolved Iron, mg/1        190       270
Suspended Solids, mg/1        0 •        0
                            136

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                          TABLE 29

                     Characteristics of
   Pickling - Hydrochloric Acid - Continuous Plant Wastes
     Net Plant Raw Waste Loads from Spent Pickle Liquor
Characteristics
Flow,  1/KKg
Dissolved Iron, %
Suspended Solids, mg/1
1-2

151
N/A
N/A
W-2

 50
 13.5
 88
 Plants

X-2

 39
N/A
N/A
Y-2

 67
N/A
N/A
Z-2

173
N/A
N/A
 AA-2

 13.6
 11.6
120
                          TABLE 30

                     Characteristics of,
   Pickling - Hydrochloric Acid - Continuous Plant Wastes
         Net Plant Raw Waste Load from Regeneration
               Absorber Exhaust Scrubber
Characteristics
Flow, 1/KKg
Dissolved Iron, mg/1
Suspended Solids, mg/1
      W-2

      411
        70
      132
        Plants

         X-2

        1184
          64
          70
           Y-2

          1288
            61
            85
                            137

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                             TARLE 31

                        Characteristics of
      Pickling - Hydrochloric Acid - Continuous Plant Wastes
         Net Plant Raw Waste Loads from Rinsing Operations
Characteristics                       Plants

                        1-2   W-2    X-2*   Y-2   Z-2    AA-2     BB-2*

Flow, 1/KKg             917   949   1,972   209   519       24.4   664
Dissolved Iron, mg/1      7   136     220   437   N/A   14,000   1,750
Suspended Solids, mg/1   53    20      12     7   N/A       20      52
*Includes flow from fume hood scrub.oers
                             TABLE 32

                        Characteristics of
      Pickling - Hydrochloric Acid - Continuous Plant Wastes
        Net Plant Raw Waste Loads from Fume Hood Scrubbers
Characteristics                       Plants

                              W-2         Y-2

Flow, 1/KKg                   190         174
Dissolved Iron, mg/1           24           4
Suspended Solids, mg/1          4           7
                               138

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recirculation on all stands.  Oil and water leaks in the oil
basement also contribute heavily to this problem.

Considerable  heat  is  generated during heavy reductions at
high speed on the various types of mills.  Not only  is  the
temperature  of  the product raised but also the temperature
of the rolls.  This heat is removed  from  the  mill  via  a
flooded lubrication system.  A water-oil emulsion is sprayed
on  the  material  as  it  enters  the rolls.  This emulsion
drains off between stands and each stand has its  own  spray
system.   In the older mills this emulsion was used once and
sewered without any treatment.

Modern continuous  cold  reduction  mills  recycle  the  oil
emulsion  in the flooded lubrication system.  Each stand has
its own collection tank and pump to return the  emulsion  to
the  sprays.   A  five  stand  tandem  mill  would have five
recycle systems, one for each stand.  With this arrangement,
it is possible to renew one tank of emulsion at a  time,  or
all  at  once.   It  is  also  possible to use different oil
emulsions in each  tank  if  the  product  being  rolled  so
requires.   Mills using these recycle systems have no direct
discharge to the sewer.  However, they do have  the  problem
of disposal of large batch dumps of spent rolling emulsions.

The  once-through  system  has  caused many problems for the
older mills to  remove  and  recover  this  oil.   Treatment
plants  and palm oil recovery systems have been installed to
reclaim these oils for  reprocessing  and  reuse.   In  this
process various techniques are used to break the emulsion to
separate  the  oil  from the water.  The water is discharged
while the oil is returned to a processor for  upgrading  and
resale.  The cost of palm oil and the treatment cost for its
recovery  brought  about  the  development  of  the  recycle
system.

The high cost of rolling oil makes it  impractical  for  new
mills  to  use  the once-through system, hence it is the oil
cost and not pollution control that  dictates  the  type  of
system  to  be  installed  in new mills.  The recycle system
eliminates the continuous discharge of  oil  emulsions  from
cold  rolling  mills, however, it does not eliminate the oil
discharge problem.  Regardless of how tight the  system  may
be, there is always miscellaneous spills and leaks that will
occur  and there is the problem of treating batch discharges
of spent rolling solutions.

Table 33 summarizes the plant raw waste loads for the plants
studied.
                                  139

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                          '/ABLE 33

                     Characteristics of
                  Cold Rolling Plant Wastes
                  Net Plant Raw Waste Loads
Characteristics                            Plants

                           X-2    BB-2     DD- 2   HE-2   FF-2

Flow, 1/KKg                   74  1,268    1,647     73  759
Suspended Solids, mg/1        90    N/A      9^2    537  194
Oil                       41,136     54    1,399  1,180  354
                          TABLE  34

                     Characteristics of'
           Hot Coatings - Galvanizing Plant Wastes
                  Net Plant Raw  Waste Loads
Characteristics                          Plants

                               1-2      V-2     MM-2       NN-2

Flow,  1/KKg                    917    19,500   2,239       5,024*
Suspended Solids, mg/1          94        16      88         104
Oil and Grease, mg/1            15         5      48          20
Zinc,  rag/1                     N/A       N/A       0.2       145
Chromium, mg/1                 N/A       N/A       4.5         1.8
Hexavalent Chromium, mg/1      N/A       N/A       0.003       0.011
 Including flows from fume hood scrubbers
                             140

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HOT COATING OPERATIONS

Wastewaters generated by the various hot coating  techniques
practiced  in  the  iron  and steel industry fall into three
categories:

1.  Continuously running rinse  waters,  which  may  include
rinses  following  alkaline  and  acid  cleaning operations;
rinses following chemical treatment and surface  passivation
operations;  final rinses; and running waetewater flows from
fume scrubbing systems associated with air pollution control
devices.

2.  Intermittent discharges, which may include  spent  baths
from  alkaline  and  acid  cleaning  operations; flux baths;
chemical treatment solutions; and  ion  exchange  regenerant
solutions.  The plating baths are normally not discharged as
wastewater, being either recovered or regenerated as part of
the  coating  operations, or sold to outside contractors for
processing and recovery.

3.  Noncontact  cooling  waters  associated  with  the   hot
coating  processes  may  include  furnace  cooling water and
molten metal pot cooling water.
General  process  and  water  flow  schematics  of   typical
galvanizing lines are presented on Figures 10-12.

The   continuously   running   rinse   waters  generated  in
galvanizing may include alkaline cleaning  rinses;  sulfuric
or  hydrochloric  acid  rinses;  and  chromate  or phosphate
treatment final rinses.  Combined total flow rates may range
from 10 to 150 I/sec  (158-2,380 gpm), depending upon whether
the noncontact cooling waters  are  included  or  not.   The
wastewaters  may  contain  suspended  and  dissolved matter,
sulfates, chlorides, phosphates, silicates, zinc,  chromium,
and  oily  matter  in  concentrations ranging from traces to
high  levels,  depending  on  galvanizing   line   operating
conditions.  Intermittent overflows of concentrated alkaline
or  acid  cleaning  solutions  and  flux  tank solutions may
occur,   contributing   to   the   load   normally   running
continuously.   These can be minimized by close attention to
maintenance and operating conditions and  through  provision
of  dragout  recovery  units  where  possible.  Spent pickle
liquor is normally  collected  separately  for  disposal  or
treatment.   Typical  noncontact  cooling water sources from
galvanizing lines include zinc pot cooling and, from the so-
called "furnace lines," indirect furnace cooling waters.
                                  141

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Terne Coating

General process and water flow schematics of a typical terne
line operation are presented on Figure 13.

The continuously  running  rinses  from  the  terne  coating
operation may include rinses following immersion in alkaline
or  mineral  spirit  degreasing  solutions;  and sulfuric or
hydrochloric acid rinses.  Total flows may range from 10  to
60   I/sec   (158-950   gpm),  depending  upon  whether  the
noncontact  cooling  waters  are  included  or  not.    This
wastewater  may contain suspended and dissolved matter, oily
matter,  sulfates,  chlorides,  iron,  lead,  and   tin   in
concentrations  which  depend  on line operating conditions.
Intermittent discharges are limited  to  dragout  or  spills
from  cleaning and pickling tanks.  Spent pickle liquors are
normally collected separately  for  disposal  or  treatment.
The noncontact cooling water originates due to the necessity
for continuously cooling the molten terne pot.

Aluminizing

General  process  and  water  flow  schematics  of a typical
aluminizing line is presented on Figure 1U.

Continuous  running  rinses  from   the   aluminum   coating
operation  are limited to alkaline or acid cleaning solution
rinse waters.  There are no chemical treatment  rinses,  and
usually  no  final  rinse  after  coating.  Often, the steel
strip used on an aluminum coating line has been prepared for
coating on some other nearby cleaning and pickling line,  so
there  are no wastewaters in direct contact with the product
at all.  In these cases, the only waters attributable to the
process are the noncontact cooling waters  used  to  control
temperatures of the furnace and of the molten aluminum pot.

Tables 34 and 35 summarize the net plant raw waste loads for
the plants studied.

MISCELLANEOUS RUNOFFS

Miscellaneous runoffs may be defined as some minimal flow of
wastewater  that emanates from material storage or auxiliary
operations  associated   with   a   basic   steel   process.
Generally, the wastewater flow is intermittent and the water
percolates  into the soil or evaporates.  In some instances,
the area is diked to prevent  the  water  from  leaving  the
area.   However, the areas deserve mention in the event that
one of them may be located within easy access of  a  stream,
causing  most  likely  color  or solids problems.  The items
                                  142

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                           TABLE  35

                      Characteristics  of
            Hot  Coatings  -  Terne  Plate Plant Wastes
                   Net Plant Raw  Waste Loads
 Characteristics
 Flow,  1/KKg
"Suspended  Solids, mg/1
 Oil  and  Grease, mg/1
 Load,  mg/1
 Tin, mg/1
        Plants
 00-2

2,152
   48
   73
    0.20
    2.0
                                                       PP-2
Rinses
4,116
   40
    5
   <0.05
   <2
Fume Hooc!
  5,946
      9
      0
     <0.05
     <2
                            143

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included in this category are generally associated with  the
coke, iron, and steelmaking operations as follows:

1.  Ingot Casting
2.  Pig Casting
3.  Coal Pile
4.  Ore Pile
5.  Stone Pile
6.  Slagging

Ingot Casting

Generally,  the  only  water  usage  associated  with  ingot
casting is the spray cooling of the ingot molds in the  mold
preparation  and  cleaning  area.  The hot molds are sprayed
with water to cool them, and at  the  same  time  knock  off
minor  amounts  of scale adhering to the mold surfaces.  The
majority of the water used is evaporated upon contacting the
hot mold.  Any excess spray water,  which  is  usually  very
minor, falls to the ground, where it generally evaporates or
permeates  into  the  ground.  Since this water is generally
good  quality  mill  water   containing   relatively   heavy
fractions  of  scale,  which  collects on the surface of the
ground, its permeation into the ground cannot be  considered
a source of pollution.

The excess spray water contacting the ground is generally so
minor  that  there  is rarely, if ever, sufficient volume to
cause an overland runoff from the area.  If a runoff problem
were to exist from excessive  spraying  of  the  molds,  any
potential  pollution  problems,  which  would be confined to
suspended scale  particles,  could  be  better  resolved  by
tightening  up on spray water usage rather than by providing
treatment for the runoff.

Pig Casting

The  lime  wash  used  to  coat  the  molds  may  create   a
housekeeping  problem around the pig machine.  Small volumes
of water are used to wash down the area  and  to  clean  the
spray  equipment.   Water is also required to cool the pigs.
This water also washes off the surplus lime from the molds.

As in the case of ingot casting, excess spray  water  is  so
minimal  that  there  is rarely sufficient volume to run off
from an area.  Excess spray water falls to the ground  where
it  either  evaporates  or permeates into the ground.  Since
lime is used as a mold release  agent  in  the  pig  casting
process,  this  minor excess water may be slightly alkaline.
However, the excess  water  is  of  such  small  volume  and
                                     144

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alkalinity  so  slight, that the pollution potential of this
stream is negligible.

Some plants may divert this runoff to a small basin which is
periodically cleaned out.  However, due to the small  volume
of  water  and the intermittent nature of the pig operation,
there is no  overflow  from  this  pit.   Where  significant
runoffs  occur,  they could best be handled by tightening up
on spray water usage.

Raw Material Storage Piles

Large quantities of raw materials are  required  to  operate
blast  furnaces  and  integrated  steel mills.  As a general
rule, a minimum of six months supply is kept on hand at  all
times.   This  will vary according to the plant location and
the source of the raw material.  Huge piles  of  coal,  iron
ore,  and  limestone will be observed next to the coke plant
and blast furnaces.  The  raw  materials  to  operate  these
plants are taken from these piles.

Coal Pile

Coal is delivered to the plant by barge, rail or truck.  The
newly-delivered coal is scattered uniformly on the coal pile
and  is  compacted  by  running a bulldozer over the freshly
stored coal.  This is done  to  reduce  the  amount  of  air
trapped  in  the coal pile to prevent spontaneous combustion
from taking place and  igniting  the  coal  pile.   In  some
instances, a sealant is used on the exposed coal to minimize
windage losses from the storage pile.

These  storage piles are generally at grade level.  However,
some mills utilize concrete pits for raw  material  storage.
Sewers  are  never  intentionally  located  in these storage
yards due to the problem of keeping them open.  As a result,
storm water tends to collect in pools at  the  base  of  the
pile  and  under  extreme drainage conditions, will overflow
and  seek  the  nearest  sewer.   As  a  rule,  this   water
percolates  through  the  storage  pile  into the ground and
there is not normally a visible runoff.

Coal storage  piles  at  large  steel  mills  are  generally
located  near a waterway adjacent to the wharf or dock where
the coal is unloaded.  These piles vary in  size,  depending
upon  the  capacity  of  the blast furnace facilities, which
determines the load on the by-product  coke  ovens  and  the
amount of reserve supply kept on hand.
                                   145

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Because  of  the  proximity of the coal storage piles to the
waterway, rainfall runoff from these piles may discharge  to
the  river.   In  addition,  rainfall permeating through the
pile may percolate into the ground and eventually seep  back
into the waterway.

Depending  upon exposed surface area, rainfall intensity and
duration,  runoff  or  permeability  coefficients,  and  the
quality  of  the  coal,  the  quantity  and character of the
runoff and seepage discharges may vary considerably.

Generally, however, direct pile  runoff  during  periods  of
heavy  rainfall  would  be  contaminated with suspended coal
particles, with associated color  and  turbidity.   Indirect
pile  runoff,  that  runoff  that seeps through the pile and
lags the surface runoff, may be  more  highly  contaminated.
As  the  rainfall  seeps through the pile, it is in extended
contact with the coal.  This seepage will generally  collect
at the bottom of the pile and will either provide a residual
surface runoff that continues after the rainfall has ceased,
or seep into the ground.

Because  of  the extended contact of this rainwater with the
coal, it may pick up significant  contamination  within  the
pile from leaching or chemical reactions that may occur.  In
addition to solids, this seepage may pick up heavy metals or
other  dissolvable components within the coal.  In addition,
if the particular coal stored contains significant fractions
of iron pyrites, the seepage will become fairly acidic  from
exothermic  wet  and dry oxidation reactions that occur with
these pyrites in the pile.  These reactions  are  equivalent
to those that produce acid mine drainage from coal mines.

Samples  taken  of  coal pile runoff from the base of a coal
pile after rainfall had  ceased  at  an  actual  plant  site
(Plant  C)  contained,  among  other  things,  the following
constitutents in significant quantities.

                             Concentration __ (mq/1)
     Suspended Solids                412
     BOD5                             15
     Dissolved Solids               1413
     Sulfate                         592
     Cyanide                           3.23
     COD                            1995
     pH                                7.6

The high COD value measured from this sample is probably due
to the high concentration  of suspended coal fines.  The BODJ5
                                  146

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does not correlate with the COD in magnitude since the  BOD5
test  would not produce any significant biochemical reaction
with the suspended coal.

Because of the limited sampling that was possible during the
study, it is not practical to specifically characterize  all
of  the constituents that might appear in the runoff.  Also,
these constituents would vary  depending  upon  the  factors
discussed above.

Iron Ore and Limestone

Iron  ore  and limestone are generally delivered by rail and
truck.  The newly-delivered material is scattered across the
top of the storage pile to provide uniform mixing  with  the
materials  already  in  the  pile.  These piles are at grade
level or in concrete pits and no intentional effort is  made
to  sewer  the area.  Normal storm runoff will accumulate at
the base of the pile and percolate  into  the  ground  water
table.   There  is normally no visible runoff into the local
sewer.

Ore^Pile Runoff

Based upon the character of ores in general, the predominant
constituent of contaminated runoff from an ore pile would be
suspended solids,  consisting  mainly  of  iron  oxides  and
silica.   As  in  the  case  of  coal piles, the quality and
quantity  of  these  runoffs  and  the  presence  of   other
constituents  would  depend  on  the  many  variable factors
outlined above.

Stone Pile Runoff

However, it might be expected that runoff from  these  piles
would  contain  primarily  suspended  solids  in the form of
calcium carbonate and some alkalinity.  Again, their quality
and quantity would depend  on  variable  factors  previously
outlined.

Slagging

For  all  of  the  steelmaking  processes and the ironmaking
operation, slag is always generated.   The  molten  slag  is
usually  deposited  into  ladles  from  the furnaces.  These
ladles are transported to a slag  dump  where  the  slag  is
allowed  to  air cool or is sprayed with water.  The slag is
then transported to a slag processing plant where the  steel
scrap  is  reclaimed  and  the  slag crushed into a saleable
product.  The waste products from this process are generally
                                  147

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airborne dust and become waterborne when wet dust collecting
systems  are  added.   When  open  hearth  slag  is  wetted,
hydrogen  sulfide  will  be emitted due to sulfur content of
slag.

Hot blast furnace slag is usually dumped into a  large  pit,
open  at  one  end,  to  enable  removal after quenching and
quenched and cooled to a temperature  at  which  it  can  be
transported  relatively safely to a final disposal site or a
slag processing plant.

During quenching of the slag, there is little or  no  actual
runoff  from the site, the great majority of the water being
evaporated.  As the slag temperature  is  lowered,  however,
some  excess  quench  water  will  remain unevaporated.  The
quench pits are normally graded so that  this  excess  water
will  collect  in  the bottom of the pit rather than run off
overland from the site.  Once the cooled slag is removed for
final disposal, the pooled water laying in the bottom of the
quench pit will remain and be flashed off by  the  next  hot
slag charge.

However,  during  this  period  of slag cooling, some of the
excess quench water  may  permeate  into  the  ground,  thus
constituting a subsurface discharge.

Samples  of  pooled quench water after contact with the slag
indicate that this is a highly  alkaline  (1,067  mg/1  M.O.
Alkalinity) wastewater, low in suspended matter, but high in
dissolved  solids  probably  in the form of calcium and mag-
nesium sulfate, sulfide, and sulfites  (890 mg/1 sulfate, 499
mg/1 sulfide and 1,560 mg/1 sulfite).  The  main  source  of
the  alkalinity is probably calcium carbonate leached out of
the slag.

Although the  actual  amounts  of  undesirable  contaminants
permeating  into  the  ground  is highly variable, depending
upon the amount of excess quench water  used,  the  time  of
contact  between  slag and pooled water and the general soil
permeability at the quench site,  certain  conditions  might
produce undesirable subsurface discharges.

These potentially undesirable discharges could be eliminated
if these quench pits were to have an impermeable lining such
as  concrete  or  other  suitable  material.   Excess quench
waters would then remain in the quench pit until  such  time
as  they   are  evaporated  by  the next hot slag charge.  In
fact, concrete-lined  slag pits do exist at some plants where
the slag quench station is in the immediate vicinity of  the
blast  furnace.   This  is  done  in   order  to prevent soil
                                   148

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removal during quench pit cleaning and possible weakening of
the blast furnace foundation.

MAINTENANCE DEPARTMENT WASTES

The maintenance required to  keep  a  large  steel  mill  in
operation  can  at times generate large quantities of liquid
wastes which through improper handling can adversely  affect
the  plant  effluent quality.   A majority of these are oily
wastes resulting from changing gear box and crankcase  oils,
solvent  cleaners  used  to clean parts and equipment, paint
thinners and cleaners, and cutting oils.  In addition, truck
and  locomotive  repair  shops   are   another   source   of
wastewaters containing oil and solids.  These operations are
widely  spread  throughout  the  mill and a central disposal
system is seldom practical.

The volume of these wastes varies from less than a gallon to
several thousand gallons at any one  source.   They  may  be
disposed  of  on  a random basis as generated at a frequency
from daily to less than once  a  year.   It  is  impossible,
therefore,  to  estimate or predict these liquid waste loads
generated by the plant maintenance department.

Small quantities of oily wastes are generally disposed of at
the source by draining into the nearest available  sewer  or
spreading  over  the yard area for local dust control.  This
method may create problems if this oil  is  discharged  into
nonprocess sewers where no treatment is provided.

Large quantities of oily wastes (gear box and hydraulic) are
collected  in  drums  for  sale to a scavenger or are reused
elsewhere in the mill for dust  control  or  fuel  oil.   In
areas  where  there  is a large concentration of oil storage
and use, oil sumps and collection tanks are installed.   The
waste  oil  is  recovered  or sold, and any water associated
with the oil is metered into an oil treatment  system  prior
to being discharged.

The  major  constant source of this type of waste is cutting
oil from the roll shop.  All rolls used in  the  shaping  of
the  steel  are  faced  to exact shapes and tolerances.  The
rolls are used  and  refaced  as  required  to  produce  the
specified sizes and shapes of steel.  The cutting oil drains
from  the rolls and metal chips during handling and storage.
In the newer  mills,  the  cutting  oils  are  filtered  and
reused;  however,  there is still drainage from the disposal
of the oil saturated chips.  The older  mills  use  a  once-
through  cutting  oil.   Spent cutting oil and shop drainage
are collected in an oil sump.  In the newer mills this waste
                                     149

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oil is pumped from this sump to an oil treatment or recovery
plant.  In the older mills this  waste  is  sewered  without
treatment.

In  the  cold rolling mills surveyed and practicing complete
recycle  of  the  rolling   solutions,   tramp   oil-bearing
wastewater from the maintenance shop and leakage from pumps,
etc.,  in  the  oil cellar averaged 2.5 I/sec  (40 gal./min).
This could be considerably  higher  in  older  mills.   This
waste  was  treated  in  a  central treatment plant prior to
discharge.

At truck and locomotive repair shops, wastes  are  generated
in  routine  maintenance  and  servicing  of these vehicles.
This generally  consists  of  oily  wastes  attributable  to
routine  oil  changes  as  well  as floor drainage while the
vehicle is  being  repaired.   These  vehicles  are  usually
washed  while in the shop and a greater volume of wastewater
is generated which would again  contain  oil,  greases,  and
solids.   In  older  mills,  this  wastewater  is discharged
directly to the nearest sewer.  Newer mills  have  installed
some  modest  form  of  treatment  at  the  shop;  typically
settling and oil skimming.  Others  may  direct  this  small
waste  stream  to  the nearest wastewater treatment facility
for main process wastewaters.

As  a  rule,  the  disposal  of  liquid  wastes   from   the
maintenance department can be accomplished by the continuous
education of the maintenance personnel on proper disposal of
oil,  good  housekeeping  practices, and the availability of
the  necessary  equipment  to  do  the  job.   Those  plants
surveyed  having  the  best  housekeeping, generally had the
best operating waste treatment systems.

Noncontact Cooling Water

A general schematic presenting  typical  water  usage  in  a
steel mill is presented on Figure 20.

Water requirements for a fully integrated steel mill average
from 167,000 to 210,000 1/kkg  (40,000 to 50,000 gal./ton) of
steel  produced.   There  are four classes of water use in a
steel mill:   (1)  process  water.   (2)  service  water,   (3)
boiler feedwater, and  (4) noncontact cooling water.

Process  water  is  that water coming in direct contact with
the  product,  including  waters  used  for  gas   cleaning.
Service  water consists of  the potable water system, as well
as the non-potable system for general use in  the  mill  for
clean  up, etc.  Boiler feedwater is generally service water
                                  150

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treated to make it  suitable  for  boiler  use.   Noncontact
cooling  waters  are  those waters used for cooling purposes
which do not come  in  contact  with  the  product  and  are
discharged  without degradation of the initial water quality
other than elevation in temperature.

Of these four  water  uses,  process  water  and  noncontact
cooling  water  are  the  major water volumes required, each
using many times the  amount  of  water  per  ton  of  steel
required for the other two uses.

As a general rule, the quality of water used for process and
noncontact  cooling  in  the steel industry is not critical.
The use of traveling screens on the water intakes to  remove
coarse  debris  and  the  use of 3/32 in. final screens will
generally provide suitable water for use in  the  mill.   In
special  cases   (cold  rolling  mills,  tin  plating  mills,
galvanizing and  special  coating,  etc.),  where  silt  and
dissolved  salts  in  the  water  would  affect  the product
quality, additional treatment will be required to obtain the
necessary  water  quality.   No  additional   treatment   is
generally required for the noncontact cooling systems.

The   industry   is   presently  using  river,  lake,  well,
impounded,  and  brackish  waters  for  noncontact   cooling
purpose with no major problems and with a minimum of special
engineering  considerations.   Heavy silt loads during storm
runoff can create temporary problems in  special  pieces  of
equipment,  however,  mills  experiencing  this problem have
installed special cleaning systems to overcome this problem.

In order to establish the noncontact cooling water  require-
ments  for  making  steel, the water system of an integrated
mill producing 3,000,000 ingot tons per year and  practicing
a  high  degree of recycle was reviewed.  No effort was made
to determine the actual quantities  of  water  used  by  the
individual  pieces  of  equipment.   The plant, however, did
consist of the following production units:   (1) coke  plant,
 (2)  blast  furnace,   (3) powerhouse,  (4) basic oxygen shop,
 (5) open hearth shop, and  (6) rolling and  finishing  mills.
The  noncontact  cooling  water requirements for these units
were determined.  For an average daily production  of  8,219
ingot  tons  of  steel,  168,000,000  gal./day of noncontact
cooling water is used, or 20,500 gal. of noncontact  cooling
water  is  required  to  produce  1 ingot ton of steel.  The
following is a breakdown of the water usage  per  production
unit:

                                             gal./ingot
                              gpm/T Steel      T Steel_
                                  152

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Coke Plant         5.21           2.19          3,154
Blast Furnace      3.65           2.56          3,686
Boiler and
  Powerhouse                      3.04          4,378
Basic Oxygen
  Furnace                         1.22          1,757
Open Hearth                       1.16          1,670
Rolling and
  Finishing Mills                 4.08
These  figures  were  taken from a steel plant known to have
better than average water  use  practices,  and  might  well
represent  the  lower  limit  of  the  water  used for these
purposes.

CHARACTERIZATION AND QUANTIFICATION OF WASTES FROM
WATER, STEAMX AND ELECTRIC POWER GENERATION INI NTEGRATED
STEEL_MILLS

INTRODUCTION

This  section   establishes   the   quality   and   quantity
requirements  of  the  various  classes of water used in the
steel industry for  process  water,  service  water,  boiler
makeup  water,  and  noncontact cooling water.  The quantity
and type of wastes generated from the preparation and use of
this water is also presented.

CLASSIFICATION OF WATER USED IN THE STEEL INDUSTRY

When dealing with water usage in  the  steel  industry,  the
typical  water  systems  used  in  the  mill  are  generally
described in  such  broad  terms  as  "mill  water  system,"
"service  water  system,"  "process  water system," "cooling
water system," etc.  The actual quality of the water in each
of these systems can vary from  plant  to  plant,  depending
upon  the  availability and quality of the raw water supply,
the  age  of  the  facility,  equipment   design   and   age
considerations,  pollution control requirements, and general
plant and company policy on water use and reuse practices.

This diversity of quality in water use is recognized by  the
industry  itself.   Although various articles are written on
general water quality requirements in  the  industry,  these
requirements are described in broadly qualitative terms, and
not   by   strictly  defined  specifications  achievable  by
specific water treatment processes.
                                  153

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This wide diversity in water use and quality practices is in
part a result of the historical development of the industry.
Early in the 1900's when  many  of  today's  existing  large
integrated  steel  complexes  were  first  built, one of the
major criteria  for  selection  of  a  plant  site  was  the
availability  of relatively unlimited quantities of water of
sufficient quality to require little or no treatment  before
use.     Since    neither   historical   nor   environmental
considerations at that time dictated the practice  of  water
reuse,  the  less complicated and more expedient practice of
once-through use was  established.   Obviously,  with  once-
through  use  of  water  as the rule of operation, raw water
quality had to be very close to that  needed  in  the  mill,
since  any substantial treatment of that large a quantity of
water would prove uneconomical.

Equipment failure problems, such as  "burn-out"  of  cooling
plates  and  stove  valve discs at critical cooling areas of
blast furnaces, etc.r were condoned, and  their  repair  was
part  of  the  normal  maintenance routine in the plant.  In
fact, cooling side equipment design probably  centered  more
around  accommodating  the  existing  quality  of water than
obtaining optimum cooling efficiency.

As the steel industry progressed into this century, however,
these practices began to change, slowly at first, but  at  a
continually  accelerating  pace.   As older mills are phased
out and newer mills put on line, this change  in  water  use
practice will become much more evident.

The  move to increased treatment and reuse of water in steel
plants was dependent on  several  factors.   With  increased
environmental  pressure,  an  effort  was  made  to  improve
aqueous discharges,  including  those  discharges  from  wet
scrubbing  systems  that  were  installed  to clean airborne
emissions.  The industry began to  find,  and  continues  to
realize  that  higher  quality  makeup  to  a  recirculating
system, with treatment in the recirculation system, provides
for more economical usage than a once-through  system  using
larger   volumes  of  lower  quality  water,  but  requiring
treatment of the entire waste stream before discharge.   The
recirculating  systems  on  the  other  hand can be run at a
lower water quality with treatment of only a small volume of
blowdown before discharge.

Another factor was the more  sophisticated  design  of  mill
equipment,  requiring  higher quality water to maintain peak
efficiency  and   prevent   equipment   failures.    Process
equipment  downtime is now less acceptable than in the past,
because  higher  productivity  is   required   to   maintain
                                  154

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profitability  due  to  the  large  investment in production
equipment.

Another factor, in some geographic areas, was the  discovery
that  an adequate water supply of the proper quality to meet
expanded production needs was not  available.   Thus,  lower
quality  waters  had  to  be  upgraded to provide the proper
quality requirements.  This  in  turn  led  to  the  use  of
recirculatipn  systems  to  minimize the quantity of treated
makeup required.

The development of more sophisticated coating processes that
yield a high quality product required high  quality  contact
water  supplies  in the process.  Rather than use this water
only once and throw it away, many plants use it in a cascade
pattern  until  its  quality  is  spent,  or   recycle   and
regenerate it for reuse.

The  following  discussion  will  describe  the more or less
"typical" variety - of  makeup  water  quality  used  in  the
industry   on  a  subcategory  basis.   This  discussion  is
summarized in schematic form in Figure 20.

By-Product Coke Making

Coke quench water - Plants generally use fresh  river  water
after  coarse  screening  as makeup to recirculating system.
Plants may also use by-product coke plant  wastewaters,  but
this  is  usually  not  acceptable  from  an  air  pollution
standpoint.

Contact and noncontact cooling  waters  -  Makeup  generally
consists  of  fresh  river  water  after  screening  and, if
necessary, plain sedimentation.

Beehiye_Coke Making

Quench water - Makeup to recirculating quench  water  system
is  generally  fresh  river  water  after  screening and, if
necessary, plain sedimentation.

Burden Preparation^^gintering

Sinter spray water - Makeup is generally fresh  river  water
after screening and plain sedimentation.

Iron Making: - Fe and Fe-Mn Blast Furnaces
                                   155

-------
Contact  process and cooling water - Makeup to recirculating
system  is  generally  fresh  river   water   after   coarse
screening.

Noncontact  cooling  water  -  Generally  once-through fresh
river water after coarse screening.

Steelmaking - Basic Oxygen_Furnace - Wet and Semi-Wet

Contact process and cooling  water  and  noncontact  cooling
water  -  Makeup to recirculating systems is generally fresh
river water which has been coarse screened, strain filtered,
or clarified.  Noncontact water may also  have  chlorine  or
algicide added, if tight recycle systems are used.

Steelmakinq - Qpen_Hearth_Furnace

Contact process and cooling waters - Makeup to recirculating
system  is generally fresh river water which has been coarse
screened, strain filtered, and sometimes cold-lime softened.

Noncontact cooling water - Makeup is generally  once-through
fresh  river  water  that  has been coarse screened.  It may
also  be  coarse  screened  fresh  river  water  makeup   to
recirculating system with algicide added.

Steelmaking - Electric ^Furnace

Semi-Wet.   Contact process and cooling water and noncontact
cooling water - Makeup to recirculating system is  generally
fresh   city  water  that  has  been  used  as  once-through
noncontact transformer cooling water.

Wet.   Contact  process  and  cooling  waters  -  Makeup  to
recirculating system is generally fresh river water that has
been coarse screened and strain filtered.

Noncontact  cooling  water  -  Makeup is either once-through
fresh river water that has been coarse screened  and  strain
filtered,  or   fresh  river  water  makeup  to recirculating
system that has been coarse screened, strain  filtered,  and
treated with algicide.

Vacuum Degassing

Contact process and cooling water - Fresh river water makeup
to  once-through  systems is coarse screened and  strain fil-
tered.  Cold lime softening  is  also  used  on  makeups  to
recirculating systems.
                                   156

-------
Noncontact cooling water - Makeup to recirculating system is
generally  fresh  river water that has been coarse screened,
strain filtered or clarified,  and  chlorinated  or  treated
with algicide.

Continuous Casting
                             V
Contact  process  and  cooling  water and noncontact cooling
water - Makeup to  recirculating  system  with  fresh  river
water  that  has  been coarse screened, strain filtered, and
cold lime softened.

Hot ^Formings-All Types

Contact process and cooling  water  and  noncontact  cooling
water  -  Makeup  to  recirculating  or  once-through system
generally will be fresh river water  that  has  been  coarse
screened    and    treated   by   plain   sedimentation   or
clarification.

Sulfuric Acid_and Hydrochloric_Agid Pickling

Pickling Section.  Pickling section makeup  water  may  vary
widely  in  quality,  depending upon the age of the pickling
installation and  the  product  grade  pickled.   Generally,
pickling  section makeup water may be fresh river water that
has been coarse screened,  or  coarse  screened  and  strain
filtered,  or coarse screened and clarified.  It may also be
fresh city water.

Rinsing Section.  Again makeup water quality varies with the
age of the operation and the product produced.  In  general,
however,  makeup  water  will  be fresh river water that has
been screened  and  clarified,  or  screened  and  cold-lime
softened, or it may be a fresh city water makeup.

Cold Rolling

Contact  process and cooling water - Fresh makeup water to a
recirculating system is usually city water, or good  quality
well  water,  or  fresh  river  water  that  is screened and
clarified.

Pipe and Tubes

Hot Worked.   Contact  process   and   cooling   water   and
noncontact  cooling water - Makeup to recirculating or once-
through system will generally be fresh river water that  has
been  coarse  screened and treated by plain sedimentation or
clarification.
                                  157

-------
Cold Worked.  Contact process and cooling water - Makeup  to
recirculating  system  may  be city water, high quality well
water, or river water that has been screened  and  cold-lime
softened.

Wire Making

Contact  process and cooling water - Makeup to recirculating
system may be  city  water,  high  quality  well  water,  or
screened and clarified river water.

Coatings

Hot_Coating.  Intermediate rinses - Makeup to a once-through
system  may  be  city  water  or  river  water that has been
screened and settled or screened and clarified.

Final rinses - Makeup to  a  once-through  or  recirculating
system  may  be  city  water  or  river  water that has been
screened, clarified  or  cold-lime  softened,  and  deminer-
alized.

Noncontact  cooling  water - Makeup to a once-through system
may be city water or river water that has been screened  and
clarified.

Cold Coating.   Solution  tanks makeup - Makeup is generally
city water  or  river  water  that  has  been  screened  and
clarified, or screened and cold-lime softened.

Intermediate rinses - Makeup to a once-through system may be
city water or river water that has been screened and settled
by plain sedimentation, or screened and clarified.

Final  rinses  -  Makeup  to  once-through  or recirculating
system may be city  water  or  river  water  that  has  been
screened,  clarified  or  cold-lime softened, and demineral-
ized.

Noncontact cooling water - Makeup to a  once-through  system
may  be city water or river water that has been screened and
clarified.

2UANTITY_ANDDUALITY OF TREATED WATER REQUIRED IN
THE STEEL INDUSTRY

QuantitY_geguirements

In the previous section it was shown how  varied  the  water
usage is in the steel industry relative to type of treatment
                                   158

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performed.   It  was shown that it was necessary to classify
water usage by treatment received rather  than  by  industry
subcategory, because of the great number of combinations and
permutations of water use that are practiced.

A  similar  case  presents  itself relative to treated water
quantity requirements.   As  evidenced  by  the  efforts  to
establish effluent limits guidelines for the steel industry,
the   amount   of   process  water  discharged,  even  among
individual subcategories may vary widely.   Water  use   (and
thus water makeup) may vary from systems that use water on a
oncethrough  basis  to  systems  whose  only  makeup  is  to
replenish in-process evaporation.

Thus, because of the variations in types  of  treated  water
used  and  the  quantity  used,  on  a subcategory basis, no
general quantitative estimate of type and amount of  treated
water used on a subcategory basis can be provided.

However,  a  quantitative estimate of treated water usage by
type of treatment is available  on  an  industry-wide  basis
from the 1967 Census of Manufacturers.  Subject data is from
the year 1968 and is summarized below:

Quality Requirements

For  the  purposes of this section, the quality requirements
are based upon the treatment received,  since  specific  raw
water  treatment processes generally provide fairly specific
water qualities, depending upon the process.

Coarse Screening.  Coarse screening is  employed  to  remove
general  debris  from  the water source at the intake.  This
includes twigs, fish, cans, bottles, etc., anything that  if
admitted  into the plant system would create gross blockages
of pump impellers, cooling loops, piping, etc.

Although definitions of coarse screen  size  are  imprecise,
coarse screens usually have 1/4 in. openings or larger.

Strainers or Straining Filters.     Strainers    are   still
basically screening devices, although of finer size.   Their
function  is  still  to  remove  relatively  gross  sizes of
particulates  from  the  incoming  water.    Screen  size  is
generally   1/4  in.   or  less, with many applications going
into fine mesh sizes.

This equipment is capable of removing  grit-sized  materials
and  other  debris which, if introduced into the plant water
                                   160

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system,  might  cause  buildups  in  areas  of   poor   flow
streamline and cause eventual blockages.

Sedimentation.   Plain  sedimentation  usually  involves the
introduction of the water to be treated into a  large  basin
or  tank  to  reduce  the  velocity of flow to a point where
sediment and other suspended matter may settle  out  by  the
force of gravity.

For a sedimentation unit to operate properly, the horizontal
velocity  must be minimized and the detention time maximized
such that the sediment has sufficient time to settle to  the
bottom  and  not  be subjected to scour once it has settled.
Practical limits to the optimization of the above parameters
exist since overall pond size is usually  limited  by  other
factors.

In  addition,  a  properly  designed sedimentation unit must
have  good  inflow  distribution  and   outflow   collection
principles incorporated into its design to prevent excessive
turbulence  and  resuspension of materials in these critical
areas.

Generally,  a  properly  designed  sedimentation  unit   can
produce  a  treated  water  containing 50-100 mg/1 suspended
matter, depending upon the relative fineness of matter to be
removed.

Clarification.  In the steel industry, clarification usually
involves introduction of the raw water into a circular  unit
with  a  bottom  shaped like an inverted cone.  The water is
introduced near the bottom of the cone and allowed  to  rise
in an upflow pattern through the unit.  The change in cross-
sectional  area  as  the  water  rises  reduces  its  upflow
velocity to a point where solids begin to  settle.   As  the
solids  settle,  they are contacted with other solids in the
upflow water, agglomerate or coalesce, and  thus  experience
enhanced settling.

The  net  effect  is the formation of a fluid blanket or bed
through which raw water must  pass.   As  the  water  passes
through the bed, further solids are removed by this bed.  In
practice, chemicals may also be added with the wastewater to
help  produce  this  blanket or to enhance the agglomeration
tendencies of the suspended matter in the raw water.

A  properly  designed  clarifier  with  closely   controlled
addition  of flocculating agents or chemicals, can produce a
treated water containing 30-50 mg/1 suspended solids.
                                  161

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Cold Lime Softening.  In the steel industry, cold  softening
processes  are  used  to  reduce  natural  hardness  in  the
incoming water supply.  In this process, lime and  sometimes
soda  ash  are added to precipitate various forms of calcium
and magnesium in the raw water which contribute to the total
hardness.   Often  coagulants  such  as  aluminum   sulfate,
ferrous  sulfate,  ferric  sulfate,  or sodium aluminate are
also added in conjunction with the  softening  chemicals  to
aid in settling the precipitates formed.

An  additional  benefit from a cold lime softening operation
is that it can also be used as a clarification operation  to
remove  suspended  matter,  since the precipitating hardness
parameters and  coagulants  would  assist  suspended  solids
removal.

A  properly  designed  and  operated cold lime softening and
clarification  operation  can  produce   a   treated   water
containing  30-50 mg/1 suspended matter and 30-70 mg/1 total
hardness.

Algicide Addition or^Chlgrination.  In the  steel  industry,
treated  water  from  sedimentation,  clarification  or cold
softening operations is sometimes treated with algicides  or
chlorine to inhibit the growth of bacterial organisms within
the plant internal piping systems.

In  particular,  where  the  water  is  to  receive  further
treatment in bed-type units  (filters, zeolite softeners, ion
exchangers)  the water is  periodically  shot-chlorinated  to
inhibit biological growth and fouling of the bed media.

The  net  effect  of  algicide  or  chlorine  addition is to
disinfect the water supply before use or further treatment.

Filtration.    If  the  treated  water  from   sedimentation,
clarification,  or  cold lime softening units is intended to
go on to ion exchange type treatment units, it is  subjected
to   an   intermediate   filtration   step,   usually  after
chlorination.

The filtration step removes  finely divided suspended  matter
that was not removed by the  sedimentation, clarification, or
cold lime softening units as well as after-precipitates that
may  form  from  cold lime softening practices.  The primary
function of this filter bed  is to prevent the fouling of the
ion exchange resin beds by residual suspended matter.

The  filters  usually  employed  have  sand  and  gravel  or
anthracite coal, sand, and gravel media.
                                  162

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A  properly designed and operated filter system of this type
can produce a treated water containing  less  than  10  mg/1
suspended matter.

Adsorption.  Another treatment unit that is often used prior
to  ion  exchange is activated carbon adsorption.  This unit
is designed to remove  any  trace  organics  that  might  be
present  in  the  water  and  might foul the resin beds.  In
addition this unit removes  any  residual  chlorine  in  the
water which might oxidize the resin beds.

The effluent from a carbon adsorption unit should be free of
soluble organic matter and free residual chlorine.
        S o f te nincf .   Zeolite  softening  is  an ion exchange
process where the ion exchange resin is usually operated  on
a  sodium  cycle  basis to remove hardness producing cations
from the water supply.  This process  is  normally  used  to
produce water for boiler makeup.

A  zeolite softener can produce an effluent water containing
zero total hardness.

Demine ral i zat ion .    Demineralization,   or   complete   ion
exchange, is used in the steel industry to produce very high
quality  water  for  high  quality  product  operations, for
example, final rinsing of coated products.

In this process, essentially all the cations and anions  are
removed, with some exceptions, from the water to be treated,
In  particular, strong acid cation resins are used to remove
essentially all the cations from the water.  Weak base anion
resins  are  used  where  background  silica  and  carbonate
concentrations   permit,  to  remove  all  but  these  trace
cations.  Where background silica and carbonate  levels  are
unacceptably high (some well waters) , a strong base resin is
used.

A  properly designed and operating cation-anion ion exchange
system  will  produce  a  water  containing  essentially  no
cations and no anions (except for silica and carbonate for a
weak base system) in the treated water supply.

2UAOTITY_AND_2yALITY_QF_WASrES_GENERATED_FROM
WATER, TREATMENT OPERATIONS

Most   raw   water   treatment  operations  produce  wastes.
Although in many cases  these  waste  streams  contain  only
those  contaminants  originally  removed  from the raw water
supply, they also may contain other contaminants in the form
                                   163

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of treatment chemicals and reaction  products  of  treatment
chemicals  used  to  aid  or  affect treatment operations or
regenerate treatment equipment.

It is obvious, then, that the amounts of waste  contaminants
generated  will vary according to water quality and chemical
usage rate.  In turn, chemical usage rate is  also  affected
by incoming water quality.

The  quality  and  quantity  of  wastes generated from water
treatment operations are discussed below.
Coarse Screening

Wastes generated from this treatment process  are  basically
the  general  debris  that  collects  on  the screen that is
periodically fcackwashed.  The amount of backwash water  used
is  highly variable and not accurately known.  The frequency
of backwash is dictated by the general debris conditions  of
the intake water source, which varies over a period of time.

Because   the  backwashing  is  a  simple  physical  removal
operation, the debris in the backwash  constitutes  100%  of
the  debris  removed  from  the intake water.  Thus, for the
purposes of this section, the quantity and quality of wastes
generated from the backwashing of coarse screening units  is
as follows:

Backwash Flow, gal./lOO Ib debris removed - Highly Variable
pH      -  Ambient
Debris  -  100 lb/100 Ib screened

Strainers or Straining Filters

As  in  the  case  of  coarse  screening, the backwashing of
strainers is a physical operation that removes 100%  of  the
material collected in the strainer.  Backwash flow is highly
variable  while  the  frequency  of backwashing is dependent
upon the debris conditions of the intake.
                                                x
For the purposes of this section, the quantity  and  quality
of  wastes generated from the backwashing of strainers is as
follows:

Backwash Flow, gal./lOO Ib debris removed - Highly Variable
pH      -  Ambient
Debris  -  100 lb/100 Ib screened

Sedimentation
                                   164

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The dragout or excavated wastes from a sedimentation tank or
basin operations is dependent, in quantity and quality, upon
the  suspended  matter  removed  across  the  unit  and  the
hydraulic loading on the unit.

Thus,  for  the  purposes  of  this section, the quality and
quantity  of  wastes  generated  from  the  dragout  from  a
sedimentation unit is as follows:

Flow           B = (SII-SEE)/(SB)

  Where;       B = Dragout rate, gpm
               I = Unit influent rate, gpm
               E = Unit effluent rate, gpm
               SI= Influent suspended solids
                    concentration, mg/1
               SE= Effluent suspended solids
                    concentration, mg/1
               SB= Dragout suspended solids
                    concentration, wtX

pH                    -   Ambient
Suspended Matter (SB) -   Approximately 1 wtX (or less)

Clarification

Like the sedimentation process, the underflow from a process
clarifier  is  dependent,  in quantity and quality, upon the
suspended solids removal across the unit and  the  hydraulic
loading on the unit.

Thus,  for  the  purposes  of this section, the quantity and
quality of waste generated in the  underflow  from  a  water
treatment clarifier is as follows:

Flow           B = (SII-SEE)/(SB)

  Where;       B = Underflow rate, gpm
               I = Unit influent rate, gpm
               E = Unit effluent rate, gpm
               SI= Influent suspended solids
                    concentration, mg/1
               SE= Effluent suspended solids
                    concentration, mg/1
               SB= Underflow suspended solids
                    concentration, wtX

pH                    -   Ambient
Suspended Matter (SB) -   Approximately 1 wtX (or less)
                                  165

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Cold Lime goftening

Since   cold   lime   softening   processes  usually  employ
clarification   to   remove   precipitating   hardness   and
background  suspended  matter  from  the  water  supply, the
quality of the underflow from this  unit  is  dependent,  in
quantity  and  quality,  on  the  natural  suspended  solids
removal, and the hardness removal across the  clarifier,  as
well as the hydraulic loading on the unit.

Thus,  for  the  purposes  of this section, the quantity and
quality of wastes generated in the  underflow  from  a  cold
lime softening operation is as follows:

Flow           B = ± (SI + HI) I -  (SE * HE) E1/ (SB)

  Where;       B = Underflow rate, gpm
               I = Unit influent rate, gpm
               E = Unit effluent rate, gpm
               SI= Influent suspended solids
                    concentration, mg/1
               HI= Influent total hardness
                    concentration, mg/1 as CaCO3
               SE= Effluent suspended solids
                    concentration, mg/1
               HE= Effluent total hardness
                    concentration, mg/1 as CaCO3
               SB= Underflow suspended solids
                    concentration, wt%

pH                    -  10-11
Suspended Matter  (SB) -  Approximately 1 wtX (or less)
Total Hardness    (HE) -  30-70 mg/1 as CaCO3

Algicide Additign_or_jChlorination

There are no wastewaters associated either with the algicide
addition or chlorination water treatment operations.

Filtration

Filtration,   like  sedimentation  or  clarification,   is  a
suspended solids removal process whose wastes, on a quantity
and quality basis are  dependent  upon  the  solids  removal
across  the  unit  and  the  hydraulic  loading on the  unit.
Although the backwash rate on a filtration unit is generally
fixed by the filter media, the  duration  and  frequency  of
backwash  cycles are dependent upon the previously mentioned
parameters.
                                   166

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Therefore, for the purposes of this  section,  the  quantity
and  quality  of  wastes  generated  in  the  backwash  of a
filtration unit is as follows:

Flow.  Approximately 15-20 gpm/sq ft  of  bed  area,  for  a
length of time sufficient to restore the bed for service.

pH               -  Ambient
Suspended Solids -  SB = (SII-SEE)/(B)

  Where;       I = Unit influent rate,  gal./cycle
               E = Unit effluent rate,  gal./cycle
               B = Unit backwash rate,  gal./cycle
               SI= Influent suspended solids
                    concentration, mg/1
               SE= Effluent suspended Solids
                    concentration, mg/1
               SB= Backwash average suspended
                    solids concentration, mg/1

Adsorption

As  a  treatment  unit  in  the  steel  industry,  a  carbon
adsorption unit, on a theoretical basis,  should  not  be  a
source of aqueous wastewater discharges.  Unless the unit is
being  used  to  remove large amounts of organic matter, the
system is used more as a polisher.  Thus, bed life is on the
order of 2-5 years, depending upon operating conditions.  At
this time, the bed is usually removed and  replaced  with  a
new bed.

However,  on  a  practical  basis,  the  carbon  bed must be
backwashed on a periodic basis to loosen and reclassify  the
bed  and  also  to  remove suspended solids leakage and cold
softening  after-precipitates  which  were  not  removed  by
previous  treatment  units.  Thus, in this sense, the carbon
adsorption unit operates as  a  filtration  system  and  the
quantity  and  quality  of the wastes generated is dependent
upon the suspended solids removal across the  unit  and  the
hydraulic loading on the unit.

Thus,  for  the  purposes  of this section, the quantity and
quality of wastes generated in  the  backwash  of  a  carbon
adsorption unit is as follows:

Flow.   As  specified  by  carbon bed supplies, flow will be
specified in gpm/sq ft of bed area.   Duration  of  backwash
will be as necessary to restore the bed for service.

pH               -  Ambient
                                  167

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Suspended Solids -  SB = (SII-SEE)/(B)

  Where;       I = Unit influent, rate, gal./cycle
               E = Unit effluent rate, gal./cycle
               B = Unit backwash rate, gal./cycle
               SI = Influent suspended solids
                     concentration, mg/1
               SE = Effluent suspended solids
                     concentration, mg/1
               SB = Backwash average suspended
                     solids concentration, mg/1

Zeolite Softening

Since  zeolite  softening  units are used to remove hardness
producing cations from a water supply, the  waste  generated
during   the  regeneration  of  these  units  will  contain,
ideally, all the hardness producing cations  removed  during
the  service  cycle.   These wastes will also contain excess
sodium chloride used in the regeneration of the unit.
Thus, the quantity  and  quality  of  wastes  generated  and
dependent  upon the hardness removal across the unit and the
hydraulic loading on the unit.  Although the flow  rates  at
the  various  stages  of  regeneration  and  the  regenerant
concentration are fixed  by  the  resin  specification,  the
duration  and  frequency  of the regeneration cycles and the
quantity of  regenerant  required  are  dependent  upon  the
previously mentioned parameters.

Therefore,  for  the  purposes of this section, the quantity
and quality of wastes generated during the regeneration of a
zeolite softener is as follows:

Flow.  Approximately 1-1.5 gpm/cu ft during regeneration  or
rinse  cycle, or 4-8 gpm/sq ft during backwash, for a length
of   time   sufficient   to    meet    resin    regeneration
specifications.
PH
Total Hardness

  Where;
     Ambient
  -  HR = (HII-HEE)/(R)

R = Regenerant flow rate, gal./cycle
I = Unit influent rate,  gal./cycle
E = Unit effluent rate,  gal./cycle
HR= Regenerant total hardness
     concentration, mg/1 as CaCO3
HI= Influent total hardness
     concentration, mg/1 as CaCO3
HE= Effluent total hardness
                                  168

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                    concentration, mg/1 as CaCO3_

The  above  characterization  of  the  wastes from a zeolite
softener regeneration  excludes  an  estimate  for  residual
sodium  chloride in the wastewater.  This value is variable,
depending upon capacity desired condition of the  resin  and
general operating conditions.
Dem ine r al i z at ion

Cation Units.   Since  cation ion exchange units are used to
remove cations from a water  supply,  the  wastes  generated
during   the  regeneration  of  these  units  will  contain,
ideally, all the cations removed during the  service  cycle.
These  wastes  will  also  contain  excess  acid used in the
regeneration of the unit.

Thus, the  quantity  and  quality  of  wastes  generated  is
dependent  upon  the  cation removal across the unit and the
hydraulic load on the unit.  Cation removal will be affected
by the type of ion exchange resin used.

Although  the  flow  rates  at   the   various   stages   of
regeneration  and  the regenerant concentration are fixed by
the resin specifications, the duration and frequency of  the
regeneration  cycle,  and  the total quantity of regenerants
required  are  dependent  upon  the   previously   mentioned
parameters.

Therefore,  for  the  purposes of this section, the quantity
and quality of wastes generated during the regeneration of a
cation ion exchange unit is as follows:

Flow.  Approximately 0.5-1.5 gpm/cu ft  during  regeneration
or  rinse  cycle,  or  4-8  gpm/sq ft during backwash, for a
period  of  time  sufficient  to  meet  resin   regeneration
specifications.

pH             -  less than 6.0
Total Cations  -  CR =  (CII-CEE)/(R)

  Where;       R = Regenerant flow rate, gal./cycle
               I = Unit influent rate, gal./cycle
               E = Unit effluent rate, gal./cycle
               CR= Regenerant total cation
                    concentration, mg/1 as CaCO3
               CI= Influent total cation
                    concentration, mg/1 as CaCO3
               CE= Effluent total cation
                                  169

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                    concentration, mg/1 as CaCO3_

The  above  characterization of the wastes from a cation ion
exchange unit regeneration excludes an estimate of  residual
excess  regenerant  acid in the wastewater.  This value will
depend upon the type  of  acid  used  (H2SOft  or  HCl) ,  the
capacity  required,  the condition of the resin, and general
operating conditions.

Anion Units.  Since anion ion exchange  units  are  used  to
remove  all anions from a water supply, the wastes generated
during  the  regeneration  of  these  units  will   contain,
ideally,  all  the  anions removed during the service cycle.
These wastes will also contain excess caustic  used  in  the
regeneration of the unit.

Thus,  the  quantity  and  quality  of  wastes  generated is
dependent upon the anion removal across  the  unit  and  the
hydraulic  load  on the unit.  Anion removal across the unit
will be affected by the type of ion exchange resin used.

Although  the  flow  rates  at   the   various   stages   of
regeneration  are  fixed  by  the  resin specifications, the
frequency and duration of the  regeneration  cycle  and  the
total  quantity  of  regenerants required are dependent upon
the previously mentioned parameters.

Therefore, for the purposes of this  section,  the  quantity
and  quality  of wastes generated during the regeneration of
an anion ion exchange unit is as follows:

Flow.  Approximately 0.5-1.5 gpm/cu ft  during  regeneration
or rinse cycles, or 3 gpm/sq ft during backwash for a period
of    time    sufficient    to   meet   resin   regeneration
specifications.

pH            -  greater than 9.0
Total Anions  -  AR = (AII-AEE) / (R)
  Where;
R = Regenerant flow rate, gal./cycle
I = Unit influent rate, gal./cycle
E = Unit effluent rate, gal./cycle
AR= Regenerant total anion
     concentration, mg/1 as CaCO3_
AI= Influent total anion
     concentration, mg/1 as CaCO3_
AE= Effluent total anion
     concentration, mg/1 as CaCO3_
                                  170

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The above characterization of the wastes from an  anion  ion
exchange  unit'regeneration excludes an estimate of residual
excess sodium hydroxide regenerant in the wastewater.   This
value  will depend upon the capacity required, the condition
of the resin, and general operating conditions.
                                  171

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                         SECTION VI

             SELECTION OF POLLUTANT PARAMETERS
INTRODUCTION

The selection of the control parameters was accomplished  by
a  three  step  process.   First,  a broad list of pollutant
parameters to be evaluated  was  established.   Second,  the
list  of  anticipated  control parameters and procedures for
analyses  of  these  critical  parameters  was  established.
Thirdly,  the  data  from  the  field  sampling  program was
examined in detail to establish the need to deviate from the
anticipated list, based on the field experience.

BROAD LIST OF POLLUTANTS

Prior to the initiation of the plant visiting  and  sampling
phase of the study it was necessary to establish the list of
pollutant  parameters  that was to be analyzed for each type
of waste source.  These parameters were  selected  primarily
on  the basis of a knowledge of the materials used or gener-
ated in the operations, and on the basis of pollutants known
to be present as indicated by previously reported  analyses.
The  purpose  of  the  broad  list  was  to  identify  those
pollutants present in a significant amount but not  normally
reported  or  known  to  be  present to such an extent.  The
parameters that may be present in steel industry  wastewater
streams  are  presented  in  table  form  by  operations  as
follows:

Table 41 - Hot Forming Operations
Table 42 - Pipe and Tube Operations
Table 43 - Pickling Operations
Table 44 - Cold Rolling Operations
Table 45 - Hot Coating - Galvanizing Operations
Table 46 - Hot Coating - Terne Plating Operations
Table 47 - Cold Coating - Chrome and Tin-Plating
           Operations

RATIONALE FOR SELECTION OF CONTROL PARAMETERS

On the basis of prior analyses  and  experience,  the  major
wastewater  parameters  that  are  generally  considered  of
pollutional  significance  for  the  hot  forming  and  cold
finishing  operations of the iron and steel industry include
suspended solids, oil and grease, iron, total and hexavalent
chromium, tin, lead, and zinc.  Other parameters are present
in significant amounts but were not established  as  control
                              173

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                       TABLE  41

                HOT FORMING  OPERATION
                      PARAMETERS
 Acidity  (Free and Total)
 Alkalinity  (Pht. and M.O.)
     _
 Chloride
 COD
 Dissolved Solids
*Flow
 Hardness/ Total
 Heat
 Iron, Total
 Mercury
 Nitrate
*0il and Grease
*pi.
 Phosphorus, Total
 Sulfate
*Suspended Solids
 Total Solids
                      TABLE 42

               PIPE AND TUBE OPERATION
                     PARAMETERS
 Acidity (Free and Total)
 Alkalinity ;Pht. and M.O.)
 BODJ5
 Chloride
 COD
 Color
 Dissolved Solids
*Flow
 Heat
 Iron, Total
 Mercury
*0il and Grease
*pH
 Sulfate
*Suspended Solids
 Total Solids
                     174

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                      TABLE 43

                 PICKLING OPERATION
                     PARAMETERS
 Acidity (Free c.nd Total)
 Alkalinity vPht. ana M.O.)
 BOD_5
 Chloride
 COD
 Color
 Dissolved Solids
*Flow
 Heat
*Iron, Dissolved
 Iron, Ferrous
 Iron, Total
 Lead
 Mercury
*0il and Grease
*pH
 Phosphorous,  Ortho
 Phosphorous,  Total
 Silica
 Sulfate
 Sulfide
*Suspended Solids
 TOC
 Total Solids
 Turbidity
                         175

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                      TABLE 44

               COLD ROLLING OPERATION
                     PARAMETERS
 Acidity (Free and Total)
 Alkalinity (Pht. andM.O.)
 BODJ5
 Chloride
 COD
 Color
 Dissolved Solids
*Flow
 Heat
*Iron, Total
 Mercury
*0il and Grease
*pH
 Phosphate, Total
 Phosphate, Ortho
 Sulfate
 Surfactant (ABS)
*Suspended Solids
 Total Solids
 Turbidity
                         176

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                      TABLE 45

         HOT COATING - GALVANIZING OPERATION
                     PARAMETERS
 Acidity (Free c id Total)
 Alkalinity (Pht.  and M.O.)
 Ammonia
 COD
 Chloride
*Chromium, Hexavalent
*Chromium, Total
 Color
 Copper
 Cyanide, Free and Total
 Dissolved Matter
*Flow
 Fluoride
 Heat
 Iron, Dissolved
 Iron, Total
 Lead
 Mercury
 Nickel
 Nitrate
 Nitrogen
*pH
 Phosphate, Ortho and Total
 Solvent Extract Matter
 Sulfate
 Sulfide
*Suspended Matter
 Tin
 TOC
 Total Matter
 Turbidity (J.T.U.)
*Zinc
                     177

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                      TABLE 46

        HOT COATING - TERNE PLATING OPERATION
                     PARAMETERS
 Acidity (Free and Total)
 Alkalinity (Pht. and M.O.)
 Ammonia
 BOD
 COD
 Chloride
 Chromium,  Hexavalent
 Chromium,  Total
 Color
 Copper
 Dissolved Matter
*Flow
 Heat
 Iron, Dissolved
 Iron, Total
*Lead
 Mercury
 Nickel
 Nitrate
 Nitrogen
*pH
 Phosphate, Ortho
 Phosphate, Total
 Solvent Extract Matter
 Sulfate
 Sulfide
*Suspended Matter
 TOC
 Total Matter
*Tin
 Turbidity (J.T.U.)
 Zinc
                        178

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                      TABLE 47

  COLD COATING - CHROME AND TIN PLATING OPERATIONS
                     PARAMETERS
 Acidity (Free and Total)
 Alkalinity (Pht. andM.O.)
 Ammonia
 BOD
 COD
 Chloride
*Chromium,  Hexavalent
*Chromium,  Total
 Color
 Copper
'•''Cyanide, Free and Total
 Dissolved Matter
*Flow
 Fluoride
 Heat
 Iron, Dissolved
 Iron, Total
 Lead
 Mercury
 Nickel
 Nitrate
 Nitrogen
*pH
 Phosphate,  Ortho and Total
 Solvent Extract Matter
 Sulfate
 Sulfide
*Suspended  Matter
*Tin
 TOG
 Total Matter
 Turbidity  (J.T.U.)
 Zinc
                          179

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parameters  because their presence in the effluent is not as
significant, and the cost of treatment  and  technology  for
removal  in  these operations is considered to be beyond the
scope of best practicable or best  available  technology  at
this  time.   In  addition, some parameters cannot be desig-
nated as control parameters until sufficient  data  is  made
available  on  which  to  base effluent limitations or until
sufficient data on treatment capabilities is developed.

Standard raw waste loads and guidelines are  developed  only
on the critical parameters which were starred in the tables.
Multiple  analyses  of  these anticipated control parameters
were provided for to give added accuracy to the data.

SELECTION OF CRITICAL PARAMETERS BY OPERATION

The rationale for selection of the major waste parameters is
given below.

Hot Forming - Pipe and Tube Operations

Wastewaters from hot forming and pipe  and  tube  operations
result from washing scale from the surface of the steel with
water,  and in the water used to transport the scale through
the flume beneath the mill line; the water used to cool  the
rolled  product  becomes  part  of  the  mill effluent.  The
effluents from hot  mills  contain  suspended  particles  of
scale   and  oils  which  originate  in  the  hydraulic  and
lubricating systems.  The scale particles range  from  large
pieces  to  submicron  sizes, depending upon the hot forming
operation, and <*re mixtures of the various iron oxides.  The
oils in such effluents are only slightly water-miscible  and
appear as flotant oil.

Cold Rolling Operations

Effluents  from  cold  rolling operations contain emulsified
oils and suspended solids resulting from  stable  oil  emul-
sions utilized in the cold rolling and reduction process.

Pickling Operations

Spent  pickling solutions and acid rinse waters represent by
far the most significant  source  of  these  wastes.   Spent
pickling solutions from continuous strip picklers contain 5X
to  9%  free  acid  and  1056  to  16% iron salts; from batch
operations, such solutions contain 0.5% to  2.OX  free acid
and 15% to  22% iron salts.  Approximately 10-15% of  the acid
used in pickling is discharged in the rinse waters as  highly
diluted free acid and  iron  salts.  Hydrochloric and  sulfuric
                                  180

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acids  are  the  most  widely used pickling acids for carbon
steel.

Hot Coating Operations

Wastewater  effluents  from  these  processes  result   from
rinsing  and quenching operations.  In addition to suspended
solids and oils these effluents may contain acids, alkalies,
and soluble metals.
Environmental„.Impact .of gollutants

Chromium

Chromium, in its various valence  states,  is  hazardous  to
man.   It  can  produce lung tumors when inhaled and induces
skin  sensitizations.   Large  doses   of   chromates   have
corrosive  effects  on  the  intestinal  tract and can cause
inflammation of the kidneys.  Levels of chromate  ions  that
have  no  effect  on  man appear to be so low as to prohibit
determination to date.

The toxicity of chromium salts toward  aquatic  life  varies
widely  with  the  species,  temperature, pH, valence of the
chromium,   and   synergistic   or   antagonistic   effects,
especially  that  of hardness.  Fish are relatively tolerant
of chromium salts, but fish food organisms and  other  lower
forms  of  aquatic  life  are extremely sensitive.  Chromium
also inhibits the growth of algae.

In some  agricultural  crops,  chromium  can  cause  reduced
growth  or  death  of  the  crop.   Adverse  effects  of low
concentrations of chromium on corn, tobacco and sugar  beets
have been documented.

Iron

Natural  waters  may  be polluted by iron-bearing industrial
wastes such as those from pickling  operations  and  by  the
leaching  of  soluble  iron  salts from soil and rocks, e.g.
acid-mine drainage and iron-bearing ground water.

Although many of the ferric and ferrous salts  such  as  the
chlorides  are highly soluble in water, the ferrous ions are
readily oxidized in natural surface  waters  to  the  ferric
condition and form insoluble hydroxides.  These precipitates
tend  to  agglomerate, flocculate, and settle or be absorbed
on surfaces; hence,  the  concentration  of  iron  in  well-
aerated  waters is seldom high.  In ground water, the pH and
                                  181

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Eh may be such that high concentrations of  iron  remain  in
solution.

Iron  in  trace amounts is essential for nutrition.   Indeed,
larger  quantities  of  iron  are  taken   for   therapeutic
purposes.   The  daily nutritional requirement is 1 to 2 mg,
and most diets contain 7 to 35 mg per day, with  an  average
of  16.   Consequently,  drinking  water  containing iron in
unpalatable and unesthetic  concentrations,  say  1.0  mg/1,
would have little effect on the total daily intake.

Instead  of  physiological  reasons, therefore, the limit is
based  on  esthetic  and  taste  considerations.   Iron  and
manganese  tend  to  precipitate  as  hydroxides  and  stain
laundry and porcelain fixtures.  It has also  been  reported
that  ferric iron combines with the tannin in tea to produce
a dark violet color.

The taste threshold of iron in water has been given  as  0.1
and  0.2  mg/1  of  iron  from  ferrous  sulfate and ferrous
chloride respectively.   It  has  also  been  reported  that
ferrous  iron imparts a taste at 0.1 mg/1 and ferric iron at
0.2 mg/1.

Iron is  an  essential  constituent  of  animal  diets,  but
animals  are  sensitive  to  changes  in iron concentration.
Cows will not drink enough water if it is high in iron,  and
consequently, milk production is affected.

Most of the references deailing with this beneficial use are
expressed  in  terms  of  specific iron salts.  When iron is
added to water  in  the  form  of  chlorides,  sulfates,  or
nitrates,  the salt dissociates but the resulting ferrous or
ferric ions combine with hydroxyl ions to form precipitates.
Hence, very little of the iron remains in solution;  but  if
the  dosage  is  sufficient  and  the  water is not strongly
buffered, the addition of a soluble iron salt may lower  the
pH  of  the  water  to  a  toxic  level.   Furthermore,  the
deposition of iron hydroxides on the gills of fish may cause
an irritation and  blocking  of  the  respiratory  channels.
Finally,  heavy precipitates of ferric hydroxide may smother
fish eggs.

When testing the effects of wastes from  nail-making  plants
on  trout,  stickleback,  and  perch  with wastes containing
concentrations of chloride,  hydrogen,  ferric  and  ferrous
ions,  concentrations  of  1000  mg/1  of  these mixed salts
killed most fish within a few hours, but  hardy  stickleback
were  not  killed  until  five  hours exposure to 2500 mg/1.
Much of the killing action was  attributed  to  coatings  of
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iron  oxide  or  hydroxide  precipitates  on the gills.  The
toxicity of iron and iron salts depends on whether the  iron
is  present in the ferrous or ferric state and whether it is
in solution or suspension.

Crenothrix, Gallionella, and  other  iron  bacteria  utilize
iron  as  a source of energy and store it in their microbial
protoplasm.  They may accumulate in wells, treatment plants,
pipelines, and other waterworks structures; or they may pass
into the distribution system and cause customer  complaints.
Trouble  with  this  organism is experienced frequently when
the iron exceeds 0.2 mg/1.

Lead

Some natural waters contain lead in  solution,  as  much  as
0.4-0.8 mg/1, where mountain limestone and galena are found.
In  the  U.S.A.,  lead  concentrations in surface and ground
waters used for domestic supplies range from traces to  0.04
mg/1 averaging about 0.01 mg/1.

Foreign  to the human body, lead is a cumulative poison.  It
tends to be deposited in bone as a cumulative  poison.   The
intake  that  can be regarded as safe for everyone cannot be
stated definitely, because the sensitivity of individuals to
lead differs considerably.  Lead poisoning  usually  results
from  the  cumulative toxic effects of lead after continuous
consumption over a long  period  of  time  period  of  time,
rather than from occasional small doses.  Lead is not amoung
the  metals considered essential to the nutrition of animals
or human beings.

Lead may enter the body through food, air, and tobacco smoke
as well as from water and other beverages.  The exact  level
at  which  the  intake of lead by the human body will exceed
the  amount  excreted  has  not  been  established,  but  it
probably  lies  between  0.3  and  1.0 mg per day.  The mean
daily intake of lead by adults in  North  America  is  about
0.33  mg.   Of  this  quantity,  0.01 to 0.03 mg per day are
derived from water used for cooking and drinking.

Lead in an amount of 0.1 mg ingested daily over a period  of
years  has  been  reported  to cause lead poisoning.  On the
other hand one reference considered 0.5 mg per day safe  for
human  beings,  and  a  daily  dose of 2.0 mg for a one-year
period apparently did not affect the health of one adult.

Lead poisoning among human beings is reported to  have  been
caused   by   the  drinking  of  water  containing  lead  in
concentrations varying from 0.042 mg/1 to 1.0 mg/1 or  more.
                                  183

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On  the  other  hand,  other  instances of drinking water at
concentrations of 0.01 to 0.16 mg/1 over   long  periods  of
time have apparently been nonpoisonous.  The mandatory limit
for lead in the USPHS Drinking Water Standards is 0.05 mg/1.
Several countries use 0.1 mg/1 as a standard.

Traces  of  lead  in  metal-plating  baths  will  affect the
smoothness and brightness of deposits.  Inorganic lead salts
in irrigation water may be toxic to  plants  and  should  be
investigated  further.   It  is not unusual for cattle to be
poisoned by lead in the water; the lead need not necessarily
be in solution, but may be in suspension, as,  for  example,
oxycarbonate.  Chronic lead poisoning among animals has been
caused by 0.18 mg/1 of lead in soft water.  Most authorities
agree  that  0.5  mg/1 of lead is the maximum safe limit for
lead  in  a  potable  supply   for   animals.    The   toxic
concentration of lead for aerobic bacteria is reported to be
1.0  mg/1;  for  flagellates  and  infusoria, 0.5 mg/1.  The
bacterial decomposition of organic matter  is  inhibited  by
0.1 to 0.5 mg/1 of lead.

Studies indicate that in water containing lead salts, a film
of  coagulated  mucus  forms, first over the gills, and then
over the whole body of the fish, probably as a result  of  a
reaction  between  lead and an organic constituent of mucus.
The death of the fish is caused by suffocation due  to  this
obstructive  layer.   In soft water, lead may be very toxic;
in hard water equivalent concentrations  of  lead  are  less
toxic.   Concentrations of lead as low as 0.1 mg/1 have been
reported toxic or lethal to fish.  Other studies have  shown
that  the  toxicity  of  lead toward rainbow trout increases
with a reduction of the  dissolved-oxygen  concentration  of
the water.

Oil and Grease

Oil  and grease exhibit an oxygen demand.  Oil emulsions may
adhere to the gills of fish or coat  and  destroy  algae  or
other  plankton.   Deposition of oil in the bottom sediments
can  serve  to  exhibit   normal   benthic   growths,   thus
interrupting the aquatic food chain.  Soluble and emulsified
material  ingested  by fish may taint the flavor of the fish
flesh.  Water soluble components may exert toxic  action  on
fish.   Floating oil may reduce the re-aeration of the water
surface and in conjunction with emulsified oil may interfere
with photosynthesis.  Water insoluble components damage  the
plumage  and  costs  of  water  animals  and fowls.  Oil and
grease  in  a  water  can  result  in   the   formation   of
objectionable  surface  slicks preventing the full aesthetic
enjoyment of the water.
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Oil spills can damage the surface of boats and  can  destroy
the aesthetic characteristics of beaches and shorelines.

pH, Acidity and Alkalinity

Acidity  and  alkalinity  are  reciprocal terms.  Acidity is
produced  by  substances  that  yield  hydrogen  ions   upon
hydrolysis  and  alkalinity  is  produced by substances that
yield hydroxyl ions.  The terms "total acidity"  and  "total
alkalinity" are often used to express the buffering capacity
of  a  solution.   Acidity  in  natural  waters is caused by
carbon dioxide, mineral acids, weakly dissociated acids,  and
the salts of strong acids and  weak  bases.   Alkalinity  is
caused  by strong bases and the salts of strong alkalies and
weak acids.

The term pH is a logarithmic expression of the concentration
of hydrogen ions.  At a pH of 7, the hydrogen  and  hydroxyl
ion  concentrations  are  essentially equal and the water is
neutral.  Lower pH  values  indicate  acidity  while  higher
values indicate alkalinity.  The relationship between pH and
acidity or alkalinity is not necessarily linear or direct.

Waters  with  a  pH  below  6.0 are corrosive to water works
structures,  distribution  lines,  and  household   plumbing
fixtures  and  can  thus  add  such constituents to drinking
water as iron, copper, zinc, cadmium and lead.  The hydrogen
ion concentration can affect the "taste" of the water.  At a
low pH water tastes  "sour".   The  bactericidal  effect  of
chlorine  is  weakened  as  the  pH  increases,  and  it  is
advantageous to keep the  pH  close  to  7.   This  is  very
significant for providing safe drinking water.

Extremes  of  pH  or  rapid  pH  changes  can  exert  stress
conditions  or  kill  aquatic  life  outright.   Dead  fish,
associated  algal  blooms,  and  foul stenches are aesthetic
liabilities of any waterway.   Even  moderate  changes  from
"acceptable"  criteria  limits of pH are deleterious to some
species.  The relative toxicity  to  aquatic  life  of  many
materials   is   increased  by  changes  in  the  water  pH.
Metalocyanide complexes  can  increase  a  thousand-fold  in
toxicity  with  a drop of 1.5 pH units.  The availability of
many nutrient substances  varies  with  the  alkalinity  and
acidity.  Ammonia is more lethal with a higher pH.

The   lacrimal   fluid   of  the  human  eye  has  a  pH  of
approximately 7.0 and a deviation of 0.1 pH  unit  from  the
norm   may   result  in  eye  irritation  for  the  swimmer.
Appreciable irritation will cause severe pain.
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Phosphorus

During the past 30 years, a formidable  case  has  developed
for  the  belief  that  increasing standing crops of aquatic
plant growths, which often interfere with water uses and are
nuisances  to  man,  frequently  are  caused  by  increasing
supplies  of phosphorus.  Such phenomena are associated with
a  condition  of  accelerated  eutrophication  or  aging  of
waters.   It  is generally recognized that phosphorus is not
the sole cause of eutrophication, but there is  evidence  to
substantiate that it is frequently the key element in all of
the elements required by fresh water plants and is generally
present in the least amount relative to need.  Therefore, an
increase in phosphorus allows use of other, already present,
nutrients   for   plant   growths.   Phosphorus  is  usually
described, for this reasons, as a "limiting factor."

When a plant population  is  stimulated  in  production  and
attains  a  nuisance  status,  a  large number of associated
liabilities are immediately apparent.  Dense populations  of
pond  weeds  make  swimming  dangerous.   Boating  and water
skiing and sometimes fishing may be  eliminated  because  of
the mass of vegetation that serves as an physical impediment
to  such activities.  Plant populations have been associated
with stunted fish populations and with poor fishing.   Plant
nuisances  emit  vile  stenches,  impart tastes and odors to
water supplies, reduce  the  efficiency  of  industrial  and
municipal  water  treatmentr impair aesthetic beauty, reduce
or restrict resort trade, lower waterfront property  values,
cause  skin rashes to man during water contact, and serve as
a desired substrate and breeding ground for flies.

Phosphorus in the elemental form is particularly toxic,  and
subject  to bioaccumulation in much the same way as mercury.
Colloidal  elemental  phosphorus  will  poison  marine  fish
 (causing  skin  tissue  breakdown and discoloration).  Also,
phosphorus  is  capable  of  being  concentrated  and   will
accumulate  in  organs  and  soft tissues.  Experiments have
shown that marine  fish  will  concentrate  phosphorus  from
water containing as little as 1 ug/1.

Tin

Tin  is  not  present in natural waters, but it may occur in
industrial wastes.  Tin salts therefore, may  reach  surface
waters  or  ground  water; but because many of the  salts are
insoluble in water, it  is unlikely that much of the tin will
remain in solution or   suspension.   No  reports  have  been
uncovered  to  indicate  that  tin  can  be  detrimental  in
domestic water supplies.  Traces of tin occur in  the  human
                                  186

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diet  from  canned  foods and it has been estimated that the
average diet contains 17.14 mg of  tin  per  day.   Man  can
apparently  tolerate  850  to 1000 mg per day of free tin in
the diet.  There is no definite evidence that tin plays  any
essential biological role in human nutrition.

Rats  have  tolerated  25  mg  or  more  of  sodium stannous
tartrate in the diet over a period of 4 to 12 months without
ill effects.  Cats fed 20 mg of tin, as stannous tartrate or
stannous chloride, per kg of body weight, showed  no  effect
over  a  3  month  period but dosages of 30 and 50 mg per kg
apparently caused some loss of  body  weight.   Guinea  pigs
survived  on  a  diet containing 770 mg/kg of tin salts.  On
the basis of these feeding experiments it is  unlikely  that
any  concentration of tin that would occur in water could be
detrimental to livestock.

It  is  apparent  that  trace  concentrations  of  tin   are
beneficial  to  fish.   Stannous  ions at a concentration of
about 0.6 mg/1 accelerated the growth of goldfish.   It  has
been reported that goldfish survived 1000 mg/1 of SnCl2 (626
mg/1  of  tin)  in  very soft water at pH 3.5 for 1.0 to 1.5
hours and in hard water at pH 3.8 for 4 to 5  hours.   Young
eels  have  survived stannous chloride at a concentration of
1.2 mg/1 of tin for over 50 hours, but succumbed to 6.0 mg/1
in 2.8 hours.

Toxic Substances

The terms "toxic substance" or  "toxic  minerals"  occur  in
standards  of  criteria that have propsoed or promulgated by
state and interstate water-pollution-control  agencies,  but
unfortunately  the terms are not well defined.  Furthermore,
where  either  term  is  used,   qualitative   rather   than
quantitative  limits  are  set.   The New England Interstate
Water Pollution Control Commission, for  example,  specified
that  "substances  potentially  toxic"  shall  be  "none" in
Classes A  and  B,  and  "not  in  toxic  concentrations  or
combinations" in Classes C and D  (see Chapter III).

Total^Suspended Sgljds

Suspended   solids   include   both  organic  and  inorganic
materials.  The inorganic components include sand, silt, and
clay.  The  organic  fraction  includes  such  materials  as
grease, oil, tar, animal and vegetable fats, various fibers,
sawdust,  hair,  and  various  materials from sewers.  These
solids may settle out rapidly and bottom deposits are  often
a  mixture  of  both  organic  and  inorganic  solids.  They
adversely affect fisheries by covering  the  bottom  of  the
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stream  or lake with a blanket of material that destroys the
fish-food bottom fauna  or  the  spawning  ground  of  fish.
Deposits  containing  organic  materials  may deplete bottom
oxygen  supplies  and  produce  hydrogen   sulfide,   carbon
dioxide, methane, and other noxious gases.

In  raw  water  sources for domestic use, state and regional
agencies generally specify that suspended solids in  streams
shall  not  be  present  in  sufficient  concentration to be
objectionable  or  to  interfere   with   normal   treatment
processes.   Suspended  solids  in  water may interfere with
many industrial processes, and cause foaming in boilers,  or
encrustations  on  equipment exposed to water, especially as
the temperature rises.  Suspended solids are undesirable  in
water  for  textile  industries;  paper and pulp; beverages;
dairy  products;  laundries;  dyeing;  photography;  cooling
systems,  and  power plants.  Suspended particles also serve
as a transport mechanism for pesticides and other substances
which are readily sorbed into or onto clay particles.

Solids may be suspended in water for a time, and then settle
to the bed of the stream or lake.  These  settleable  solids
discharged   with   man's   wastes   may  be  inert,  slowly
biodegradable materials, or rapidly decomposable substances.
While in suspension, they  increase  the  turbidity  of  the
water,    reduce    light   penetration   and   impair   the
photosynthetic activity of aquatic plants.

Solids in suspension are  aesthetically  displeasing.   When
they  settle  to  form sludge deposits on the stream or lake
bed, they are often much more damaging to the life in water,
and they  retain  the  capacity  to  displease  the  senses.
Solids,  when  transformed  to  sludge  deposits,  may  do a
variety of damaging things, including blanketing the  stream
or  lake  bed  and  thereby destroying the living spaces for
those benthic organisms  that  would  otherwise  occupy  the
habitat.   When  of  an  organic  and therefore decomposable
nature, solids use a portion or all of the dissolved  oxygen
available  in  the  area.  Organic materials also serve as a
seemingly inexhaustible  food  source  for  sludgeworms  and
associated organisms.

Turbidity  is  principally  a measure of the light absorbing
properties of suspended solids.  It is frequently used as  a
substitute  method of quickly estimating the total suspended
solids when the  concentration is relatively low.

Zinc
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Occurring abundantly in rocks  and  ores,  zinc  is  readily
refined into a stable pure metal and is used extensively for
galvanizing, in alloys, for electrical purposes, in printing
plates,  for  dye-manufacture  and for dyeing processes, and
for many other industrial purposes.  Zinc salts are used  in
paint    pigments,    cosmetics,    Pharmaceuticals,   dyes,
insecticides,  and  other  products  too  numerous  to  list
herein.   Many  of these salts  (e.g., zinc chloride and zinc
sulfate) are highly soluble in water;  hence  it  is  to  be
expected  that  zinc  might occur in many industrial wastes.
On the other hand, some zinc  salts  (zinc  carbonate,  zinc
oxide, zinc sulfide) are insoluble in water and consequently
it  is to be expected that some zinc will precipitate and be
removed readily in most natural waters.

In zinc-mining areas, zinc  has  been  found  in  waters  in
concentrations  as  high  as  50  mg/1 and in effluents from
metal-plating works and small-arms ammunition plants it  may
occur  in  significant  concentrations.  In most surface and
ground waters, it is present only in trace  amounts.   There
is  some  evidence  that zinc ions are adsorbed strongly and
permanently on silt, resulting in inactivation of the zinc.

Concentrations of zinc in excess of 5 mg/1 in raw water used
for drinking water supplies cause an undesirable taste which
persists through conventional treatment.  Zinc can  have  an
adverse effect on man and animals at high concentrations.

In  soft  water,  concentrations of zinc ranging from 0.1 to
1.0 mg/1 have been reported to be lethal to fish.   Zinc  is
thought  to  exert  its  toxic  action  by forming insoluble
compounds with the mucous that covers the gills,  by  damage
to the gill epithelium, or possibly by acting as an internal
poison.   The  sensitivity  of  fish  to  zinc  varies  with
species, age and condition, as well as with the physical and
chemical characteristics of the water.  Some acclimatization
to the presence of zinc  is  possible.   It  has  also  been
observed  that  the effects of zinc poisoning may not become
apparent  immediately,  so  that  fish  removed  from  zinc-
contaminated to zinc-free water (after 4-6 hours of exposure
to  zinc) may die 48 hours later.   The presence of copper in
water  may  increase  the  toxicity  of  zinc   to   aquatic
organisms,  but  the  presence  of  calcium  or hardness may
decrease the relative toxicity.

Observed values for the distribution of zinc in ocean waters
vary widely.  The  major  concern  with  zinc  compounds  in
marine  waters  is  not one of acute toxicity, but rather of
the long-term sub-lethal effects of the  metallic  compounds
and  complexes.   From  an  acute  toxicity  point  of view.
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invertebrate marine animals seem to be  the  most  sensitive
organisms  tested.   The  growth  of  the  sea  urchin,  for
example, has been retarded by as little as 30 ug/1 of zinc.

Zinc sulfate has also  been  found  to  be  lethal  to  many
plants, and it could impair agricultural uses.
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                        SECTION VII

              CONTROL AND TREATMENT TECHNOLOGY
INTRODUCTION

Plant  studies  were conducted in each subcategory at plants
that were deemed to be  the  best  relative  to  performance
levels  attained  by their treatment facilities.  The plants
visited were selected by the EPA from the  candidate  plants
listed  in  Table  18.  Table 48 presents a brief summary of
treatment practices employed at all plants visited  in  this
study,  and  shows  the  variability of treatment techniques
employed in the industry.  Included in each subcategory  are
tables presenting the size, location, and ages of the plants
that were visited.

RANGE  AND  PERMUTATIONS OF TREATMENT TECHNOLOGY AND CURRENT
PRACTICE AS EXEMPLIFIED BY PLANTS VISITED DURING THE STUDY

In each subcategory, a discussion is presented on  the  full
range  of  technology employed within the industry, followed
by a discussion on the treatment practices, effluent  loads,
and reduction benefits at the plants that were visited.  The
effluent  is  stated  in terms of gross plant effluent waste
load.  In addition, this section contains a general treatise
on parameters inherent in steel industry wastes.

HOT FORMING - PRIMARY

The wastewaters produced are primarily  the  result  of  the
following  types  of  water systems employed in the blooming
and slabbing mills.   Wastewaters  result  from  the  direct
water   spray  cooling  of  mill  equipment,  high  pressure
descaling spray water system, automatic  scarfing  high  and
low pressure spray waters, and water discharged from the wet
type of scarfer fume collection systems.

The  wastewaters  from  descaling and mill equipment cooling
are generally discharged via flumes or trenches to  inground
concrete  settling  chambers  called  scale  pits  where the
heavier iron oxide particles are settled out.   These  scale
pits generally contain underflow weirs with launders to trap
oils and greases picked up by the cooling waters.  The waste
oils  are  removed from the water surfaces by belt, rope, or
other type of floating oil skimmers,  and  pumped  to  large
capacity  waste  oil  storage  tanks  where contract haulers
periodically remove the  accumulated  oils.   The  scale  is
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                          TABLE 48

               WASTEWATER TREATMENT PRACTICES
                 OF PLANTS VISITED IN STUDY
PLANT                               PRACTICE

HOT FORMING PRIMARY

    A-2        Primary and secondary clarification with
               partial recycle of clarified wastewaters,
               accompanied by deep bed filtration of the
               remainder.  The filter effluent is discharged
               to receiving stream.

    B-2        Primary and secondary clarification followed
               by deep bed filtration.  The filter effluent
               is discharged to receiving stream.
                                      *
    C-1        Deep bed filtration of scale pit effluent
               followed by discharge" to receiving stream.

    D-2        Primary and secondary clarification followed
               by deep bed filtration.  Filtet discharge is
               returned to intake pumps for recycle and
               reuse throughout the mill.

    L-2        Primary clarification including oil skimming,
               followed by chemical treatment, vacuum filtra-
               tion, and cooling with partial blowdown of 1-
               2%.  Treated water is reused in mill and
               elsewhere in plant as makeup and noncontact
               cooling water.

HOT FORMING SECTION

    E-2        Primary settling of mill wastes followed by
               secondary clarification, sand filtration,
               cooling, and recycle back to mills.  Blowdown
               from system is less than 4%.

    F-2        Primary and secondary clarification including
               oil skimming.  Portion of effluent is returned
               as flushing and coil cooling water.  Remainder
               is discharged to a central treatment system
               undergoing vacuum filtration, chemical treat-
               ment, and cooling with discharge of cooling
               tower blowdown.
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PLANT                              PRACTICE

     G-2       Primary and secondary clarification including
               oil skimming, followed by sand filtration,
               cooling, and total recycle.

     H-2       Scale pit effluent is sent to cyclonic solids
               separator with clarified water discharged,
               and concentrated sludges returned to scale
               pit.

     1-2       Scale pit effluent treated by extended settling
               in a terminal lagoon.

HOT FORMING FLAT

     J-2       Primary and secondary clarification, chemical
               treatment, gravity filtration and discharge
               to receiving stream.

     K-2       Primary and secondary clarification, filtra-
               tion, cooling and recycle for mill use.  Blow-
               down from system is 2-3%.

     L-2       Primary clarification including oil skimming,
               followed by chemical treatment, vacuum filtra-
               tion, and cooling with partial blowdown of
               1-2%.  Treated water is reused in mill and
               elsewhere in plant as makeup and noncontact
               cooling water.

     M-2       Primary clarification including oil skimming,
               followed by chemical treatment, clarification,
               filtration, and discharge to receiving stream.

     N-2       Primary clarification, high flow sand filtra-
               tion, cooling, and total recycle to mill.

PIPE AND TUBES

     E-2       Primary settling, clarification, filtration,
               cooling and recycle to other hot forming
               operations.

     GG-2      Primary sedimentation, oil separation, and
               recycle to pond for plant use.

     HH-2      Total recycle system.  Settle in series of
               ponds, return to reservoir for process reuse
               throughout plant.
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PIANT                              PRACTICE

     II-2      Sedimentation, oil skimming, filtration, final
               settling lagoon, and discharge to receiving
               stream.

     JJ-2      Primary sedimentation, mixing with acid rinses,
               lagooned for evaporative cooliug, and recycled
               for plant reuse.

     KK-2      Primary and secondary sedimentation, oil
               separation, polyelectrolyte addition, and
               discharge to receiving stream.

PICKLING - BATCH SULFURIC - CONCENTRATED

     1-2       Spent pickle liquor disposed of via contract
               hauling.

     0-2       Batch evaporative crystallization of spent
               sulfuric acid.  Acid recovered with production
               of a ferrous heptahydrate.

     P-2       Batch pickle liquor regeneration by vacuum
               crystallization.

     Q-2       Batch pickle regeneration through cooling of
               spent pickle liquor and precipitation of
               ferrous sulfate heptahydrate.

     R-2       Combining pickle liquor in an equalization
               tank, flash mixing with acetylene sludge,
               lagooning, and discharge to creek.

     S-2       Spent pickle liquor disposed of via contract
               hauling.

PICKLING - BATCH SULFURIC - RINSE

     1-2       Rinses mixed with other plant wastes in a
               terminal lagoon and discharge to receiving
               stream.

     0-2       Rinses recycled back as makeup to pickle tank.

     P-2       Rinses metered to sewer discharge.

     Q-2       Pinses and mists from filter recycled back as
               makeup to pickle tank.
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PLANT                         PRACTICE

    R-2        Combining acid rinses with other wastes in an
               equalization tank, flash mixing with acetyxene
               sludge, lagooning, and discharge to creek.

    S-2        Standing rinse reused as makeup to pickle tank.
               Running rinse is treated with lime and lagooned,
               Lagoon sludges are contract hauled, and over-
               flows ar<- recycled to rinse.

PICKLING - CONTINUOUS SULFURIC

    T-2        Pickle liquor regeneration by evaporative
               concentration.

    T-2        Rinses recycled back as makeup to pickle tank.

PICKLING - BATCH HYDROCHLORIC - CONCENTRATED

    U-2        Spent pickle liquor disposed of via contract
               hauling.

    V-2        Spent pickle liquor disposed c ? via contract
               hauling.

PICKLING - BATCH HYDROCHLORIC - RINSE

    U-2        Rinses treated in batch treatment tank by
               sodium carbonate neutralization.

    V-2        Caustic neutralization of rinse waber prior to
               sanitary sewer discharge.

PICKLING - CONTINUOUS HYDROCHLORIC - CONCENTRATED

    1-2        Spent pickle liquor disposed of via contract
               hauling.

    W-2        Pyrolytic regeneration of hydrochloric acid.

    X-2        Spent adid recovery via hydrochloric acid
               regeneration.

    Y-2        Pyrolytic regeneration of hydrochloric acid.

    Z-2        Neutralization of spent pickle liquor clari-
               fication, with disposal of the supernatant to
               the sewer.
                         195

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PLANT                              PRACTICE

    AA-2       Deep well disposal of spent liquor.

    BB-2       Deep well disposal, or regeneration at an
               off-site HC1 plant.

PICKLING - CONTINUOUS HYDROCHLORIC - RINSE

    1-2        Dilution and mixing with other mill wastes
               in a terminal lagoon with discharge to
               receiving stream.

    W-2        Dilution of rinse waters and sewr discharge.

    X-2        Dilution of rinse waters and sewer discharge.

    Y-2        Dilution of rinse waters and sewer discharge.

    Z-2        Rinses are combined with' concentrated pickle
               liquor and treated by neutralization, clarifi-
               cation, and discharge to sanitary sewer.

    AA-2       Cascade rinse system and deep well disposal.

    BB-2       Rinses mixed with cold mi-11 wastes, neutral-
               ized, clarified, lagooned and discharged to
               receiving stream.

SCALE REMOVAL - SHOT BLAST

    CC-2       Dry removal system, no aqueous discharge.

WIRE MAKING

    1-2        Dilution and reaction with other mill wastes
               in a terminal lagoon and discharge to receiving
               stream.

    Q-2        No process wastewaters - noncontact cooling
               waters from wire drawing are discharged un-
               treated.

    LL-2       Mixing with other process wastewaters for
               chemical treatment that includes oil skimming,
               chemical reduction, coagulation, sedimentation^
               clarification, and aeration.
                             196

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PLANT                         PRACTICE

COLD ROLLING

    X-2        Air flotation, chemical treatment, clarifica-
               tion, and plant reuse.

    BB-2       Mixing .;ich acid rinse waters, neutralization,
               aeration, clarification, lagooning, and dis-
               charge to receiving stream.

    DD-2       Oil skimming, chemical treatment., sedimentation,
               and discharge to receiving stream.

    EE-2       Oil skimming, chemical treatment, lagooning,
               and sewer discharge.

    FF-2       Primary sedimentation, mixing, chemical treat-
               ment, clarification, and-sewer discharge.

HOT COATINGS - GALVANIZING

    1-2        Dilution and reaction with othsr mill wastes
               in a teiminal lagoon and discharge to receiving
               stream.

    MM-2       Mixing of coating wastewaters, oil separation,
               aeration, sedimentation, lagooning and recircu-
               lation to service water with intermittent blow-
               down to receiving stream.

    NN-2       Lime treatment, polymer addition, and clarifica-
               tion.

HOT COATINGS - TERNE PLATE

    00-2       Mixing and dilution of rinse waters prior to
               discharge.

    PP-2       Mixing and dilution of rinse waters prior to
               discharge.
                                197

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cleaned  out by mechanical means such as clam shell buckets,
drag link conveyors, etc.

The  wastewaters  discharged  from  scale  pits  are  either
discharged  to  plant  sewers  or  are  recycled back to the
mills.   The  suspended  solids  content  in  overflows   is
generally  100  to  200  mg/1,  but these wastewaters can be
further treated by means of filtration  or  thickeners  with
chemical coagulation.

The  wastewaters  from  the  automatic  scarfer  spray water
systems are generally routed into  a  scale  pit  where  the
heavy slag particles are settled out and the overflow waters
discharged  to  the  plant sewers.  Often these spray waters
are discharged into the same primary scale pit as  the  mill
equipment cooling and descaling waters.

The  water systems employed for the wet type of scarfer fume
collection  systems  depend  upon  the  type  of   equipment
utilized.   High  energy  venturi  scrubbers  or wet type of
precipitators are used due to  the  saturated  condition  of
gases.  The high energy scrubbers use a recycle water system
with a 3-6 I/sec (50 to 100 gpm) blowdown rate discharged to
the scale pits.

The  wet  precipitators can be classed as intermittent spray
or continuous water types.

The   intermittent   type   uses   internal   water   sprays
periodically  to  clean  or  wash down the collector plates,
whereas the continuous water type uses flooded and irrigated
collector plates.  The  wastewaters  from  the  precipitator
systems   are  generally  discharged  to  a  thickener  with
chemical coagulation.  The clarified waters can be  recycled
back  to  the  precipitator  systems  or discharged to plant
sewer systems.

Plant Visits

Five primary plants were visited  in  the  study.   Table  6
presents  a  summary  of  the  plants  visited in respect to
geographic location, daily production, plant age, and age of
the treatment facility.  Table 49 presents  the  plants  raw
and effluent waste loads.
ELiJlt. A- 2 - Figure 21.  Wastewaters from blooming and billet
mills  are combined at this plant.  The plant practices both
primary and secondary clarification followed by a series  of
deep  bed  filters.   Part  of  the  clarifier  overflow  is
recycled to the mills.  The filter effluent is discharged.
                            198

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-------
Plant B-2  -  Figure  22.   Blooming  mill  wastewaters  are
treated  by  primary and secondary clarification followed by
deep bed filtration.  The filter effluent is  discharged  to
the receiving

Plant  C-2  -  Figure  23.   Blooming  mill  wastewaters are
treated via  primary  sedimentation  followed  by  deep  bed
filtration and recycle to a variety of plant water uses.

Plant  D-2  -  Figure  24.  This plant combines blooming and
billet  mill  wastewaters  for  treatment.   Oil   skimming,
primary and secondary clarification are utilized followed by
deep bed filtration.  Filter discharge is returned to intake
pumps for recycle and reuse in the mill.

Plant L-2  Figure 32.  This plant uses primary clarification
including  oil  skimming,  followed  by  chemical treatment,
vacuum  filtration,  and  cooling  with  partial   blowdown.
Treated  water  is  reused in mill and elsewhere in plant as
makeup and ncncontact cooling water.

HOT FORMING - SECTION

The wastewaters produced are primarily the result of  reheat
furnace  noncontact  cooling  waters, mill equipment cooling
waters, and high pressure  spray  water  descaling  systems.
The  furnace  cooling  waters are generally once-through and
discharged to plant sewers.

The mill  equipment  cooling  and  high  pressure  descaling
waters  are discharged via flumes and trenches to scale pits
where the heavier solids are settled out.  Oils and  greases
picked  up  by  the  cooling waters are trapped in the scale
pits by means of underflow weirs and launders.

The oils are removed from the surface of scale pit waters by
means of belt, rope  or  floating  type  oil  skimmers,  and
pumped  to  large  capacity oil storage tanks where contract
haulers periodically remove the accumulated oils.  The scale
pit  overflow  waters  are  generally  discharged  to  plant
sewers, but sometimes recycled back to the mills as sluicing
or  flushing  waters in flumes and trenches.  Some mills use
mechanical scraper  or  drag  line  buckets  to  remove  the
heavier  iron  oxide scale beneath the mill stands and stock
pile the scale for recycling in mills.  The waters are still
flushed into scale  pits  or  settling  chambers  for  final
sedimentation and skimming of waste oils and greases.
                                201

-------
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                                                    202

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                                                                    203

-------
204

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Thickeners  with  chemical  coagulation or filtration can be
used to further treat the  scale  pit  overflow  waters  and
reduce the suspended solids from 100-200 mg/1 to 25 mg/1.

Ei§ILt Visits

Seven section locations containing ten production units were
visited  in  the  study.   Table 7 presents a summary of the
plants visited in  respect  to  geographic  location,  daily
production,  plant  age,  and age of the treatment facility.
Table 50 presents the plants raw and effluent waste loads.
   Qt A- 2 - Figure 21.  Wastewaters from blooming and billet
mills are combined at this plant.  The plant practices  both
primary  and secondary clarification followed by a series of
deep  bed  filters.   Part  of  the  clarifier  overflow  is
recycled to the mills.  The filter effluent is discharged.
       Bzl  -  Figure  24.  This plant combines blooming and
billet  mill  wastewaters  for  treatment.   Oil   skimming,
primary and secondary clarification are utilized followed by
deep bed filtration.  Filter discharge is returned to intake
pumps for recycle and reuse in the mill.

Plant E-2 - Figure 25.  This plant utilizes primary settling
of   wastes   from   two   mills,   followed   by  secondary
clarification, sand filtration, cooling, and recycle back to
mills.  Slowdown from system is less than 4X.
   Qt F-2 - Figure 26.  This  plant  practices  primary  and
secondary  clarification including oil skimming.  Portion of
effluent is returned as flushing  and  coil  cooling  water.
Remainder  is  discharged  to  a  central  treatment  system
undergoing  vacuum  filtration,  chemical   treatment,   and
cooling with discharge of cooling tower blowdown.

Plant  (3-2  -  Figure  J27.   This plant utilizes primary and
secondary clarification including oil skimming on two mills,
followed by sand  filtration, cooling, and total recycle.

Plant H-2 - Figure 28.  The plant scale pit effluent is sent
to cyclonic solids separator with clarified water discharged
to receiving stream.

Plant 1-2 - Figure 29.  All wastewaters from this plant  are
discharged to a terminal treatment lagoon.

HOT FORMING FIAT

Plate Mills
                               206

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Plant  K^2  -  Figure  31.  This plant practices primary and
secondary clarification, filtration/  cooling,  and  recycle
for  mill  use.   Blowdown  from  system  is approximate 3X.
Table 51 presents the plants raw waste and effluent loads.

The  wastewaters  produced  are  primarily  the  result   of
noncontact  reheat  furnace  cooling  waters, mill equipment
cooling waters, and high pressure water  descaling  systems.
The  noncontact  reheat furnace cooling waters are typically
once-through and discharged to the plant sewers.   The  mill
equipment  cooling  and high pressure spray descaling waters
are discharged to scale pits via flumes and  trenches.   The
scale  pits  generally  contain underflow weirs and launders
for trapping of waste oils and greases.  The waste oils  are
skimmed  from the scale pit water surfaces by means of belt,
rope, or floating type oil skimmers and are pumped to  large
capacity   oil   storage   tanks   where   contract  haulers
periodically remove  the  accumulated  oils.   The  overflow
waters  are discharged to the plant sewers, or recycled back
to the mill as flushing or sluicing  waters  in  flumes  and
trenches.

HOT STRIP AND SHEET MILLS

The  wastewaters produced are primarily the result of reheat
furnace noncontact cooling waters,  mill  equipment  cooling
water,  high  pressure  descaling  waters, and the hot strip
final cooling waters.  The reheat furnace noncontact cooling
waters are generally once-through and  discharged  to  plant
sewer systems.  The mill equipment cooling and high pressure
descaling  waters  are discharged to scale pits via trenches
and flumes.

The  scale  pits  generally  contain  underflow  weirs   and
launders  to  trap  waste  oils.  The waste oils are skimmed
from the scale pit water surfaces by means of belt, rope  or
floating  oil  skimmers and are pumped to large capacity oil
storage tanks where contract haulers periodically remove the
accumulated  oils.   The  scale  pit  overflow  waters   are
generally  discharged  to  plant sewers, or recycled back to
the mill versus flushing or sluicing  waters  in  flumes  or
trenches.

The  final  strip  cooling waters are sometimes recirculated
separately and reduced in temperature via cooling towers due
to the large quantities  of  good  quality  water  required.
During  rolling,  about  8X of the cooling water evaporates,
and this loss  plus  the  loss  across  the  cooling  towers
establishes  a  requirement  for makeup water to the system.
These waters are generally not contaminated.  Blowdown  from
                           214

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the  cooling  towers  would be required to prevent dissolved
solids concentrations from reaching unacceptable levels.

The overflow waters from the scale pits are sometimes pumped
back to the mill as flushing or sluicing waters in flumes or
trenches.   The  suspended  solids  in  overflow  waters  is
generally  100-200  mg/1.  The waters can be further treated
by  means  of  thickeners  with  chemical   coagulation   or
filtration.

Plant Visits

Visits  were made to five plants in this subcategory.  Table
8 presents a summary of the plants  visited  in  respect  to
geographic location, daily production, plant age, and age of
the  treatment  facility.   Table 51 presents the plants raw
waste and effluent loads.
      Jr2 - Figure 30.   This  plant  utilizes  primary  and
secondary   clarification,   chemical   treatment,   gravity
filtration, and discharge to the receiving stream.

Plant  L-2  -  Figure   32.    This   plant   uses   primary
clarification  including  oil skimming, followed by chemical
treatment,  vacuum  filtration,  and  cooling  with  partial
blowdown.   Treated water is reused in mill and elsewhere in
plant as makeup and noncontact cooling water.

Plant  M-2  -  Figure  33.   This  plant  utilizes   primary
clarification  including oil skimming, following by chemical
treatment,  clarification,  filtration,  and  discharge   to
receiving stream.

Plant  N-2  -  Figure  34.   This  plant  practices  primary
clarification, high flow sand filtration, cooling, and total
recycle to mill.

PIPE AND TUBE MILLS - HOT WORKED

The  wastewaters  produced  are  primarily  the  result   of
equipment water cooling and product water cooling.

Butt Welded Pipe Mills

The butt welded pipe mills' wastewaters are from the cooling
waters  used  in  reheat furnaces, cooling waters in welding
and drawing operation, and mill  bed  cooling  boshes.   The
waters are generally discharged to scale pits or sumps where
most  of  the  suspended  solids are settled out.  The scale
pits have underflow weirs and launders for trapping any oils
                           217

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or greases.  The oils are removed from the water surface  by
means of belt, rope, or floating oil skimmers and discharged
to  waste  oil  collection  tanks.   The  scale pit overflow
waters are discharged to plant sewers.

Electric Resistance Welded Pip_e Mills

The wastewaters from these pipe mills result from noncontact
equipment cooling  waters  which  are  discharged  to  plant
sewers  and  water  soluble oil spray cooling waters used on
the pipe after the seam  has  been  welded.   These  soluble
water  oil  systems  are  recycle  systems  with filtration.
These water systems are makeup systems.

Seamless Tube Mills

Seamless tube wastewaters  result  from  noncontact  cooling
waters   on   piercing  mandrels,  sizing  mandrels,  reheat
furnaces, etc.  The  waters  are  discharged  to  the  plant
sewers.

Direct  contact  spray  water  mill equipment cooling is the
other source of wastewater.  These waters are discharged  to
scale  pits  for  sedimentation of solids.  Oils and greases
are trapped by underflow weirs and  launders.   The  oil  is
skimmed  from  the water surfaces by means of belt, rope, or
floating oil skimmers.  The overflow waters from scale  pits
are discharged to plant sewers.

Plant Visits

Visits  were  made  to  five hot worked pipe and tube mills.
Table 9 presents a summary of the plants visited in  respect
to geographic location, daily production, plant age, and age
of the treatment facility.  Table 52 presents the plants raw
waste and effluent loads.
      E-2 - Figure 25.  This plant utilizes primary settling
of  mill  wastes  followed  by secondary clarification, sand
filtration, cooling, and recycle for use by two hot  forming
   section  mills.  Slowdown from the overall system is less
than U%.

Plant  GG-2  -  Figure  35.   This  plant  utilizes  primary
sedimentation,  oil separation, and recycle to pond for mill
use.
Plant I I- 2 - Figure  36.   Wastewaters  at  this  plant  are
treated  by  sedimentation,  oil skimming, filtration, final
settling lagoon, and discharge to receiving stream.
                            221

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Ei§:Q£ JJ~2 - Figure  _37.   Wastewaters  at  this  plant  are
treated  by  primary sedimentation, mixing with acid rinses,
lagooned for evaporative cooling,  and  recycled  for  plant
reuse
       KKz_2  -  Figure 38.  This plant practices primary and
secondary  sedimentation,  oil  separation,  polyelectrolyte
addition, and discharge to receiving stream.

PIP.! MP TUBE MILLS - COLD WORKED

Plant Visits

A  visit  was  made  to  one cold worked pipe and tube mill.
Table 10 presents a summary of the plant visited in  respect
to geographic location, daily product, plant age, and age of
the  treatment  facility.   Table 52 presents the plants raw
waste and effluent loads.

Plant HH-2 - Figure 39.  This plant has an  excellent  total
recycle  system.   Wastewaters are settled in ponds and then
returned to  reservoir  for  process  reuse  throughout  the
plant.

PICKLING

Several   different   treatment   systems   have  been  used
throughout the years in dealing with the  liquid  discharges
associated  with  the pickling process.  They may be grouped
into two general classes:  disposal processes; and recycling
processes.

Disposal Procesges

1.  Dumping to a waterway
2.  Dumping on an alkaline bed
3.  Contract hauling
4.  Dumping into municipal treatment facilities
5.  Simple neutralization
6.  Modified neutralization
7.  Controlled neutralization/oxidation
8.  Deep well disposal

None of these  methods  offers  the  ideal  answer  for  the
treatment of this wastewater.

Dumping,   hauling,   and   deep  well  injection  move  the
contaminants from one place to another and, therefore,  only
relocate  the  pollution  problem.   Neutralization destroys
valuable materials which  could have been recycled.
                              226

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                                        227

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It also will produce a  sludge  or  semi-solid  which,  when
improperly   handled,   can  cause  serious  land  pollution
problems.  In addition, many neutralized discharges  contain
high  concentrations  of dissolved solids, usually sodium or
calcium sulfate or chlorides.

However, in relation to one another, each has its advantages
and   disadvantages.    Each   method   deserves    separate
discussion.   All  are pontentially subject to regulation by
permit authorities on local or national level.

Dumping  to  a  Waterway.   This  method  includes   dumping
directly   or   indirectly   into  streams,  rivers,  lakes,
including barging or piping to sea.

Disadvantages.  Water pollution  and  community  objections.
This  method  simply  moves  the pollutant from one place to
another.  No recovery of products.

Advantages.  Low investment cost.  Low operating cost.

Remarks.  The dissolved iron salts are more objectionable in
most cases than the free acid.   The  iron  causes  a  brown
discoloration of the water and objectionable slime deposits.
Ferrous  iron  exerts  a  high  oxygen demand, which totally
depletes the dissolved oxygen of the receiving stream.

Dumping on an Alkaline Bed.  This  method  includes  dumping
onto  piles  of  oyster  shells,  steel  mill slag, or other
alkaline materials.

Disadvantages.  Only part  of  the  free  acid  is  normally
neutralized and the dissolved iron runs off.  No recovery of
products.

Advantages.  No investment cost.  Low operating cost.

Remarks.  The pollution problem of color and slime from iron
remains   unsolved.    Free  acid  and  dissolved  iron  can
contaminate ground waters or surface waters.
Contract Hauling.  It is assumed that this  method  includes
the subsequent proper treatment of the waste by the contract
hauler.    Therefore,   the   cost   would  include  hauling
 (transportation) and treatment.

Disadvantages.  High  unit  cost.   Contract  hauling  costs
generally range upwards from  $0.03 per gal.  The producer of
the  waste  remains  legally  responsible  for the manner of
                              230

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ultimate disposal and any resultant pollution.  No  recovery
of products.

Advantages.   Low  investment  cost.  This is frequently the
least expensive method of  disposal  for  small  volumes  of
waste  if  the  contractor  is reliable and applies approved
treatment technology.

Remarks.   The  producer  is  directly  dependent  upon  the
reliability of the contract hauler.

Dumping  into Municipal Treatment Facilities.  Some pickling
operations dump their liquid discharges, either  treated  or
untreated, directly into municipal sewer systems.

Disadvantages.   Limited  to small quantities.  Waste pickle
liquor generally has to be partially neutralized  with  soda
ash,  caustic  soda or ammonia.  In some cases, could impose
unnecessarily excessive loads on the municipal  system.   No
recovery of products.

Advantages.  Low investment cost.  Modest operating cost.

Remarks.   Neutralization  of  the  free  acid,  but not the
ferrous sulfate, will generally be required.

Simple  Neutralization.   A  commonly  used   treatment   is
neutralization  of the spent pickle solutions with treatment
chemicals.  This approach is intended to  raise  the  pH  to
about 7, so that a neutral liquid can be discharged.

Disadvantages.   Problems  arise  in  the  disposal  of  the
resultant sludge.   Ferrous  hydroxide  in  the  neutralized
mixture is extremely difficult to settle and the sludge must
be pumped into lagoons where it has to be kept indefinitely.
This is no small problem.  The pickling of 1,000,000 tons of
steel  can  result — if neutralization is used on the spent
liquor — in the production of 200,000 tons of  sludge  that
will  not  dewater.   The  sludge  requires 150 acre feet of
permanent fill volume and high freight or real estate costs.
Simple neutralization may cost from $0.02 to $0.05 per  gal.
No recovery of products.

Advantages.    Low   to   medium  cost  initial  investment.
Operating cost  is  usually  less  expensive  than  contract
hauling for large volumes.

Remarks.  Simple neutralization techniques will probably not
meet  the  future  effluent  discharge  standards  as far as
dissolved solids are concerned, especially iron.
                             231

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Modified   Neutralization.    This    method    is    simple
neutralization  plus  the  filtration  of the resultant iron
hydroxide sludge.

Disadvantages.   Medium  to  high  investment  costs.   High
operating   costs.    Increased  operating  complexity.   No
recovery of products.
Advantages.
freight.
Some water can be sewered, thus reducing sludge
Remarks.  Filter cake contains 1 to 2 Ib of water per Ib  of
solids  and  is slow drying unless spread over a large area.
Runoff or seepage  from  filter  cake  dumping  ground  will
contain iron contaminants.

Controlled  Neutralization/Oxidation.   This  method is more
acceptable than simple neutralization because it neutralizes
the solution to a pH of  7  to  9,  and  then  oxidizes  the
resultant   ferrous   hydroxide   to   magnetic  iron  oxide
(magnetite)  and water.  Thus,  the  usual  hydroxide  sludge
problem is avoided.

Disadvantages.   High investment cost.  High operating cost.
Increased  operating  complexity,  requiring   sophisticated
process and equipment.  High temperature and relatively long
retention time required in the process.

Advantages.   Easy-to-dewater solids.  Sludge weight onesixth
(1/6)  that  of simple neutralization.  Recoverable magnetic
iron oxide.   Solids make good landfill.

Remarks.   Solids  can  be  centrifuged   to   moist   earth
consistency,  or  slurry  can be piped directly to a natural
drainage area for accumulation of solids and decantation  of
excess water.
	   Well   Disposal.   There  are  several  hundred  deep
injection wells in the United States, but only a dozen or so
are used to dispose of waste  pickling  liquors.   Depending
upon  local  conditions  and  geology,  some  of  these  are
relatively troublefree in  operation  and  maintenance,  and
some are extremely troublesome.

Disadvantages.   Great  depth  needed  to minimize chance of
pollution problems by contaminating ground  waters.   Medium
to  high  initial  investment.   Precise filtration required
prior to injection.  No recovery of products.
                             232

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Advantages.   Elimination  of   neutralizing   costs.    Low
operating cost.  Versatility.

Remarks.   Highly dependent on local geology.  Great risk is
involved because the contaminants may penetrate waterbearing
strata.  Great care must be taken to avoid pumping too  high
a  solids  concentration  into  the porous starta because it
would be very easy to block the strata and force the well to
shut down.

Recycling Processes

The only really effective method industry can  use  to  stop
pollution is to eliminate discharges from a particular plant
or  operation.   By  attacking  waste  at  its  source,  the
potential may exist where pollution control can be converted
from a non-productive expense  to  a  cost-cutting,  perhaps
even profitable, investment.

Any  comprehensive  solution  to  this  complex problem must
simultaneously resolve all related difficulties at one  time
and in one system.  Many attempts have been made in the past
to  cope  with  these  effluent  problems.   They have often
failed because of inability or refusal to  comprehend  these
separate  problems  as interdependent aspects of one complex
problem.

Conservation by recycling in a "closed-loop"  system  is  an
answer.    This   will  minimize  the  cost  and  volume  of
effluents,  stop  waste  and  inefficiency,  and   eliminate
discharges  of  noxious  materials from pickling plants.  In
this way, scale removal operations may  become  less  costly
and pollutionfree.

The  system  should be simple and easy to operate, corrosion
resistant and mechanically sound  and,  most  important,  be
economically  viable.   Such  systems are available and have
been proven effective in many pickling operations.

Sulfuric.  Most common is acid recovery through  removal  of
ferrous  sulfate  by  crystallization.   Spent pickle liquor
high in iron content is pumped into a crystallizer where  it
is  cooled,  and the iron is crystallized as ferrous sulfate
heptahydrate.  The crystals  are  then  separated,  and  the
remaining  (recovered)   acid  is pumped back to the pickling
tank.  The discharge from  the  system  is  ferrous  sulfate
heptahydrate in pure, crystalline form, a chemical byproduct
with  commerical  value.   Sale  of  this chemical may offer
potential  income  where  market  conditions  permit.    The
crystals  are  dried,  bagged, and marketed, or sold in bulk
                             233

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quantities.   Ferrous  sulfate,  commonly  referred  to   as
"copperas,"  is  used  in appreciable quantities in numerous
industries, with its most important value in the manufacture
of inks, dyes,  paints,  and  fertilizers.   Its  use  as  a
flocculating  agent  in waste treatment and sewage plants is
exceptionally  noteworthy  because  the  demand   for   this
chemical  increases  constantly  as  municipal sewage plants
improve and expand their treatment facilities.

Hydrochloric.   The  only   existing   commercially   proven
technology  at  this  time for the regeneration of acid from
spent  hydrochloric  acid  pickling  solutions  is   through
thermal  decomposition.   The  spent pickle liquor contains,
essentially, free hydrochloric acid, ferrous  chloride,  and
water.   This  liquor  is  generally  first  heated  so that
evaporation removes some of the water and thus  concentrates
the  solution.   The  concentrated  solution is subjected to
temperatures of about 925° to 1,050°C (1,700°  to  1,920°F).
At  this  temperature,  evaporation  and decomposition takes
place.  Water is further evaporated and the ferrous chloride
decomposes into iron oxide and hydrogen chloride.  The  iron
oxide  is  separated  and  removed  from  the  system.   The
hydrogen chloride gas is reabsorbed  into  water   (sometimes
rinse  water  or  scrubber  water  is  used),  thus making a
reusable hydrochloric  acid  solution.   There  are  several
types   of   these  "roaster"  processes  available  and  in
operation  throughout  the  world.   The  basic   difference
between  the  processes  is  the design and operation of the
roaster/reactor itself.   Each  different  design,  however,
seems  to have its own distinct advantages and disadvantages
associated with it.

Crystallization Processes  (Sulfuric Acid)

Q2Stinuous TyjDe.  There are three acid  recovery  plants  in
North  America   (two  in  Canada, one in the U.S.A.) at this
time employing a continuous vacuum crystallization  process.
Spent  pickle liquor with high iron content is precooled and
continuously pumped to a multi-stage crystallizer  where  it
is  further  cooled  by  evaporation  in a vacuum maintained
through high pressure steam ejectors and a mechanical vacuum
pump.  The acid/crystal slurry is pumped to  a  concentrator
and  from there to a centrifuge for crystal separation.  The
recovered acid is then returned at about 10° to 16°C  (50° to
60°F) to the pickling tanks.  Regular operator attention  is
required and a consistent composition of spent pickle liquor
is required for its optimum and practical operation.

In  order  to  maintain  continuous  operation of the vacuum
crystallizers, it is necessary to supply those units with  a
                               234

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continuous  supply  of  consistent pickle liquor.  This then
involves the necessity of adequate storage tanks at each end
of the recovery system.

The continuous type process is illustrated in Figure 40.
   ch Type.  This process is in successful operation  in  17
plants  throughout  the  North  American  continent  on both
continuous and batch pickling lines, handling strip, sheets,
rods, wire, bar, and other product configurations.  In  each
case, pickling costs were reduced significantly.  The oldest
such system has been in operation for over seven years.  See
Figure 41.

The  heart  of the system is a batch type crystallizer where
spent pickling liquor  is  agitated  and  cooled  through  a
recirculating  chilled  water  circuit.  After separation of
crystals by decanting, the recovered acid is reheated to 60°
to 65°C (140° to 150°F) prior  to  return  to  the  pickling
tank.   The  plant  is  very  simple  and  does  not require
continuous operator attention.

Acid entrained  in  the  pickling  tank  exhaust  system  is
removed in the acid mist filter and rinse water is reused in
the  pickling  tank.   The  system  then  has  "zero  liquid
discharge. "

Where the batch crystallizer is to be  used  in  conjunction
with  pickling  lines  that  discharge  pickle  liquor  on a
continuous basis, or those that dump many various batches of
liquor at indeterminate times, a "conditioning holding tank"
is added to the system.

This  pickling  and  acid  recovery   system   offers   many
advantages  and  features:    (a.) purchased acid consumption
reduced as much as SOX;  (b.) it allows recovery and reuse of
significant amounts of inhibitors;  (c.) eliminates costs and
problems of disposing of spent pickle liquors, rinse waters,
and scrubber waters;  (d.) shows savings in  water  costs  in
rinsing and scrubbing by direct recovery of all of the rinse
water (and the acid in it); (e.) it can also offer increased
production  because of constant optimum pickling conditions;
(f . ) it lowers operating costs through the simplicity of the
system (does not require constant operator attention) ;   (g. )
minimizes  delay  in  dumping and making up acid tanks;  (h.)
eliminates  environmental  problems  indoors  and  pollution
problems  outdoors  by recovering acid from mist; (i.) trims
load on municipal sewers and sewage  plants;  finally,   (j.)
most important, it ends water pollution from pickling.
                             235

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The  available  commercially  proven  processes  under  this
category are essentially the same, in that  each  heats  the
pickle  liquor  to  relatively  high temperatures in thermal
reactors.  At these high temperatures, decomposition  occurs
yielding  iron  oxide  (ferric oxide, Fe2(X3) , water (vapor) ,
and hydrogen chloric  (HC1) gas.   Water  vapor  is  scrubbed
prior  to discharge to atmosphere.  Iron oxide particles are
separated and discharged  from  the  system.    The  hydrogen
chloride  gas  is  absorbed  into  water  which  produces  a
"regenerated" hydrochloric acid solution, generally from 15X
to 2 IX HC1  (by  weight) .   The  regenerated  acid  is  then
recycled back into the pickling operation.

The two variations of this process that are noteworthy are:
       Roaster  T.ype  Process.   This process incorporates a
relatively large roaster vessel which  is  heated  to  about
1,000°C (1830°F).

Pickle  liquor is pumped at high pressure through filters to
the top of each spray roaster, entering through  four  spray
heads,  which  atomize  the pickle liquor.  Four natural gas
burners, arranged symmetrically around the circumference  of
the  roaster, heat the atomized pickle liquor as it descends
in the roaster.  As the temperature of the liquid rises, the
water and free HCl  vaporize  yielding  steam  and  hydrogen
chloride  gas  while  the iron chloride is converted to iron
oxide and hydrogen chloride gas.  The relatively heavy  iron
oxide  drops  down  into  the  cone of the roaster while the
water  vapor,  hydrogen  chloride  gas,  and   products   of
combustion rise.

To draw the hydrogen chloride gas from the roaster, negative
pressure  is  created  by  exhaust fans installed in series.
The system  is  made  negative  to  prevent  the  escape  of
hydrogen  chloride  gas  should a leak develop in the piping
system.

Some of the iron oxide  particles  are  very  fine  and  are
carried  off  the  top  of  the  roaster with the discharged
roaster gases.  These particles are  removed  by  a  cyclone
installed in the system immediately after the roaster.

The cyclone is located on an elevated platform directly over
the  oxide storage hopper so that the fine particles of iron
oxide fall directly into the storage bin.  This  arrangement
eliminates   the   difficult   problem  of  conveying  these
microscopic particles.
                              238

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To convert the gas to HCl acid,  it  is  passed  through  an
absorber,  consisting  of  a brick lined shell with a carbon
grill and ceramic saddles.

The steam and gas enter the  bottom  and  rise  through  the
grill  while the water percolates down, condensing the steam
and  converting  the  gas  to  HCl  acid.   The  non-soluble
products of combustion go up the stack.

Water  is  metered  to  the  absorber to produce 20% HCl (by
weight).  Details of this process are  presented  on  Figure
42.

Fluid-Bed  Roaster Ty_B§.  This is basically the same type of
process as the spray roaster type except  that  the  reactor
vessel   itself   is  relatively  smaller  in  size  than  a
comparable spray roaster.   This  is  possible  because  the
roaster  vessel  contains  a  fluid  bed which allows longer
retention times because of the bed itself.

Because of the nature of this process using the  fluid  bed,
the resultant iron oxide leaves the system as a small pellet
instead of a dust.

Vital  plant  components  are the reactor, a cyclone, a pre-
evaporator/venturi scrubber combined with a  separator,  and
an absorber.

The  spent pickle liquor to be regenerated is delivered into
the combined pre-evaporator/venturi scrubber in which it  is
concentrated,  utilizing  the  waste heat recovered from the
hot gases emitted from the reactor.

The concentrate is subsequently charged into a fluidized bed
of  granular  ferrous  oxide  maintained  at  about   800°C.
Evaporation  of  the residual water and decomposition of the
ferrous chloride  takes  place  simultaneously.   The  major
portion  of  Fe2O3  clings immediately to the surface of the
hot fluidized grains.  A residence time of several hours  in
the  bed  assures  adequate  grain growth to a range of 0.2-
2.2 mm diameter.  The reactor is controlled  to  a  constant
fluid bed level.

A small amount of Fe2O3 that has not taken part in the grain
growth  is  carried  over  and subsequently collected in the
cyclone and recharged to the reactor.  Hot gases leaving the
reactor contain hydrochloric  acid  gas,  superheated  water
vapor,  combustion  products  of  the  heating medium, and a
small amount of ultrafine dust.  The dust is washed out in a
                              239

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                                    240

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high-efficiency venturi scrubber.  These fines are dissolved
in the pickle liquor feed stream and recycled.

After separation from the  liquor,  the  cooled  HCl-bearing
gases  pass  into  an  absorber charged with water (possibly
rinse  water),  in  which   acid   below   the   azeoptropic
composition  is  recovered by adiabatic absorption.  Most of
the commercial plants built  so  far  produce  10-12%  acid,
although  some  go  as high as 18%.  The vapors issuing from
the absorber are discharged via a suction fan that  maintain
the entire plant under negative pressure.

Acid  recovery  efficiency  is over 99.5%, with losses being
confined to small quantities in the  waste  gas.   There  is
almost a complete absence of iron in the regenerated liquor.
The  small  amount  of  dust  from  the  reactor  that could
otherwise contaminate the  pickle  liquor  is  separated  in
high-efficiency   collectors,   thus  resulting  in  optimum
conditions for pickling.

Fuel is  burned  directly  in  the  fluidized  bed.   Rugged
structural  elements  permit  direct  and  complete burning;
separate  combustion  chambers   are   not   needed,   which
simplifies the design and saves on cost.

Bulk  density  of the pelletized iron oxide product is 2920-
3570 kg/cu m.  (180-220 Ib/cu ft).  The pellets retain  their
shape  even in the presence of water and during handling and
storage.  Chlorine composition is 0.02%.   Details  of  this
process are presented on Figure 43.

Other   processes   that   are   currently   under  research
development or demonstration include the following:

Sulfuric Acid Process.  A system has  been  demonstrated  at
pilot  plant  level  which  utilizes a process well known in
Europe.  This process is a "heating" process rather than the
more common and proven "cooling" processes.  The process, in
effect, heats spent pickle liquor to  about  150°  to  175°C
(302°  to 347°F), at which time fresh acid is added to bring
the acid  concentration  to  about  50%  to  55%  H2SO4^   (by
weight).   At this point, the ferrous sulfate content of the
pickle liquor precipitates as  ferrous  sulfate  monohydrate
(crystals) .   Details  of  this  process  have not been made
available at this time.

Hydrochloric  Acid  Processes.   A  pilot  plant  has   been
developed  and  demonstrated  and  is  now in the process of
being moved to a commercial operation.  This  process  is  a
thermal  decomposition  type  process  but  claims  a unique
                         241

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roaster reactor which is neither the "spray roaster" design,
nor the "fluid-bed" design.  The reactor is a  "sliding-bed"
type  unit  which  produces a "sintered" agglomerate of iron
oxide, and requires  only  a  relatively  small  reactor  in
comparison to the other types of roasters.

A  wet chemical process is also in development at this time.
It has been proven  in  the  laboratory,  pilot  plant,  and
demonstration plant level.

Waste  pickle  liquor is concentrated by thermal evaporation
and then air oxidized, under pressure, to produce a solution
of ferric chloride and some iron oxide.   This  solution  is
then  hydrolyzed  to produce HC1 gas and iron oxide.  HCl is
recovered in an absorbing tower.  The  iron  oxide  that  is
produced  can be recycled, used commercially, or disposed of
as a non-polluting solid.

Waste pickle liquor storage provides a means of  reserve  to
even  out  the  flow and the composition of the waste pickle
liquor.  The pickle liquor is pumped to the evaporator where
the solution is concentrated.  This concentrated solution is
fed to the oxidizer, which converts the ferrous chloride  in
the  waste  pickle  liquor  to  ferric  chloride.   From the
oxidizer the ferric chloride solution is blown over  to  the
hydrolyzer,  where  hydrolysis  of the ferric chloride takes
place and black ferric oxide and hydrogen chloride  gas  are
produced.   The  hydrogen  chloride  gas  is  absorbed in an
absorber to produce hydrochloric  acid  at  a  concentration
between  20-31%,  depending  on  feed composition.  The iron
oxide is separated in the recovery system  consisting  of  a
wet  separator,  a  slurry  tank,  a  vacuum  filter,  and a
conveyor system for ferric oxide disposal.  The process flue
gases are scrubbed in a  tail  gas  scrubber.   The  process
provides   the   steel   industry  with  unique  operational
capability.  Waste pickle liquor  can  be  concentrated,  or
oxidized   to  produce  sewage  grade  ferric  chloride,  or
processed to  produce  a  high  strength  hydrochloric  acid
solution.   The iron oxide produced is a dense non-polluting
material which can be recycled to the steelmaking operation,
sold as a commercial product,  or  disposed  of  as  a  non-
polluting  solid.   Details of this process are presented on
Figure 44.

Plant Visits

Visits were made to 15 plant locations covering the  various
subcategories  of  pickling.   Tables  10 and 11 present the
summary of the  plants  visited  in  respect  to  geographic
                          243

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location,  daily  production,  plant  age,  and  age  of the
treatment facility.

Batch Sulf uric

Tables 53 and 54 present the plants raw and  waste  effluent
loads.

Plant  1-2  - Figure 29_.  Waste pickle liquor hauled away by
private contractor.  All rinses are combined with other mill
wastes in a terminal lagoon and discharged to a canal.
      O-2 - Figure jt5.   Plant  utilizes  batch  evaporative
crystallization of spent sulfuric acid.  Acid recovered with
crystallization of spent sulfuric acid.  Acid recovered with
production  of  ferrous  sulfate  heptahydrate.   Rinses are
recycled to process as makeup to pickle tank.
      P-2 - Figure 46 and 47.  Plant utilizes  batch  pickle
liquor  regeneration  by vacuum crystallization.  Rinses are
metered to the sewer.

Plant  Q-2  -  Figure  48.   Plant  practices  batch  pickle
regeneration  through  cooling  of  spent  pickle liquor and
precipitation of ferrous sulfate heptahydrate.   Rinses  and
mists from filter are recycled back to pickle tank.

Plant  Rz2  -  Figure  49.  Plant combines pickle liquor and
rinses in an equalization tank, flash mixes amd treats  with
acetylene  sludge,  lagoons,  and  discharges  to  receiving
stream.

Plant S-2  -  Figure  50.   Concentrated  pickle  liquor  is
contract  hauled.   Standing  rinse  is  reused as makeup to
pickle  tank.   Running  rinse  is  treated  with  lime  and
lagooned.   Lagoon  overflow  is  recycled,  and  sludge  is
contract hauled.

Continuous Sulfuric

Table 55 presents the plants raw and waste effluent loads.

Plant T-2  -  Figure  51.   Concentrated  pickle  liquor  is
regenerated   by   evaporative  concentration.   Rinses  are
recycled back as makeup to pickle  tank.   Steam  condensate
serves as final rinse.

      Hydrochloric
                             245

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i i i i i i i i
:SS: PICKLING H2S04-BATCH
CONCENTRATED & RINSE;
PICKLING SULFURIC ACID
RECOVERY
f: Q-2
JC'i'ION: 109 METRIC TONS/DAY
(120 TONS/DAY)

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STEEL INDUSTRY STUDY
FURIC ACID PICKLING AND RECOVERY
BATCH OPERATION
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM

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SO4-BATC
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STEEL/DAY (255 TOXS

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AND RINSES
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256

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Tables  56  and 57 present the plants raw and waste effluent
loads.

Plant U-2 - Figure  5_2.   Waste  pickle  liquors  and  rinse
waters  are  neutralized in a batch treatment tank by sodium
carbonate prior to sanitary sewer discharge.
      V-2 - Figure^ 53  and  54.   Spent  pickle  liquor  is
contract  hauled.  Rinses are neutralized with NaOH prior to
sanitary sewer discharge.

Continuous Hydrochlojrlg

Tables 56 and 57 present the plants raw and  waste  effluent
loads.

Plant  1-2  -  Figure 2.2 •  Plant dilutes concentrated pickle
liquor and rinses with  other  mill  wastes  in  a  terminal
lagoon and discharges to a canal.
       w-2  -  Figure 5J5.  Waste pickle liquor is treated by
pyrolytic regeneration of  hydrochloric  acid.   Rinses  and
fume  hood  scrubber  wastes  are diluted and metered to the
sewer.  Absorber vent scrubber treated with caustic solution
and discharged.
Plant Xz2 - Figures 5£ and 57.  Plant practices  spent  acid
recovery  via  hydrochloric  acid  regeneration.  Rinses are
diluted and metered t@ the sewer.   Absorber  vent  scrubber
treated in clarif ier with other plant waetewaters.

Plant  Y-2  -  Fjgares  5J  and  59.  Waste pickle liquor is
treated by  pyrolytic  regeneration  of  hydrochloric  acid.
Rinses  and  absorber vent scrubbers are diluted and metered
to the sewer.

Plant Z-2 - Figure 6Q.  Plant treats waste pickle liquor and
rinses jointly via  equalization,  neutralization,  aeration
and   clarification   with  polymer  addition,  followed  by
discharge to a sanitary sewer.
Plant &&-2 - Figure £i.  Plant  uses  cascade  rinse  system
with  rinses  and concentrated pickle liquor disposed of via
deep well disposal.

Plant BB-2 -  Fi
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DRY SCALE REMOVAL

Although the use of acids  (pickling)  is  the  most  common
method  for  scale removal, a mechanical process called grit
blasting or blast cleaning is  also  used.   Sand,  aluminum
oxide,  or  cast-iron  shot are directed against the work by
compressed air or  a  mechanical  device  using  centrifugal
force.   These impinge on the surface of the steel and erode
or abrade away the scale.

Grit blasting leaves a bright metallic surface  without  any
adhering  scale.   It  is  capable  of  cleaning a number of
products that cannot successfully be  cleaned  by  pickling,
and  it does not induce the hazards of under-pickling, over-
pickling, or pitting which may attend the pickling process.

Grit blasting can process only a limited number of items  at
one  time.   As  the  shot builds up with scale its cleaning
effectiveness decreases, and items are difficult to  inspect
for  surface  defects  because of the cleaning action of the
shot.

Some plants use a combination of blast cleaning and pickling
to increase the plant production.  Blast cleaning is used to
remove the heavy scale.  This is followed by a short  pickle
to  remove  final  traces of scale and rust.  Pickling alone
could be used, but pickling times would be  increased  three
to four fold, thereby reducing overall plant output.

One such plant installed a blast cleaning system for $50,000
in  1963  to  clean  rods  prior  to  pickling  and  further
processing.  Annual operating costs of  the  unit  for  1973
were  $73,000.   In  1973  the  plant shipped 40,740 tons of
product; 70% of  which  was  blast  cleaned  at  a  cost  of
$2.55/ton.

Blast  cleaning  systems  require good ventilation to remove
the dusty air from the area.  Prior to  discharging  to  the
atmosphere,  this  dust  must  be removed from the air.  Dry
baghouses are most commonly used for this purpose,  however,
wet scrubbers could be used.  As a general rule there are no
wastewater discharges from a blast cleaning operation.

CQLD ROLLING OPERATIONS

Several   different   treatment   systems   have  been  used
throughout the years to  treat  wastewaters  resulting  from
cold rolling operations.  These systems have progressed from
direct  discharge  to the receiving stream without treatment
to the treatment and reuse of the wastewater with no  direct
                                273

-------
discharge to the receiving stream.  The high cost of rolling
oils,   and   the   promulgation  of  regulations  requiring
pollution control have all but eliminated  the  once-through
direct  discharge of these wastes.  Oil recovery systems and
closed-loop recycle systems  are  widely  utilized  for  the
recovery  and  reuse  of  rolling  oils.   Oil  is the major
pollutant in these wastes  and  all  treatment  systems  are
primarily  designed  for its removal.  The various treatment
systems are listed here according to the degree of treatment
they provide.

1.  The simplest attempt to remove the oil from cold rolling
wastewater was to divert the  water  through  a  scale  pit.
Free  floating  oil was removed by a skimmer, some oil would
adhere to the scale  and  settle  and  the  emulsified  oils
passed  through the pit and were discharged to the receiving
stream.

2.  Oil separators specifically designed for the removal  of
the particular rolling oil replaced the scale pit, with some
attempt  to  break  the emulsions and remove as much of this
oil as possible.  Emulsified oils were still  discharged  to
the receiving stream in significant quantities.

3.  A refinement to Step 2  to  include  chemical  addition,
flocculation,  air  flotation, and surface skimming followed
by discharge to the receiving stream.

4.  Utilization  of  spent  pickle  liquor  to  acidify  the
wastewater and break the emulsion.  The oil is removed by an
oil  separator.   The  water is neutralized with lime, mixed
with  other  mill  wastewater   and   clarified   prior   to
discharging  to  the receiving stream.  Some mills discharge
the  clarified  water  into  a  retention  lagoon  prior  to
discharging to the receiving stream.

5.  Another modification to the aforementioned system is  to
collect  the  spent  rolling oil emulsions in a storage tank
along with other oil-bearing  wastewater  generated  in  the
cold  rolling  operation.   Some  floating oil is removed in
this tank.  The wastewater from the tank  is  metered  to  a
mixing  tank where spent pickle liquor is added to break the
emulsion.  The wastewater then goes to an oil  separator  to
remove  the oil.  The treated wastewater is then returned to
the mill water system and used as makeup water  to  the  gas
cleaning system.

Plant Visits
                              274

-------
Visits  were  made  to  five cold rolling operations.  Table
presents  summary  of  the  plants  visited  in  respect  to
geographic location, daily production, plant age, and age of
the  treatment  facility.   Table 58 presents the plants raw
and waste effluent loads.

Plant X-2 - Figure  56.   This  plant  utilizes  a  combined
treatment  system for cold rolling and pickling wastewaters.
Treatment  system  consists  of  air   flotation,   chemical
treatment, clarification, and plant reuse.

Plant  BB-2  -  Figure  62.   This  plant combines cold mill
wastewater with acid rinse waters, utilizing neutralization,
aeration, clarification with  polymer  addition,  lagooning,
and discharge to the receiving stream.

Plant  DD-2 - Figure 63.  This plant practices oil skimming,
chemical treatment,  sedimentation,  and  discharge  to  the
receiving stream.

Plant EE-2 - Figure £4.  Plant wastewater treatment practice
includes  equalization,  oil  skimming,  chemical treatment,
lagooning, and sewer discharge.

Plant FF-2 - Figujre 65.  Wastewaters are treated by  primary
sedimentation,  mixing, chemical treatment, and discharge to
sewer.

COATING OPERATIONS

The  process  wastewaters  generated  during   hot   coating
operations  include  alkaline  and acidic cleaners and their
rinses, fume scrubbing wastewaters, and  chemical  treatment
solutions  and  their  rinses.   A  wide  variety of ways to
handle coating wastes exists throughout the steel  industry,
and  yet  certain  basic treatment systems are commonly used
much more than others.  These are listed here  according  to
the degree of treatment they provide.

1.  No matter what wastewater treatment technique,  if  any,
is used, an important first step is to minimize the quantity
of  wastes  requiring  treatment.   This  is accomplished by
providing dragout recovery  tanks  downstream  of  the  main
cleaning tanks; by utilizing high pressure spray rinses with
recycling  of  rinse waters where practical; and by careful,
even critical, attention to maintenance of equipment such as
rolls and squeegees  designed  to  reduce  solution  losses.
Some  plants,  primarily hot coating lines with their slower
line speeds, minimize carryover  of  wastes  so  effectively
that   no  treatment  of  wastewaters  is  required.   Spent
                              275

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pickling  and cleaning  solutions are  collected  separately
for  disposal via dumping on wasteland, contract hauling, or
deep wells.

2.  The  simplest  treatment  of  wastewaters  from  coating
operations  usually begins with blending acidic and alkaline
wastes,  then  providing  space  and  time   for   suspended
precipitates  to  settle  out.  This blending of wastewaters
causes oily matter to break  out  of  any  emulsified  forms
present,  becoming  susceptible  to  removal via skimming or
through adhering to the settleable solids.  To  avoid  slugs
of   extremely   acidic   or   alkaline   wastewaters,   the
concentrated solutions are collected separately, stored, and
then allowed to combine with rinses  in  predetermined  flow
ratios  to  provide  the  best mixing conditions possible in
this relatively crude system.

3.  A  significant  improvement  in  treatment  methods   is
attained  through  controlled neutralization of the combined
wastewaters, using an alkaline  material  such  as  lime  or
caustic  soda  to  achieve higher pH levels than is possible
through  simply  blending  the  wastewaters.   Normally,   a
polymer  is  also  used to enhance settling characteristics,
and relatively sophisticated  clarifiers  are  installed  to
efficiently  handle the large volumes of metallic hydroxides
which precipitate out.  Sludges are dewatered  using  vacuum
filtration  and  go  to landfill areas.  The effluent waters
are suitable for discharge, sometimes requiring a  final  pH
adjustment with acid.

4.  Refinements in treatment techniques would depend on  the
sources  of  wastewaters  handled  in  the treatment system.
These would be tailored to specific needs, for example:

Reduction  of  Hexavalent  Chromium.    Coating   operations
producing   chromate  or  dichromate  wastes  normally  have
separate pretreatment stages to reduce toxic  Cr+6  to  Cr+3
prior  to neutralization.  Most often, the ferrous iron from
pickling rinse solutions or spent pickle liquors is  blended
with  the  chromium wastewaters.  In rarer cases, additional
reducing agents such as bisulphites or sulfur dioxide  gases
are used in place of or in addition to pickling wastes.  The
reduced  chromium-containing wastes are then passed along to
a  controlled  neutralization  treatment  stage,  where  the
addition  of  lime or caustic soda precipitates all chromium
as the  hydroxide.   Alternatively,  the  chromates  may  be
precipitated  out  of  solutions  by  the addition of barium
salts,  such as sulfates or  carbonates.   A  precipitate  of
barium  chromate  is  separated  out for subsequent separate
recovery  of  barium  and  chromium.   Also,  ion   exchange
                             280

-------
techniques  can  be  utilized  to recover clean chromic acid
from strong solutions contaminated  by  iron  and  trivalent
chromium.   The  recovered  acid is reused in the plating or
chemical treatment operations.

5.  Joint treatment systems combining wastewaters from  many
different  sources  into  one  terminal  treatment plant are
becoming increasingly common.  In  these,  wastewaters  from
coating  operations usually represent a minor portion of the
total flow.  Such terminal treatment systems may incorporate
any or all of the individual pretreatment  stages  mentioned
above.

Plant Visits

Visits  were made to nine different plant locations to study
the  individual  operations  included  under   the   coating
category.   Tables  13  and  14  present  the summary of the
plants visited in  respect  to  geographic  location,  daily
production,  plant  age,  and age of the treatment facility.
Tables 59, and 60 presents the plants raw and waste effluent
loads.

Plant  1-2  -  Figure  29.   This   plant   treats   coating
wastewaters  by dilution and reaction with other mill wastes
in a terminal  lagoon,  with  subsequent  discharge  to  the
receiving stream.

Plant  MM-2  -  Figure  66.  This plant combines all coating
wastewaters  with  wastes  from  other  sources.   Treatment
includes    equalization,    oil    separation,    aeration,
sedimentation, lagooning, and recirculation to service water
with intermittent blowdown to river.

Plant NN-2 - Figure 67.  This plant  utilizes  equalization,
mixing,   two-stage   lime   addition,   polymer  feed,  and
clarification  for   treatment   of   coating   wastewaters.
Clarifier  underflows  are  vacuum  filtered,  then  used as
landfill.  Overflows are discharged to the receiving stream.

Plant 00-2 - Figure 6>_8.   This  plant  utilizes  mixing  and
dilution  of  rinse  waters  prior  to  discharge.  Solution
dragout is minimized through strict attention to maintenance
of equipment.

Plant PP-2 - Figure 69.   This  plant  utilizes  mixing  and
dilution or rinse waters prior to river discharge.  Solution
dragout is minimized through strict attention to maintenance
of equipment.
                       281

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Plant  2Q-2  -  Figure  70.   This  plant   treats   coating
wastewaters  with  separate  chrome  treatment and recovery,
fluoride    precipitation    with    lime,     equalization,
clarification, flocculation, sedimentation, and discharge to
the receiving stream.

Plant   RRz2   -  Figure  71.   This  plant  treats  coating
wastewaters with chrome precipitation  using  barium  salts,
equalization,   mixing  with  acid  wastes,  neutralization,
clarification,   detention,   additional   lagooning,    and
discharge to the receiving stream.

Plant  SS-2 - Figure 72.  At this plant, coating wastewaters
and other plant wastewaters are  discharged  to  a  terminal
treatment   plant  for  chemical  treatment,  aeration,  oil
skimming, settling, and discharge.

Plant TIV2 - Figure 73.  Coating wastewaters at  this  plant
are  treated  by  mixing and diluting of all rinses prior to
discharge to  the  river.   Solution  dragout  is  minimized
through strict attention to maintenance of equipment.

SPECIFIC PARAMETER DISCUSSION

Acidity and Alkalinity

Acidity and alkalinity are arbitrary terms used to express a
wastewater1s reactive capacity towards hydroxyl and hydrogen
ions respectfully in terms of a common substance.

The  purpose  of the test, and its common terminology, is to
facilitate the calculation  of  equivalent  amounts  of  any
substance   (acid  or base) required to neutralize the acidic
or alkaline components in a water or waste stream.

The test used is an acid base titration with  arbitrary  end
points  based  on  the  carbonate/bicarbonate  ion  and  its
critical conversion points of pH U.6  for  the  irreversible
reaction and pH 8.5 for the reversible reaction.

Through  application  of  the  titrametric data, free acids,
total acidity, bicarbonate alkalinity, carbonate alkalinity,
and free hydroxide concentrations can be estimated.

Aside from common acids,  alkalies,  and  the  ever  present
carbonate  ion,  many  other  substances found in steel mill
wastes,  such  as  heavy  metal  ions   (Fe,  Zn,  Al,  etc.)
phosphates,  silicates,  ammonium  compounds, etc., have the
ability to react with hydrogen and hydroxyl ions.
                               288

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PROCESS : COATINGS-COLD-TIli-HALOGZX
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289

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PROCESS : COAT'NGS-COLD-TIN-HALOGEH
COATINGS-COLD-CI:ROME
PLANT: RR-2
DRODUCTIOJJ: (TIK-HALOGEN)
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In general, the acid or alkaline capacity of a waste is  not
the  primary  basis for treatment prior to discharge,; except
in some specialized waste situations.  In most cases, it  is
the toxicity or other detrimental qualities of the substance
contributing  to acidity or alkalinity that is the basis for
its removal.  An example of this would be in  the  treatment
of  heavy  metals   (Fe,  Ni,  Crr etc.) via precipitation as
hydroxides.

Three methods of treatment applicable for the disposition of
wastes containing high acidity or alkalinity values  are  as
follows:

Blending   with   Other   Wastewaters.   This  technique  is
applicable only if  sufficient  dilution  or  neutralization
capacity  is  available  in  the  receiving stream such that
discharge  standards  are  not  exceeded  for  the  acidity,
alkalinity, or any component in the waste.

Direct.  Neutralization  with  Acids  or BagesA  This form of
treatment is utilized  when  high  concentrations  or  large
volumes of waste are encountered.
QlJSSlical Precipitation.  This method is restricted to wastes
capable  of generating precipitates with chemical treatment.
A  typical  example  of  this   technique   would   be   the
precipitation of carbonate alkalinity with calcium.

Chlorides

The  chloride  ion  is  an  anion  that forms highly soluble
compounds with  most  cations.   Because  of  their  soluble
nature,  the  analysis  of  chloride  is  often  used  as an
indication of  the  dissolved  solids  content  of  a  waste
providing  it  is  the predominant anion species.  Chloride-
based compounds are generated in numerous production  areas,
particularly  during  the by-product coking operations, some
blast  furnace  operations,  the  pickling  of  steel   with
hydrochloric acid and certain plating operations.

No  treatment exists at this time for the economical removal
of chlorides from a waste stream, hence reduction or removal
of chloride  would  have  to  be  met  by  in-plant  process
control.

Chromium

Chromium is used in the steel industry as a basic ingredient
in  the  manufacture  of stainless steel.  The percentage of
chromium in the steel determines its resistance to corrosion
                                293

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from various chemicals and atmospheres.  In the  manufacture
of stainless steel, the chromium becomes an integral part of
the  steel and is not generally found in the wastewater from
the hot melting and rolling operations.

Chromium  in  the  form  of  chromic  acid  is   also   used
extensively  in  the steel industry in the electroplating of
sheet, strip pipe, and wire to form a protective coating  of
chromic  oxide on the steel.  A 5-30 second hot bath of 0.5-
1.0% chromic acid follows the normal  plating  operation  to
form   a  layer  of  chromic  oxide  which  adds  additional
corrosion resistance to the steel and  protects  the  bright
metallic  appearance.   The  length  of  bath determines the
degree of resistance to corrosion.   Following  the  chromic
acid  bath,  the  steel  is  rinsed to remove residual acid.
This rinse water becomes polluted with chromic acid and is a
treatment and disposal problem.

Several other processes using chromic acid and chromates  in
combination  with other compounds are in use by the industry
to  prepare  the  steel  for   electroplating   and/or   the
application of organic coatings such as paints and lacquers.
Some  of these processes are Chromodizing, Cronak Treatment,
Iridite Treatment, and Anozinc  Treatment.   Whenever  these
processes  are  used  or  whenever  electrolytic tin, chrome
(tin-free steel), zinc or galvanized processes are  used,  a
wastewater  containing  chromic  acid  will be generated and
must be treated before discharge to the receiving waters.

There  are  four  treatment  systems  for  the  recovery  or
treatment  of  chrome-bearing  waste currently in use in the
industry.  These systems are (1) reduction of  the  Cr+*  to
Cr+3  and  precipitation  with  lime,   (2)  recovery  by ion
exchange,  (3) evaporative recovery systems, and  (4) the  M&T
Process  which  precipitates the Cr+* in the hexavalent form
using a proprietary compound.  Each  of  these  systems  and
combinations  thereof,  when  properly  operated,  produce a
suitable effluent  for  discharge  to  the  local  receiving
waters.

Reduction  and  Precipitation.   The reduction of hexavalent
chromium to the trivalent form and precipitation  with  lime
is   most   generally  used  to  treat  those  waters  being
discharged from a plant.  In this process,  the  pH  of  the
chrome-bearing  wastewater  is lowered to 2-3 using sulfuric
acid or spent pickle liquor.  At this point,  a  variety  of
reducing  agents  can  be  used  to reduce the Cr+6 to Cr+3.
These   include   anhydrous   sodium    bisulfite     (sodium
metabisulfite  or  ABS),  sodium  sulfite,  sulfur  dioxide,
ferrous sulfate, and organic materials  such  as  sugar  and
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methyl  alcohol.   In the steel industry waste pickle liquor
is generally  used,  for  it  normally  contains  sufficient
ferrous iron to reduce the chrome to the trivalent form.  At
a  pH of 2 this reaction is practically instantaneous and is
noted by the change in color from yellow to green.

At this point, the chrome is in a  soluble  trivalent  form.
In  order  to remove the chrome from the solution, the pH is
raised to 8.5-9 using lime, at which point insoluble hydrous
chromic oxide rapidly precipitates, and can be removed in  a
settling  basin.   The  treated  water  is  satisfactory for
discharge.  Dolomite lime and caustic soda may also be  used
to  precipitate  the  chromic  oxide;  however,  when  using
caustic soda the chromic oxide tends to go back to solution,
while the dolomite lime  produces  a  lighter  weight,  less
dense sludge which is more difficult to settle and remove.

The  reduction and precipitation of hexavalent chrome is the
most flexible  system  of  those  in  use.   It  is  readily
adaptable  to  continuous or batch operations and can handle
dilute or concentrated  solutions  with  little  difficulty.
Equipment  costs  and  operating  manpower are at a minimum.
However,  the  ultimate  disposal  of  the  chromic   sludge
presents a problem.

Whenever  chrome recovery systems are in use, chrome-bearing
wastes not suitable for recovery  are  still  generated  and
must  be  disposed  of  by  other  methods.   These  wastes,
resulting from spillage in the plating  room,  leaking  pump
seals,   backwash   wastes,   and   general   clean-up,  are
contaminated with  oil  and  suspended  solids  which  could
poison  the  recovery system.  As a result, chrome reduction
systems are also used in conjunction with  recovery  systems
to treat those wastewaters not suitable for recovery.

Ion  Exchange.   Ion  exchange  resins are used in the steel
industry in several different ways to recover chromate  from
plating  wastes  and  rinse  waters  for  reuse  and for the
production  of  demineralized  water  for  use  in   rinsing
operations.   The  resins  are  sensitive to pH and chromate
concentration making pH  control  necessary  and  making  it
necessary   to   provide   a   means   to  control  chromate
concentrations in the waste to be treated.  They  work  best
on  dilute  solutions   (under  500  ppm), and can be used to
recover concentrated plating solutions if properly  diluted.
Spent  regenerant  solutions  contain  traces  of hexavalent
chrome and must be treated before being discharged.

Three basic schemes utilizing ion exchange techniques can be
applied to recover hexavalent chromium:   (1) using an  anion
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resin,  selectively  absorb  Cr+*  from  the  wastewater and
discharge the water; (2) using a cation  resin,  selectively
absorb  the metal ions from the water while passing the Cr+*
ion.  Concentrate the treated water to recover the chromium;
(3)  using two ion exchange units in series, remove  metallic
ion  in  a  cation  exchanger while passing the Cr+* ion and
absorb the Cr+6 ion on an anion resin.  Demineralized  water
is  returned  to  the rinse line for recycle and reuse.  The
spent regenerant solution from the  anion  resin  is  passed
through  a  cation  resin  to  recover  chromic acid free of
metallic  ions  and  suitable  for  reuse  in  the   plating
operations.

(1)  Certain anion resins have  the  ability  to  selectively
absorb hexavalent chrome while allowing the metallic ions to
pass  on  through.   By  using  sodium  chloride  and sodium
hydroxide to regenerate  the  resin,  the  chromate  can  be
recovered  in  a  suitable form for reuse in a cooling tower
system.  This system recovers 90-95X of the  chrome  in  the
waste,  but  a chrome reduction system may still be required
to further treat this waste before discharge.   This  system
is  most  applicable  to treating cooling tower blowdown for
the recovery and reuse of chrome.

(2)  The use  of  a  cation  exchange  unit  followed  by  an
evaporative  recovery  system recovers chromic acid suitable
for reuse in plating baths, and provides distilled water for
reuse in the final rinse tank.  The key to success  of  this
process  is to treat as small a volume of concentrated waste
as  possible.   It  is  essential  that  waste  volumes   be
minimized  by  practicing countercurrent rinsing operations.
The overflow from the concentrated rinse tank is fed to  the
cation  exchanger  and  the  condensate from the evaporative
recovery system is the fresh  (distilled) water makeup to the
rinse system providing complete recycle of the rinse waters.
The concentrated chromic acid in the evaporator is  suitable
for  reuse  in the plating tank.  Spent regenerants from the
cation unit must be treated to remove traces of Cr+6.

The cation exchanger removes the metallic ions but  not  the
Cr*6  from  the wastewater prior to the evaporative recovery
unit.  These metallic ions would poison the plating solution
or reduce its life if they  were  returned  to  the  plating
tank.  It is essential, therefore, that they be removed from
the  waste  stream  before any effort is made to recover the
chrome.

The effluent from the cation exchanger  containing  Cr+6  is
fed  to  a  continuous  evaporator where heat is applied and
water boiled off  (evaporated) from the  wastewater  until  a
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chromic  acid  of  a concentration suitable for returning to
the plating tank  is  obtained.   This  is  collected  in  a
storage  tank  and returned to the plating bath as required.
The water condensed from the evaporator is  a  high  quality
distilled  water  and is reused as makeup water to the final
rinse tank.

The use of  a  cation  exchanger  and  evaporative  recovery
system  represents  complete  recycle  of  the  rinse water.
There is, however, in any process, spillage,  pump  leakage,
and  clean-up  water  that  contain oil and suspended matter
that cannot be recycled.  In addition, the spent  regenerant
of  the cation exchanger must be treated.  These wastes must
be treated via reduction of Cr*6 to Cr+3  and  precipitation
to remove hexavalent chrome before discharging these waters.
In   this  system,  the  final  volume  of  water  requiring
treatment is considerably smaller than  the  original  waste
stream, and chromic acid is recovered in usable form.

(3) Chromic acid can also be recovered by the exclusive  use
of   ion  exchange.   In  this  system,  the  chrome-bearing
wastewater first passes through a cation exchanger  for  the
removal  of  the  metallic ions as described above.  Cr+* is
not removed.  It then  passes  through  an  anion  exchanger
where the Cr+» is removed.  The water, now demineralized, is
used as makeup water for the final rinse tank on the plating
line.

The  cation  exchanger  is  regenerated  using a solution of
sodium chloride and sodium hydroxide.  The spent  regenerant
must  be  further  treated  in  a chrome reduction system to
remove the final traces of Cr+*.   The  anion  exchanger  is
regenerated  with  sodium hydroxide and the spent regenerant
is fed to another  cation  exchanger  that  converts  it  to
chromic  acid  suitable for reuse in the plating tank.  This
system prolongs the life of the plating bath, and  makes  it
possible   to  recover  the  chrome  in  the  spent  plating
solutions by bleeding the spent solution into  the  recovery
system at a controlled rate.  The regenerant from the second
cation  unit  must  be  further  treated to remove traces of
Here again other  chrome-bearing  wastes  not  suitable  for
recovery   by   ion   exchange,  as  well  as  spent  cation
regenerating solutions must be treated in a chrome reduction
system to remove the final traces of chromium.

Evaporative Recovery.  Evaporative recovery systems  can  be
used  exclusively  for  the  direct recovery of chromic acid
from concentrated  rinse  water.   Here  again,  as  in  ion
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exchange  systems,  countercurrent rinsing systems should be
used to minimize water volumes to  be  concentrated  and  to
provide   as   concentrated   a  feed  as  possible  to  the
evaporator.

The concentrated rinse water  is  fed  into  an  evaporator,
where  heat  is  applied and the rinse water concentrated by
boiling off water as steam.  This continues until the  rinse
water concentration is the same as the plating bath, when it
is  transferred  to a storage tank and used as makeup to the
plating solution.  The steam is condensed and is  reused  as
distilled water makeup to the final rinse tank.

The evaporative recovery systems not only recover chrome for
reuse  in  the  plating  bath,  they  also  concentrate  the
metallic ions that were in the rinse water,  and  these  are
also  returned  to  the  plating  bath.  These metallic ions
adversely affect the plating operation and limit the life of
the plating solution,  making  it  necessary  to  frequently
change the plating bath.

Here  again,  leaking  pumps,  spillage,  and  spent plating
solutions not suitable for recovery must be  treated  before
discharge   and  a  chrome  reduction  treatment  system  is
required.

M&T Process.  The M&T Process uses a proprietary compound to
directly precipitate the chromium in  the  hexavalent  form.
This  process is suitable for batch or continuous operation;
however, due to the cost of the proprietary  chemical,  this
system  is  generally  applied  only  to  low  volume waste.
Advantages of this system are  that  equipment  requirements
are  at a minimum, the sludge generated settles rapidly, and
the volume of sludge generated is only  10%  of  the  sludge
generated using the reduction process.

The  composition  of  the  proprietary  compound is unknown;
however, it is known  that  the  complete  precipitation  of
hexavalent chromium can be accomplished by treating chromium
wastewater  with  soluble  salts  of lead or barium nitrate,
chloride or acetate.  There exists, however, the possibility
of carryover of these lead and barium  salts that could prove
to be more toxic than the Cr+6.

The M&T  Process  makes  no  attempt  to  recover  chromium;
however,  it  could  be  used  in place of the reduction and
precipitation process for removing chrome from small volumes
of rinse waters and disposing  of  plating  solutions.   The
reduction  in  the  amount of equipment required and the low
volume of sludge generated  (10 % of the reduction process) by
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the MST Process may  offset  the  increased  chemical  costs
where sludge disposal is a problem.

The  chrome  recovery  and precipitation processes described
here are in use in the steel  industry  today.   The  chrome
recovery systems not only reduce the volume of waste treated
and  the  volume  of  sludge  for disposal, they recover the
costly chrome for reuse and provide  a  high  quality  rinse
water.   Most  mills also have a reduction and precipitation
process to treat those wastes  not  suitable  for  recovery.
Spent  concentrated  plating  solutions  are  disposed of by
bleeding  them  into  the  reduction  process  for  ultimate
treatment   and  removal.   Some  mills  mix  spent  plating
solutions with spent pickle liquors in storage tanks,  where
the  ferrous  sulfate  reduces the Cr+* to Cr+3 prior to the
disposal of the pickle liquor.

The ultimate goal of all systems is to remove or recover the
chrome while generating a minimum amount of sludge requiring
disposal on landfills.  In one case, the Cr+6 is reduced  to
Cr+3  and  the waste mixed with other mill wastewaters prior
to a terminal treatment plant where  the  final  pH  of  the
total  plant  waste  is  adjusted  to  pH  7.1.  Under these
conditions, the Cr+3  passes  through  the  treatment  plant
without  complete  removal,  as a pH of 8.5-9 is required to
quantitatively precipitate the Cr+3.  Dilution by other mill
wastewater reduces  the  Cr+3  concentration  to  acceptable
levels for discharge.

     r.t Lead^ Nickel, Aluminum

Copper,   lead,   nickel,   and   aluminum   are  not  major
constituents of wastewaters generated during the manufacture
of basic steel shapes and forms.  They can, however,  appear
in  small  concentrations  depending  upon  the process used
during that particular step in the steelmaking operation.

These elements, however, are  used  in  the  manufacture  of
alloy  steels  as  well  as  in cladded and specially coated
steel products.  Nickel is added to  the  steel  to  improve
resistance  to corrosion.  Copper and aluminum sheets can be
cladded to steel sheets to take advantage of the  properties
of  copper  and  aluminum  while  adding  the  strength  and
rigidity of steel.  Copper,  aluminum,  and  lead  are  also
applied  as coatings on steel via hot dip, cold coating, and
electroplating operations.  It  is  in  the  application  of
these   coatings   that  the  wastewaters  containing  these
elements are most likely to be generated.
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The most likely sources of these pollutants are the cleaning
and pickling of the  steel  prior  to  rolling,  drawing  or
applying  of coatings, the rinsing or quenching of the steel
after the coatings have been applied, and in the disposal of
spent coating solutions.  They can be  found  in  the  spent
pickle liquors and in the rinse water following the pickling
and  coating  operations.   The  wastewaters are, therefore,
generally acid in nature, and the initial water treatment is
focused on the neutralization of the acid.

The basic criteria for the neutralization  of  spent  pickle
liquors  is  to  neutralize  the acid and to precipitate the
dissolved iron.  In order to precipitate the iron,  hydrated
lime  is  used  to raise the pH of the waste to 8.5-9.0.  At
this pH, dissolved iron can be reduced in the wastewater  to
less  than 1.0 ppm.  In addition, other metal hydroxides are
also precipitated, in many cases to levels  below  0.5  ppm.
These  metal  hydroxides  include  those  of  copper,  lead,
nickel, and aluminum.  As a result no  special  emphasis  is
placed  on the removal of copper, lead, nickel, and aluminum
from  steel  mill  wastewater  because  they  are  generally
present  in acid solutions and readily precipitated whenever
these acid wastes are neutralized with lime.

Ferrous Iron

Ferrous iron is generally present  in  wastewater  generated
while  forming  steel  into usable shapes and sizes.  During
hot rolling, mill scale forms on the surface  of  the  steel
and  must  be periodically removed before further processing
the steel.  Hydraulic sprays are used to remove heavy scale;
however, as the steel assumes the  final  shape  and  cools,
thinner  scale  is formed which is more difficult to remove.
As a result, the steel must undergo  a  "pickling"  process,
that  is,  the  scale is removed by immersing the steel in a
bath of acid.

Sulfuric  acid  is  the  most  common  acid  used.    During
pickling,  the  scale removed from the steel is dissolved in
the acid in the form of ferrous sulfate.  When  the  ferrous
sulfate  concentration  in the pickling acid reaches 18-20X,
the pickling acid is no longer usable and must be discharged
and replaced with new  acid.   Three  methods  are  used  to
dispose of this spent pickle liquor which contains 1-3% acid
as  well  as  18-20X  ferrous  sulfate.  These are deep well
disposal, neutralization,  and  crystallization  to  recover
ferrous sulfate and reusable acid.

Deep  well disposal has proven successful, but not all mills
can utilize this system.  Some pickling operations recover a
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portion of their acid via crystallization, but the resulting
ferrous sulfate may create a disposal problem.

Neutralization is currently the most widely used method  for
disposing of not only the concentrated spent pickle liquors,
but  also  the  dilute  acid rinse waters resulting from the
pickling operation.  Various forms of lime and limestone are
used to neutralize this spent acid.  This is usually done in
a rapid mixing tank where  the  pH  of  the  spent  acid  is
adjusted to 8.5 with lime.  The treated waste is then pumped
to a settling basin or lagoon where the precipitated iron in
the  hydroxide  form  settles  out along with the associated
calcium sulfate precipitate.  In  a  properly  designed  and
operated   treatment   plant,  the  dissolved  iron  in  the
discharge from the settling lagoon should  be  less  than  1
ppm.   The resultant sludge in the lagcon must eventually be
removed and buried on a landfill.

Oil and Grease

Oily waste discharges from steel  mills  can  be  classified
into four categories:

1.  Free oils, which usually are  a  mixture  of  gear  oil,
bearing  oil,  hydraulic  leakage,  some  coating  oil,  and
demulsified rolling oil.

2.  Oil-coated solids, which consist of small  particles  of
metal or oxide coated with an oil film.

3.  Water/oil emulsions in which water is the  discontinuous
phase.   The emulsions themselves are generally unstable and
are relatively easily broken with heat  or  simple  chemical
treatment, such as pH adjustment.

4.  Oil/water emulsions (soluble oils) in which oil  is  the
discontinuous phase.  These materials are stable dispersions
and show no tendency to separate without treatment.

Two  basic  types  of  emulsifiers  are  available  for  the
formulation of  oil/water  emulsions  and  can  be  utilized
either  singly or in conjunction with each other.  These are
anionic  types  that  are  relatively  easily  broken   with
chemical treatment, and nonionic types which usually require
special   emulsion   breaking   chemicals   and  techniques.
Treatment processes utilizing these specialized demulsifiers
are usually restricted to batch  treatment  of  concentrated
oil wastes because of the high treatment costs.
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Two  sources  of  oil  by  type  (solubles/non-solubles)  are
present in steel production:  hot rolling and cold rolling.

An average analyses of cold mill waste streams would present
the following compositions:

1.  Free oil, water/oil emulsions,   and  oil  coated  solids
which  are  subject to flotation, will contain approximately
50% oil and 8% water.

2.  The oil/water emulsion will contain  approximately  1-5%
oil and 0.1% solids.

Hot  rolling operations would generally contribute only free
oil, water/oil emulsions, and oil coated solids,  which  are
subject to gravity separation.

These  waste  stream  analyses  could  only be classified as
typical for the industry as a whole.   Numerous  plants  may
utilize specialized synthetic lubricants such as hot rolling
emulsions,  etc., which are not in wide usage and constitute
a specialized treatment problem for a  particular  plant  or
plant area.

In general, it can be seen that the treatment of oily wastes
is  a  specific  problem for each manufacturing area or mill
and will  be  subject  to  change  with  variations  in  oil
formulations,  the state of repair of the equipment, and the
type of product to be produced.

The removal of oil from a waste stream can  be  effected  by
the   following   techniques   used   either  singly  or  in
combination with each other, depending on the nature of  the
waste stream:

Gravity   Separations.    With   the   exception  of  filter
techniques, all oil removal processes are based  on  density
separation.   The  process  is  applicable to the removal of
both floatable substances  (i.e., free oil and greases,  fine
oil  coated  solids, water/oil emulsions), and heavier-than-
water materials, such as the larger  oil  coated  metal  and
oxide  particles.   The  choice  of  a  particular  type  of
separator would be determined by the type  of  waste  stream
encountered,  and  could range from the simple API separator
in which only floatable substances are removed to  the  more
complex  dual  function  scale  pits and clarifiers  (with or
without chemical treatment) in which both the floatable  and
heavier than water phases are removed.
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High  Rate  Filtration.   In  general,  high rate filtration
employing little or no chemical pretreatment  is  applicable
for  the  removal  of  all  forms  of oil (free oil, grease,
oil/water, and water/oil) and oil  coated  suspended  solids
from  a  wastewater stream.  While the removal efficiency of
these devices will vary with the nature of the  waste  (type
of    oil,    suspended   solids,   etc.),   variations   in
concentrations  within  limits  will  cause  little  effect.
Filters,  because  of  their limited waste holding capacity,
should always be preceded by a gross  waste  removal  stage,
such  as  primary  and secondary scale pits, API separators,
clarifiers, etc., in which chemical treatment may or may not
be utilized.

The specific method of handling the filter backwash  sludges
will  again  depend  on  the  nature  of  the waste.  Common
treatment methods include chemical or  elevated  temperature
oil  emulsion  breaking with gravity separation, filter cake
generation,  and  admixture  with  other  sludge   producing
processes for further disposal.

While  conventional high rate filters do an admirable job of
removing oil, they are subject to oil fouling of the  filter
media, and hence may have to be routinely cleaned with steam
at  the termination of the backwash cycle.  A new generation
of filters has been designed using  a  radial  configuration
(nonuniform  gradient),  synthetic   (plastic)   media, and an
external  regeneration  or  cleaning  cycle.   These   units
require  only  one-fourth  the  filter depth of conventional
high rate filters, and have been shown to be immune  to  oil
fouling.

Flocculatipn.   Flocculation,  as a process, is suitable for
the removal of emulsified oils (oil/water) and suspended  or
dispersed  solids  and oils from a process water stream.   It
is not suitable for the removal of floating oils and must be
utilized in conjunction with a surface  oil  skimmer  either
preceding,  integral  with  or  following  the flocculation/
clarification step.

The  process  is  based   on   a   combination   of   charge
neutralization/  agglomeration and the generation of a metal
hydroxide floe on which the oil wastes can be adsorbed.

The flocculating chemicals (iron  or  alum)   and  adjunctant
chemicals  are  added  in  a specific order depending on the
ultimate use of the system.  High rate mixing at  the  point
of  entry followed by a period of slow agitation is required
for both optimum oil adsorption and the complete removal  of
floe from the waste stream.
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Since the process is based on gravity separation, sufficient
chemicals  (metal  hydroxides, wetting agents, etc.)  must be
added to rapidly and completely sink the oil-containing floe
to the bottom of the clarifier and  retain  it  there  until
removal.

These  metal  hydoxide  floes and their combination with oil
produce  a  very  difficult  sludge  which  usually  resists
disposition   treatment  of  any  kind.   For  this  reason,
flocculation  is  seldom   utilized   in   process   streams
containing heavy concentrations of oil.

Air  Flotation.   In  the  air  flotation process, separable
wastes are removed from a process stream by  the  attachment
of  microscopic air bubbles to the impurity and allowing the
resultant lighter than water mass to gravity separate  under
quiescent  conditions.   In  some cases where the waste will
not accept direct  air  attachment,  chemical  floes  and/or
chemical  aids  are  added to adsorb the waste and/or modify
its surface charge for proper air attachment.

Two basic types of flotators are available:  mechanical  and
dissolved   air.    In   the   mechanical   design,  air  is
mechanically entrained in the  waste  stream  prior  to  the
separation  chamber  usually  via high shear mixers.   In the
dissolved  air  flotation  system,  elevated  pressures  are
utilized  to  dissolve excess air in all or a portion of the
waste stream.  This dissolved air is then allowed to release
in the form of microscopic bubbles on  pressure  letdown  at
the inlet to the separation chamber.

The  process  in general, because of the critical amounts of
air required  and  the  difficulty  in  its  generation,  is
limited  to  relatively  low  flow  rates  and  stead  state
concentration conditions for optimum  operation.   For  this
reason,   this   process   is   usually   preceded  by  both
accumulation and equalization facilities.

The advantages in this form of treatment  over  conventional
clarification  are twofold.  First, the basic oil containing
sludge being separated has a low inherent density, and is in
itself amenable to gravity separation  and   surface  removal
and,  second,  the  amount of added flocculants required for
oil/water emulsion removal are minimal,  hence  producing  a
low volume sludge that is optimum for oil recovery.

Phosphate

Phosphates  are  used  in the steel industry as pretreatment
for strip steel prior  to  applying  various inorganic  and
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organic  coatings.   Rinsing  of  the  sheet following these
treatments   generates   a   phosphate-bearing    wastewater
requiring treatment prior to disposal.

Orthor  trisodium,  and  pyrophosphates  as  well  as  other
proprietary compounds containing phosphates are also used as
alkaline cleaners for the removal of oil and dirt  from  the
steel strip.  Phosphoric acid is used in some pickling lines
including  electrolytic  pickling.  These operations prepare
the strip for further treatment.  The alkaline  cleaner  and
pickling  acid  used  will  vary  depending  on  the type of
coating to be applied to the strip.

Proprietary phosphate treatment compounds are used to  treat
zinc  coated  strip  or  plate  to  provide a better bonding
surface  for  lacquers  and  paints.   This   treatment   is
generally  followed by a chromate rinse to protect the sheet
against oxidation until it  can  be  coated.   Coslettizing,
Parkerizing,  and  Bonderizing  are  processes  that utilize
phosphates to prepare surfaces for painting.

Several systems  may  be  used  to  precipitate  and  remove
phosphates  from  wastewaters.   Alum  at pH of 5.5-5.6 will
precipitate phosphates.  Ferrous  sulfate,  ferric  sulfate,
ferric   chloride,   and   pickle  liquor  will  precipitate
phosphates at  a  pH  of  4.5-5.0.   Lime  will  precipitate
phosphates  at  pH  of  9.  None of these systems completely
remove the phosphates;  however,  in  combination  they  can
lower  the  phosphates concentration in the wastewater to an
acceptable level.

Wastewater  treatment  systems  in  steel  mills   are   not
primarily  designed  for  the  removal  of  phosphates.  The
neutralization of pickle liquors with lime and  the  use  of
alum  as  a  flocculating  agent  to meet effluent standards
already incorporate these methods for phosphate  removal  so
that  no  special  treatment  systems are required to remove
phosphates.  In  the  lime  treatment  of  wastewaters,  the
operating pH may be predicated on the ability to obtain good
suspended solids removal rather than on phosphorous removal.

In  a  properly  designed  wastewater treatment system where
pickle liquor is neutralized with lime either  prior  to  or
after  oil removal the phosphate level should be well within
the effluent standards.

Sulfate

Sulfate as a waste product in  the  steel  industry  can  be
attributable  to  numerous  processes among which the coking
                             305

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and blast furnace operations of the basic iron industry  and
the   pickling  or  cleaning  of  steel  products  could  be
considered to be prime contributors.

The concentrations and volumes of these sources are  varied,
and are dependent on the particular processes utilized.

In   general,   low  concentrations  of  sulfate  cannot  be
considered to be detrimental.  High concentrations, however,
may be detrimental and may  lead  to  particulate  pollution
through  its  subsequent  precipitation  with  calcium  in a
receiving body.

The specific removal of sulfate from a wastewater is  seldom
justified   because  of  its  innocuous  nature.   When  the
treatment of sulfate based  wastes  are  undertaken,  it  is
usually  for the removal of other detrimental ions contained
in the sample.  Any reduction in sulfate gained under  these
circumstances is thus secondary in nature.

Treatment  processes applicable for the removal or reduction
in concentration of sulfate fall into two types--those  that
reduce  the  total  dissolved  solids  content  of the waste
stream such as evaporation and  crystallization,  and  those
that  maintain  or add to the total dissolved solids such as
dilution, ion exchange, and chemical precipitation.

The method selected for the removal of sulfate  is  dictated
not  only  by  its  concentration,  the  volume of the waste
stream, and its ultimate use such as disposal or reuse,  but
on the other ions contained with it in the waste.

Evaporation,  crystallization,  and precipitation techniques
are primarily intended for high dissolved solids  conditions
such  as  pickle liquors (ferrous sulfate), recycled contact
cooling liquors, and scrubbing liquors (ammonium sulfate).

Ion exchange, when usable, is primarily  applicable  to  low
concentration conditions.

In-plant  dilution,  which  often  makes  use of the plant's
central waste treatment facility, is the  most  widely  used
method of treatment.  If during dilution, precipitation does
occur,  it  is  subsequently removed before being discharged
into the receiving body.

Sulfide

Sulfide wastes in the iron and steel  industry  are  derived
from two principal sources:  (1) high temperature gaseous and
                              306

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solids  (slag)  production  encompassing both the coking and
blast furnace operations in the basic iron industry, and the
fossil fueled cupolas employed in the iron foundry industry,
and (2)  low temperature ionic production from  the  pickling
or  cleaning of steel with sulfuric acid.  In both cases the
sulfide ion (S=)  is derived from sulfur or sulfur containing
compounds via chemical reduction.

The sulfide ion and its associated ionic compounds have  the
following  chemical characteristics which can be utilized to
both limit its production rate or enhance its removal from a
waste stream.

1.  Its decreasing solubility with increasing  hydrogen  ion
content (low pH).

2.  Its high reactivity as a reductant, especially at low pH
values.

3.  Its reactivity  with  heavy  metals  to  form  insoluble
precipitates.

4.  Its biological degradability.

The  removal  of  sulfides  from  a  waste  stream  can   be
accomplished  either  as  a  separate  treatment  process or
combined  with  other  waste  materials.   Some   of   these
treatment methods are as follows:

Aeration.   This  process  is primarily applicable to wastes
containing high sulfide concentrations.  In  principal,  the
sulfide  compound  in  the  waste  stream  is  subjected  to
aeration in which both air stripping and insitu oxidation of
the sulfide occurs.  Both the stripping and oxidation  rates
are  a  function  of pH with maximum rates being obtained at
low pH values.  The high rates of aeration required  can  be
obtained   via   stripping   towers,  spray  towers,  lagoon
aeration, etc.

Chemical Oxidation.  Oxidants such as chlorine, ozone, etc.,
are  effective  with  sulfides   but   will   have   limited
application  in high volume or high concentration situations
because of excessive treatment costs.

BioJ-ggical Oxidation.   This  form  of  treatment  would  be
primarily  applicable  to  the removal of sulfides when they
are combined  with  other  more  difficult  wastes  such  as
phenols, etc., as found in the coke producing processes.
                              307

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Dilution   with  Other  Process  Waters.   This  process  is
essentially that of oxidation (biological and chemical)   and
is  probably the easiest and most effective treatment method
for sulfides in low concentrations.   The  success  of  this
treatment   is  dependent  on  the  presence  of  sufficient
dissolved oxygen in the other process stream to perform  the
required   oxidation.    The  presence  of  other  competing
reducing  agents  (oxygen  consuming  substances)  such   as
ferrous iron should be minimal unless additional aeration is
considered.

Suspended Solids

Suspended  solids  in  the  steel industry for the most part
fall into the following categories:

1.  Metal Oxides
2.  Metal Hydroxides

Iron oxides comprise the major source of suspended solids in
the steel  industry.   They  are  indigenous  to  the  blast
furnace   production   of   iron,   all   three  steelmaking
operations, and  the  hot  steel  rolling  operations.   The
treatment  of  the  blast furnace suspended solids have been
and will continue to be treated via  gravity  separation  in
what are referred to as thickeners.  These devices are large
circular  clarifier type structures incorporating continuous
underflow draw-off.  The disposition of the underflow sludge
is ultimately back to the blast furnace.

The removal of suspended solids from the hot  rolling  oper-
ations  on the other hand is performed by a diverse group of
methods all of which are based  on  a  sequential  treatment
scheme.

The  selection  of  the optimum treatment system is a highly
complex one based on the following criteria:

1.  Flow
2.  Particle size distribution
3.  Suspended solids loading
4.  Available space
5.  Initial and operating costs

Wastes from hot rolling operations are  highly  variable  in
composition.   Blooms,  billets,   slabs, and plate produce a
large volume of very coarse scale which  in  most  cases  is
amendable   to  treatment  utilizing  a  primary  scale  pit
followed by clarification with chemical flocculation.
                               308

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The production of  hot  rolled  strip,  sheet,  and  shapes,
however,  produces  a wide latitude of particle sizes all of
which are not only unique to  the  particular  rolling  mill
configuration  but  to  the  types  or analysis of the steel
being rolled and the temperature employed  in  its  rolling.
Scale  pit  removal rates are in turn dependent on detention
time which is influenced both by the waste  flow  rates  and
the pit sludge volume.  Filter removal efficiency is in turn
dependent   on  flow,  particle  size,  and  the  degree  of
exhaustion of the filter.

For this reason, no removal efficiency can  be  assigned  to
any  particular stage of the treatment process, but that the
process has to be designed and judged as a whole.

Red  iron  oxides  are  indigenous  to  numerous  production
operations  such  as  open  hearth  furnaces,  basic  oxygen
furnaces, electric  furnaces,  scarfing  operations,  sinter
plants,  etc.   While this waste was initially considered an
air pollution problem, its transfer to the waste stream  via
wet  air  pollution scrubbers and contact cooling waters has
necessitated its removal in every increasing quantities.

As a waste it is  usually  treated  via  gravity  separation
techniques.   For  the  most  part  its  treatment  has been
confined to thickeners  which,  when  treated  with  optimum
organic flocculant aids, have provided good separations.

Metal  hydroxide  in an integrated steel mill can be derived
from two sources:   (1) as an added material (flocculant)  to
aid  in  the removal of other soluble or particulate wastes;
or  (2)  as  a  soluble  metal  waste  to  be  removed   via
precipitation techniques.  In the addition of metal ions for
the control of dissolved and suspended solids, either ferric
sulfate or aluminum sulfate is added to the waste stream and
the pH adjusted to approximately 5-8.

The  sorbtive and agglomerative floes generated are utilized
to remove such material as insoluble  and  soluble  oils  by
sorbtion,  and  hard  to  settle  submicron  sized suspended
solids   by   charge   neutralization   and    agglomeration
(f locculation) .

The  separation  of  this floe and its entrained wastes from
the waste stream can be accomplished by the following common
means:

1.  Clarifiers
2.  Settling lagoons
3.  Air flotators
                              309

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H.  Deep bed filters

The selection of the  removal  technique  will  be  strongly
influenced   by  the  nature  of  the  influent  waste,  its
concentration, the amount of flocculant required, the stream
volume, available space, and economics.

Generally, large conditioned floes (rapid settling)  are best
handled via  clarifiers  and  settling  lagoons.   Suspended
solids  that resist optimum floe conditioning (chemically or
economically)  are  best  handled  by  high  rate  deep  bed
filters.   The  filter backwash  (cleaning) water can in turn
be run into a lagoon or  tank  for  disposition  via  vacuum
filtration,  settling and dredging, coagulation or admixture
with other wastes for disposition.

The processing of gelatinous  flocculants  containing  large
amounts  of  oil  is  best  done  via  air  flotation.   The
disposition  of  the  separated  sludge   because   of   its
gelatinous   nature   can  best  be  accomplished  via  heat
decomposition,  chemical  decomposition  or  admixture  with
other diluent solid wastes, etc.

The  precipitation  of  metal  hydroxides from plant streams
with calcium hydroxide, sodium  hydroxide,  etc.,  has  been
applied to a diverse group of metals from the steel pickling
and plating operations.  Precipitable metals include Fe, Cr,
Sn, and Zn.

The  neutralization  of  dissolved  iron  from  concentrated
pickle liquor in a mill is relatively  uncommon  because  of
the  gross sludge wastes generated and the difficulty of its
disposal.  Through proper plant design  operation,  however,
acid rinse water and some concentration of pickle liquor can
be  utilized in the waste and water treatment facilities for
their flocculating capabilities.

The precipitation of chrome unlike the other waste metals is
a two-step operation in which the hexavalent chrome  ion  is
first  chemically  reduced   (usually using ferrous iron from
pickle liquor) to its trivalent state  before  precipitation
as  its  hydroxide  can occur.  Its subsequent precipitation
with hydroxide produces a mixed sludge of ferric and chromic
hydroxide, which is gravity separated from the waste stream.
Because of the  high  ratio  of  hydroxides  to  other  bulk
solids,  the  waste  has  a  gelatinous characteristic which
makes its separation from the waste  stream  and  dewatering
difficult.  Disposition of the sludge is usually via lagoons
for  dewatering  or admixtured with other sludges to improve
its dewatering characteristics.
                              310

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The removal of tin from a waste stream as its hydroxide is a
straight precipitation reaction using any hydroxide  source.
In  the  case  of  the  hydrogen  plating process the use of
calcium hydroxide will result in a  mixed  precipitation  of
tin  hydroxide and calcium fluoride (CaF2).  Unlike straight
metal hydroxide sludges, this mixed product settles  rapidly
and  is  easily  separable  from  the waste stream.  In many
cases, the waste solids are reprocessed by an  outside  firm
for reuse.

Zinc   wastes  from  electrolytic  plating  and  galvanizing
operations are precipitable via pH adjustment to  form  zinc
hydroxide.   Zinc, unlike most metals is amphoteric (soluble
at both high and low  pH)  and  hence  relatively  close  pH
control is required for optimum conversion to the hydroxide.
Separation    is    usually   via   clarification   (gravity
separation).

Zinc

Two processes for the application of a  zinc  coating  to  a
steel  surface are currently utilized by the steel industry;
hot dipped coatings and electrolytic coatings.

The hot dip process has no apparent zinc wastes of any  kind
if  good  housekeeping  procedures are maintained.  The only
possible source of zinc from this process would  be  in  the
form  of  an  insoluble  metal oxide dross routinely skimmed
from the surface of the molten zinc bath.  The other  wastes
from   this   process,   consisting   of  alkaline  cleaning
solutions, acid pickling wastes, and oils should not contain
zinc in  any  form  since  they  precede  the  zinc  coating
operation.

The   discharge  of  zinc  from  the  electrolytic  process,
however, is a problem.  The magnitude and treatment of which
is a function of the type of plating bath utilized  and  its
inherent dragout rate.  Two main types of electrolytic baths
are  utilized,  acid  and alkaline, with each specific for a
particular type of plating operation.  Acid type baths  with
their high deposition rate and poor throwing characteristics
are  utilized  predominately  for  the  production  of steel
strip.

Alkaline cyanide baths with their lower deposition rates and
higher throwing capabilities are used predominately for  the
production of shapes such as conduit.

The amount of electrolytes entering a waste system will be a
function of the type of plating operation.   Specific figures
                              311

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for  the  amount of dragout on electrolyte lost to the waste
system from continuous strip operation are subject  to  wide
variation.   Parameters  such as the width of the strip, its
line speed, the method  of  electrolytic  removal  from  the
strip,  the  surface  tension of the electrolyte, etc., will
all affect the dragout rate.  From this it can be seen  that
plating   waste  loadings  will  be  typical  only  to  that
particular operation.  The dragout  rates  encountered  with
batch  type  operations  can show wide variations because of
their manual or semi-automatic operation.

The batch dumping  of  defective  or  spent  electrolyte  is
relatively  common and can be handled in two ways, a holding
tank having a  metered  discharge  into  an  existing  waste
processing  system,  or  the  use of a small batch treatment
plant.

Treatment methods for the  removal  of  zinc  from  a  waste
process  stream will depend on the type of electrolyte used.
The treatment of a zinc acid electrolytic waste is a  simple
one-step operation calling for the elevation of the waste pH
value  to  approximately  8.0  with the precipitation of the
zinc as its  hydroxide.   The  range  of  pH  adjustment  is
critical  as  zinc  is  amphoteric.   To  all  intents,  the
discharge of either the acid sulfate or  the  acid  chloride
electrolytic  based  wastes  into an existing buffered waste
stream would result in the precipitation of  the  hydroxide.
This  treatment  would  be  acceptable, providing subsequent
treatment facilities were available for the removal  of  the
developed  suspended  solids.   The  fluoborate  electrolyte
should be treated only with lime in a separate plant   (batch
or continuous) to effect the precipitations of both the zinc
and toxic fluoride.

Reference Level of Treatment

In  developing  the  technology, guidelines, and incremental
costs associated with the application  of  the  technologies
subsequently  to  be selected and designated as one approach
to the treatment of effluents to achieve the BPCTCA,  BATEA,
and  NSPS  effluent qualities, it was necessary to determine
what reference or minimum level of treatment was already  in
existence  for practically all plants within the industry in
any given subcategory.  The different technology levels were
then formulated in an "add-on" fashion  to  these  reference
levels  in so far as possible.  The various treatment models
 (levels of treatment) and corresponding effluent volumes and
characteristics are listed in  Tables 63 through 76.   Since
these  tables  also  list  the  corresponding  costs for the
average size plant they are presented in Section VIII.


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It was obvious from the plant visits that many of the plants
in existence today have  treatment  and  control  facilities
with capabilities that far exceed the technologies chosen to
be  the  reference  levels  of  treatment.  Even though many
plants may be  superior  to  the  base  technology,  it  was
necessary,  in order to consider the industry as a whole, to
start  at  the  reference  level  of   technology   in   the
development of treatment models and incremental costs.
                               313

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                        SECTION VIII

        COST, ENERGY, AND NON-WATER QUALITY ASPECTS
INTRODUCTION

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

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

Costs

The  water  pollution  control  costs for the plants visited
during the study are presented in Tables 49 through 60.  The
treatment  systems,  gross  effluent  loads,  and  reduction
benefits  were  described  in  Section  VII.  The costs were
estimated from data supplied by the plants.  The results are
summarized as follows:
Process
A. Hot Forming
Plant
A-2
B-2
C-2
D-2
E-2
F-2
G-2
H-2
1-2
J-2
K-2
L-2
M-2
N-2
Cost per unit weight of product
                 (IT
  $/kkg     $/ton     Product
  0.203
  0.286
  0.482
  0.445
  0.644
    69
    ,730
                              1,
                              0,
                              0.161
                              1.81
                              0.809
                              1.19
                              (NA)
                              0.604
                              0.925
0.184
0.26
0.437
0.404
0.584
1.53
0.662
0.146
1.64
0.734
1.08
(NA)
0.548
0.839
Hot
Rolled
Product
                           315

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B. Pipe and Tubes
E-2
GG-2
HH-2
II-2
JJ-2
KK-2
0.927
(NA)
(NA)
0.378
0.397
0.093
0.841
(NA)
(NA)
0.343
0.360
0.084

Pipe
and
Tubes


C. Pickling-Sulfuric
   Acid-Batch Cone
   Batch Rinse
I-.2
0-2
P-2
Q-2
R-2
1-2
1-2
P-2
Q-2
R-2
S-2
1.80
0.353
1.98
0.319
0.373
0.122
0.115
(NA)
(NA)
0.0507
0.679
1.63
0.320
1.80
0.289
0.338
0.0111
0.104
(NA)
(NA)
0.046
0.616
   Continuous
T-2
D. Pickling-
   Hydrochloric Acid-
   Batch Cone.      U-
   Batch Rinse
   Continuous
   Cone.
   Continuous
   Rinse
1-2
W-2
X-2
Y-2
Z-2
AA-2
BB-2
1-2
W-2
X-2
Y-2
Z-2
AA-2
BB-2
0.777
0.705
0.427
0.0709
1.98
0.0342
(NA)
(NA)
(-0.662)
(NA)
1.28
(NA)
0.105
0.354
(NA)
(NA)
(NA)
0.0673
0.136
0.400
0.387
0.0643
1.80
0.0311
(NA)
(NA)
(-0.600)
(NA)
1.16
(NA)
0.0953
0.321
(NA)
(NA)
(NA)
0.0610
0.123
0.363
                                                  Pickled
                                                  Product
                                                  Pickled
                                                  Product
 Pickled
Product
                                                  Pickled
                                                  Product
                                                  Pickled
                                                  Product
                                 316

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E. Cold Rolling     X-2       0.798     0.724
                    BB-2      0.169     0.153     Cold
                    DD-2      0.645     0.585     Rolled
                    EE-2      0.258     0.234     Product
                    FF-2      0.389     0.353

F. Hot. Coatings-
   Galvanizing      1-2       0.368     0.334
                    MM-2      0.908     0.824     Coated
                    NN-2      0.498     0.452     Product

G. Hot Coatings-
   Terne Plate      OO-2      (NA)       (NA)       Coated
                    PP-2      (NA)       (NA)       Product
NOTE:
(1)  NA means not available from company supplied data.
(2)  Appearance of a negative  cost  indicates  a  profitable
operation.

FULL  RANGE  OF  TECHNOLOGY IN USE OR AVAILABLE TO THE STEEL
INDUSTRY

The full range of technology in  use  or  available  to  the
steel  industry  today  is presented in Tables 63 to 76.  In
addition  to  presenting  the  range  of  treatment  methods
available, these tables also describe for each method:

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

BASIS OF COST ESTIMATES

Costs associated with the full range of treatment technology
including  investment,  capital  depreciation, operating and
maintenance, and energy and power  are  presented  on  water
effluent   cost  tables  corresponding  to  the  appropriate
category technology Tables 63 to 76.

Costs were developed as follows:

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

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

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

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

Total  annual  costs in August, 1971 dollars were calculated
on  total  operating   costs    (including   all   chemicals,
maintenance,  labor,  energy,  and  power)  and  the capital
recovery costs.  Capital recovery costs were then subdivided
into straightline ten-year  depreciation  and  the  cost  of
capital at a 7% annual interest rate for ten years.

The  capital  recovery  factor   (CRF)  is  normally  used in
industry to help allocate the  initial  investment  and  the
interest to the total operating cost of a facility.  The CRF
is equal to i plus i divided by a -1, where a is equal to  (1
*  i)  to the power n.  The CRF is multiplied by the initial
investment to obtain the annual capital recovery.  That  is:
 (CRF)   (P)  =  ACR.   The  annual  depreciation  is found by
dividing the initial investment by the  depreciation  period
 (n = 10 years).  That is:  P/10 = annual depreciation.  Then
the  annual cost of capital has been assumed to be the total
annual capital recovery minus the annual depreciation.  That
is:  ACR - P/10 = annual cost of capital.

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

a.  The treatment facilities are contained within a "battery
limit" site location and are  erected  on  a  "green  field"
site.  Site clearance costs such as existing plant equipment
relocation, etc., are not included in cost estimates.
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b.  Equipment costs are based on specific water  flow  rates
requiring  treatment.   A  change  in  water flow rates will
affect costs.

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

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

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

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

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

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

i.  The site conditions are based on:

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

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

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

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

Other factors that affect costs but cannot be evaluated:

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

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

The cost estimates  also  include  a  15%  contingency,  10%
contractor's  overhead  and  profit, and engineering fees of
15%.

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

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

Hot Forming - Primary

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

Additional Energy Requirements.  To meet EPA 1977  standards
for  wastewater  discharge  to  public waters, modifications
will be required to the wastewater  treatment  system.   The
additional   power  consumed  will  be  1.95  kwh/kkg   (1.77
kwh/ton) processed.  For the typical  3,628  kkg/day   (4,000
ton/day)  facility,  the  power required will be 295 kw  (395
horsepower).  The annual cost to operate this equipment will
be $29,625.
                      320

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Non-Water Quality Aspects.

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

Hot Forming - Section

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

Additional  Energy Requirements.   To meet EPA 1977 standards
for wastewater discharge  to  public  waters,  modifications
will  be  required  to the wastewater treatment system.  The
additional  power  consumed  will  be  8.53  kwh/kkg   (7.74
kwh/ton)  processed.  For the typical 1,179.1 kkg/day  (1,300
ton/day) facility, the power required will be  419  kw  (562
horsepower).  The annual cost to operate this equipment will
be  $42,150.

Non-Water Quality Aspects.

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

Hot Forming - Flat - Plate

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

Additional Energy Requirements.  To meet EPA 1977  standards
for  wastewater  discharge  to  public waters, modifications
will be required to the wastewater  treatment  system.   The
additional   power  consumed  will  be  5.68  kwh/kkg  (5.15
kwh/ton) processed.  For the typical  1,814  kkg/day   (2,000
ton/day)  facility,  the  power required will be 429 kw (575
horsepower).  The annual cost to operate this equipment will
be $43,125.

Non-Water Quality Aspects.

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

Hot Forming - Flat  - Hot Strip and gheet
                   321

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

Additional  Energy Requirements.   To meet EPA 1977 standards
for wastewater discharge  to  public  waters,  modifications
will  be  required  to the wastewater treatment system.  The
additional  power  consumed  will  be  10.65  kwh/kkg  (9.66
kwh/ton)  processed.   For  the typical 3,447 kkg/day (3,800
ton/day) facility, the  power  required  will  be  1,529   kw
(2,050   horsepower).   The  annual  cost  to  operate  this
equipment will be $153,750.

Non-Water Quality Aspects.

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

Pipe and Tubes

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

Additional  Energy  Requirements.   To  meet  the  EPA  1977
standards  for  discharge  of wastewater into public waters,
modifications will be required to the  wastewater  treatment
system.  The additional power consumed will be 13.82 kwh/kkg
(12.53 kwh/ton) processed.  For the typical 363 kkg/day (400
ton/day)  facility,  the  power required will be 209 kw (280
horsepower).  The annual cost to operate this equipment will
be $21,000.

Non-Water Quality Aspects.

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

Pickling - Batch Sulfuric Acid - Concentrated

Reference  Level  of:  Treatment.    Contract hauling of spent
pickle  liquor off-site for disposal or treatment.

Additional Energy Requirements.  To meet EPA 1977  standards
for  wastewater  discharge   to  public waters, modifications
will be required to the wastewater  treatment  system.   The
additional   power  consumed  will  be  0.40  kwh/kkg  (0.36
kwh/ton)  processed.   For   the  typical  227  kkg/day  (250
                      322

-------
ton/day)  facility,  the  power  required  will be 3.7 kw (5
horsepower).  The annual cost to operate this equipment will
be $375.

Non-Water Quality Aspects.

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

Pickling - Batch Sulfuric Acid - Rinse

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

Additional Energy Requirements.  To meet EPA 1977  standards
for  wastewater  discharge  to  public waters/ modifications
will be required to the wastewater  treatment  system.   The
additional   power  consumed  will  be  1.98  kwh/kkg  (1.80
kwh/ton)  processed.   For  the  typical  227  kkg/day  (250
ton/day) facility, 18.7 kw (25 horsepower).  The annual cost
to operate this equipment will be $1,875.

Non-Water Quality Aspects.

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

Pickling - Hydrochloric Acid - Concentrated - Alternate 1^

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

Additional Energy Requirements.  To meet EPA 1977  standards
for  wastewater  discharge  to  public waters, modifications
will be required to the wastewater  treatment  system.   The
additional   power  consumed  will  be  0.66  kwh/kkg  (0.60
kwh/ton) processed.  For the typical  2,721  kkg/day  (3,000
ton/day)  facility,  the power required will be 74.6 kw (100
horsepower).  The annual cost to operate this equipment will
be $7,500.

Non-Water Quality Aspects.

1.  Air Pollution:  None
2.  Solid Waste Disposal:  The sludge will be clamshelled
    and landfilled.
                       323

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Pickling - Hydrochloric Acid - Rinse - Alternate !_

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

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

Non-Water Quality Aspects.

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

Alternate Ij!

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

Additional Energy Requirements.  To meet EPA 1977  standards
for  wastewater  discharge  to  public waters, modifications
will be required to the wastewater  treatment  system.   The
additional   power  consumed  will  be  1.45  kwh/kkg  (1.32
kwh/ton) processed.  For the typical  2.721  kkg/day  (3,000
ton/day)  facility,  the  power required will be 164 kw  (220
horsepower).  The annual cost to operate this equipment will
be $16,500.

Non-Water Quality Aspects.

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

Cold Rolling - Recirculation

Reference Level  of  Treatment.   Recirculation  of  rolling
solutions  on  all  rollingstands.  Oil skimmer in recycle
sump.    Blending   of   rolling    solution   blowdown   and
miscellaneous    (tramp   oils)  wastewaters.   Treatment  of
mixture with oil separator/settler.
                     324

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

Non-Water Quality Aspects.

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

Cold Rolling - Combination

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

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

Non-Water Quality Aspects.

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

Cold Rolling - Direct Application

Reference  Level  of  Treatment.   All  stands  use  rolling
solutions   once-through.   Oil  skimmer  in  recycle  sump.
Blending of  rolling  solution  blowdown  and  miscellaneous
(tramp  oils)  wastewaters.   Treatment  of mixture with oil
separator/settler.

Additional Energy Requirements.   To meet EPA 1977  standards
for  wastewater  discharge  to  public waters, modifications
will be required to the wastewater  treatment  system.   The
                     325

-------
additional  power  consumed  will  be  15.79  kwh/kkg (14.32
kwh/ton) processed.  For  the  typical  907  kkg/day  (1/000
ton/day)  facility,  the  power required will be 597 kw (800
horsepower).   The annual cost to operate this equipment will
be $60,000.

Non-Water Quality Aspects.

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

Hot Coatings - Galvanizing and Terne Plating

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

Additional  Energy Requirements.  To meet EPA 1977 standards
for wastewater discharge  to  public  waters,  modifications
will  be  required  to the wastewater treatment system.  The
additional  power  consumed  will  be  1.47  kwh/kkg   (1.33
kwh/ton)  processed.   For  the  typical  635  kkg/day  (700
ton/day) facility, the power required will be  38.8  kw  (52
horsepower).   The annual cost to operate this equipment will
be $3,900.

Non-Water Quality Aspects.

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

ADVANCED TECHNOLOGY, ENERGY, AND NON-WATER IMPACT

The   energy  requirements  and  non-water  quality  aspects
associated with the advanced treatment technology  for  each
subcategory are discussed below.

Hot Forming - Primary

Additional  Energy Requirements.  To meet EPA 1983 standards
for wastewater discharge  to  public  waters,  modifications
will  be  required  to the wastewater treatment system.  The
additional power  consumed  will  be  1.875  kwh/kkg   (1.701
kwh/ton)  processed.   For  the typical 3,628 kkg/day  (4,000
ton/day) facility, the power required will be 283.5 kw  (380
horsepower).  The annual cost to operate this equipment will
be $28,500.

Non-Water Quality Aspects.
                     326

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

Hot Forming - Section

Additional Energy Requirements.  To meet EPA 1983  standards
for  wastewater  discharge  to  public waters, modifications
will be required to the wastewater  treatment  system.   The
additional  power  consumed  will  be  10.63  kwh/kkg   (9.64
kwh/ton)  processed.  For the typical 11.79.1 kkg/day  (1,300
ton/day)   facility,  the  power required will be 522 kw  (700
horsepower).  The annual cost to operate this equipment will
be $52,500.

Non-Water Quality Aspects.

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

Hot Forming - Flat -, Plate

Additional Energy Requirements.  To meet EPA 1983  standards
for  wastewater  discharge  to  public waters, modifications
will be required to the wastewater  treatment  system.   The
additional  power  consumed  will  be  9.080  kwh/kkg   (8.24
kwh/ton)  processed.  For the typical  1,814  kkg/day  (2,000
ton/day)  facility, the power required will be 686.32 kw  (920
horsepower).  The annual cost to operate this equipment will
be $69,000.

Non-Water Quality Aspects. ,

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

Hot Forming - Flat  - Hot Strip and Sheet

Additional Energy Requirements.  To meet EPA 1983  standards
for  wastewater  discharge  to  public waters, modifications
will be required to the wastewater  treatment  system.   The
additional  power  consumed  will  be  10.39  kwh/kkg   (9.42
kwh/ton)  processed.  For the typical  3,447  kkg/day  (3,800
ton/day)   facility,  the  power  required  will  be 1,492 kw
(2,000  horsepower).   The  annual  cost  to  operate   this
equipment will be $150,000.

Non-Water Quality Aspects.
                           327

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

Pipe and Tubes

Additional  Energy Requirements.  To meet EPA 1983 standards
for wastewater discharge  to  public  waters,  modifications
will  be  required  to the wastewater treatment system.  The
additional power  consumed  will  be  12.34  kwh/kkg   (11.19
kwh/ton)  processed.   For  the  typical  363  kkg/day  (400
ton/day) facility, the power required will be 186.5 kw  (250
horsepower).  The annual cost to operate this equipment will
be $18,750.

Non-Water Quality Aspects.

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

Pickling - Batch Sulfuric Acid - Concentrated

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

1.  Air Pollution:  None
2.  Solid Waste Disposal:
    and landfilled.
The sludge will be clamshelled
Pickling - Batch Sulfuric Acid - Rinse

Additional Energy Requirements.  To meet EPA 1983  standards
for  wastewater  discharge  to  public waters, modifications
will be required to the wastewater  treatment  system.   The
additional   power  consumed  will  be  2.90  kwh/kkg   (2.63
kwh/ton)  processed.   For  the  typical  227  kkg/day   (250
ton/day)  facility, the power required will be 27.4 kw  (36.7
horsepower).  The annual cost to operate this equipment will
be $2,754.
                              328

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Non-Water Quality. Aspects.

1.  Air Pollution:  None
2.  Solid Waste Disposal:  The sludge will be clamshelled
    and landfilled.
Additional Energy Requirements.  To meet EPA 1983  standards
for  wastewater  discharge  to  public waters, modifications
will be required to the wastewater  treatment  system.   The
additional   power  consumed  will  be  0.13  kwh/kkg   (0.12
kwh/ton) processed.  For the typical  2,721  kkg/day   (3,000
ton/day)  facility,  the  power required will be 14.9 kw  (20
horsepower) .  The annual cost to operate this equipment will
be $1,500.

Non-Water Quality. Aspects.

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

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

Non -Water Quality Aspects.

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

Pickling - Hydrochloric Acid - Rinse - Alternate I

Additional Energy. Requirements.  To meet EPA 1983  standards
for  wastewater  discharge  to  public waters, modifications
will be required to the wastewater  treatment  system.   The
additional   power  consumed  will  be  0.50  kwh/kkg   (0.45
kwh/ton) processed.  For the typical  2,721  kkg/day   (3,000
ton/day)  facility,  the  power  required  will be 56 kw (75
horsepower) .  The annual cost to operate this equipment will
be $5,625.
                             329

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Non-Water Quality Aspects.

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

Alternate II

Additional Energy Requirements.  To meet EPA 1983  standards
for  wastewater  discharge  to  public waters, modifications
will be required to the wastewater  treatment  system.   The
additional   power  consumed  will  be  0.60  kwh/kkg   (0.54
kwh/ton) processed.  For the typical  2,721  kkg/day   (3,000
ton/day)  facility,  the  power  required  will be 67 kw  (90
horsepower).  The annual cost to operate this equipment will
be $6,750.

Non-Water Quality Aspects.

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

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

Hot Coatings - Galvanizing and Terne Plating

Additional Energy Requirements.  To meet EPA 1983  standards
for  wastewater  discharge  to  public waters, modifications
will be required to the wastewater  treatment  system.   The
additional   power  consumed  will  be  3.95  kwh/kkg   (3.58
kwh/ton)  processed.   For  the  typical  635  kkg/day   (700
ton/day)  facility,  the  power  required  will  be  104  kw
 (lUOhorsepower) .  The annual cost to operate this  equipment
will be $10,500.
   zWater Quality. Aspects.
1.  Air Pollution:  None
2.  Solid Waste Disposal:  The  sludge will  be  clamshelled
    and landfilled.
                              330

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                                    TABLE 63
                         WATER EFFLUENT TREATMENT COfTS
                                 STEEL INDUSTRY

                              HOT FORKING - PRIMARY
Treatment or Control Technologies
 Identified under Item III of the
 Scope of Work:
Investment

Annua^ Costs:

  Capital

  Depreciation

  Operation & Maintenance

  Sludge Disposal

  Energy & Power

  Oil Disposal

  Chemical Costs

TOTAL
    8,591
                                    19,979

                                     6,993
                                                    ^PCTCA
                                                   601
                1,396
                  489
                .1,125
               ' 3,494
23,740

55,207

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 3,564

28,500
                                      BATEA
                                 $ 199,795   $  13,965    $ 552,077   $ 412,741
17,748

41,274

14,446
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                                        8,142
$  35,563    $   7,105   $ 130,333   $ 110,110
Effluent Quality:

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 100-200
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 600
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  50
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  100
                                         25
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                                    333

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-------
                                    TABLE 64
                         WATER EFFLUENT TREATMENT COSTS
                                 STEEL INDUSTRY

                              HOT FORMING - SECTION
Treatment or Control Technologies
 Identified under Item III of the
 Scop j of Work:               A
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TOTAL


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$  216,510 $   13,529 $ 909,213 . $  620,407 $2,042,425
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                         11,250
                8,894 .
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100-150
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204,242
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$   38,539  $   12,202 $ 198,567  $  121,682    449,007
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-------
                                    TABLE 65A
                         -WATER EFFLUENT TREATMENT COSTS
                                 STEEL INDUSTRY

                         HOT FORMING - FLAT - HS & SHEET
Treatment of Control Technologies
 Identified under Item
 Scope of Work:

Investment

Annual Costs:

  Capital

  Depreciation

  Operation & Maintenance

  Sludge Disposal

  Energy & Power

  Oil Disposal

  Chemical Costs

TOTAL
I of the
A
$ 272,940
11,736
27,294
9,553




$ 48,583
BPCTCA
1
$ 39
1
3
1

3
29

$ 39
B
,423
,695
,942
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,047

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C
$ 3,022,
129,
302,
105,
33,
112,


$ 684,
388
962
239
784
955
500


440
D I
$ 826,298
35,530
82,630
28,920

37,500


' $ 184,580
BATEA
1 E
$ 5,2^9
225
524
183

150

115
$ 1,199
1
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,913
,719

,000

,596
,941
Effluent Quality:

  Effluent Constituents
  Parameters   -  units

  Flow, gal./ton	
 7800
  Suspended Solids, mg/1  100-200

  Oil and Grease, mg/1     50-100
  E".
6-9
Resulting Effluent Levels

  7800     7800         5500
          100-150
           20-50
 6-9
             50
             15
6-9
              50
              15
6-9
                        150
            25
            10
6-9
                                     339

-------
                                    TABLE 65B
                         WATER EFFLUENT TREATMENT COSTS
                                 STEEL INDUSTRY

                           HOT FORMING - FLAT  - PLATE
                             11,492
                             26,727
Treatment of Control Technologies
 Identified under Item III of the
 Scope of Work:                A
Investment               •

Annual Costs:

  Capital

  Depreciation

  Operation & Maintenance

  Sludge Disposal

  Energy & Power

  0:1 Disposal

  Chemical Costs

TOTAL                    !
                                                 BPCTCA
                                   BATEA
                              9,354
I
$





B
21,312
917
2,131
746

1,125
C
$ 1,167
50
116
40
8
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,715
,850
,757
,500
D |t E
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21,392 123
49,748 286
17,411 100

7,500 69
,396
,245
,640
,324

,000
11,578

$

16,497

$ 251

,009 $
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96,051 $ 622
,900
,118
Effluent Quality:

  Effluent Constituents
  Parameters   -  units

  Flow, gal./ton	
                             5500
  Suspended Solids, mg/1  100-200

  Oil and Grease, mg/1	50-100

  pH	6-9
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  5500     5500         4000
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-------
                                    TABLE 66
                         WATER EFFLUENT TREATMENT COSTS
                                 STEEL INDUSTRY

                                 PIPE AND TUBES
Treatment of Control Technologies
 Identified under Item III of the
BPCTCA
BATF^
Scope of Work:
Investment $
Annual Costs:
Capital
Depreciation
Operation & Maintenance
Sludge Disposal
Energy & Power
Oil Disposal
Chemical Costs
TOTAL $
Effluent Quality:
Effluent Constituents
Parameters - units
Flow, gal. /ton
Suspended Solids, mg/1
Oil and Grease, mg/1
PH
A t B C D ' 1
182,658 $ 10,765 $ 331,392 $ 91,999 $
7,854 462 14,250 3,956
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6,393 377 . 11,599 3,220
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Resulting Effluent Levels
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50-100 20-50 15 15
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21,971
51,097
17,884

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                                    TABLL 67
                         WATER EPFLUENT TREATMENT COSTS
                                 STEEL INDUSTRY

                 PICKLING - SULFURIC ACID - BATCH -  CONCENTRATES
Treatment or Control Technologies
 Ic'antifiea under Item III of the
 Scope cf Work:
Investment

Annual Costs:

  Capital

  Depreciation

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  Energy & Power

  Disposal Costs

  Chemical Costs

  Less Credit for Acid
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TOTAL
BPCTCA
A B | C |
$ 67,500 $ 203,316 $ 83,692
2,902 8,742 3,599
6,750 20,332 ' 8,369
2,362 ' 7,116 2,929
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  Dissolved Iron, mg/1

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                                    TABLu; 68
                         WATER EFFLUENT TREATMENT COSTS
                                 STEEL INDUSTRY

                    PICKLING - SULFURIC ACID - BATCH - RINSES
Treatment or Control Technologies
 Identified under Item III of the
 Scope rf Work:
                B
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                         BATEA
Investment

Annual Costs:

  Capital

  Depreciation

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  Sludge Disposal

  Energy & Power

  Chemical Costs

  Less Credit for Recovered
  Acid and Iron Salts

TOTAL
            $ 266,423   $ 124,672
                          50,900
               11,456

               26,642

                9,325

               17,940

                7,350
                  130
               5,361
              12,467

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               1,200
             2,189
             5,090
             1,782
             2,754
            $	72,843   $  43,266
                         (-2,049]

                           9,766
Effluent Quality:

  Effluent Constituents
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  Flow, gal./ton	

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  Dissolved Iron, mq/1

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100-400
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 cold rolling mill wastes.

                                349

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-------
                                    TABLE 69
                         WATER EFFLUENT TREATMENT COSTS
                                 STEEL INDUSTRY

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

Annual Costs:

  Capital

  Depreciation

  Operation & Maintenance

  Sludge Disposal

  Energy & Power

  Disposal Costs

  Chemical Costs

  Less Credit for Recovered
  Acid and Iron Salts

TOTAL
,e
A
9 402,093
17,290
40,209
14,073
BPCTCA
1 B |
$9,057,448
389,470
905,745
317,011
BATEA
1 c |
$ 64.464
2,771
6,445
' 2,256
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3,750
7,500
. ,500
1,044,000
11,045
(-2,624,530)
$1,119,322   $(-993,759)  $  12,972
Effluent Quality:

  Effluent Constituents
  Parameters  -  units

  Flow, gal./ton	

  Suspended Solids, mg/1

  Oil and Grease, mg/1

  Dissolved Iron, mg/1

  PH	
  200-400
    8-12%
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       20       200          30
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6-9
25
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*This load allowed only wh~n these wastes are treated in combination with
 cold rolling mill wastes.
                                     352

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-------
                                    TABLE  ;0
                         WATER EFFLUENT TREATMENT COSTS
                                 STEEL INDUSTRY

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

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  Chemical Costs

  Replacement Parts
                                 $ 373,391   $ 583.136   $ 235,9 0
                                    16,056

                                    37,339
                                    13,069
                                     5,625

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25,075

58,314

20,410
10,144

23,590

 8,257
6,521
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2,720
19,418
33,480
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                                 $_  '90,359
                                               144,738
Effluent Quality:

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                                       354

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-------
                                    TABLE 71
                         WATER EFFLUENT TREATMENT COSTS
                                 STEEL INDUSTRY

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

Annual Costs:

  Capital

  Depreciation

  Operation & Maintenance
                   Sludge
  Disposal Costs:  Acid

  Energy & Power

  Replacement Costs

  Chemical Costs

  Less Credit for Recovered
  Acid and Iron Salts

TOTAL
e
A
$ 752,353
32,351
75,235
26,332
1,044,000
15,000
BPCTCA
1 B 1
$ 874,596
37,607
87,460
30,611
152,000
18,750
BATEA
I c |
$ 235,900
10,144
23,590
8,257

2,720
1-3,480
18,270
396,918


                                         D
$1,211,188   $  723,34-6   $  78,191
Effluent Quality:

  Effluent Constituents
  Parameters  -  units

  Flow, gal./ton	

  Suspended Solids, mg/1

  Oil and Grease, mg/1	

  Dissolved Iron, mg/1

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

 (2) This load allowed only when these wastes are treated in combination with
    cold rolling mill wastes.

                                     356

-------
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                                               357

-------
                                    TABLE 72
                         WATER EFFLUENT TREATMENT COSTS
                                 STEEL INDUSTRY

                          COLD ROLLING - RECIRCULATION
Treat nent or Control Technologies
 Identified under Item III of the
 Scope of Work:
             BPCTCA
             BATEA
                B
Investment

Annual Costs:

  Capital

  Depreciation

  Operation & Maintenance

  Sludge Disposal

  Energy & Power

  Chemical Costs

TOTAL
$ 186,877   $ 267,588
    8,035
   18,688

    6,541
    1,958
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     11,501

     26,759

      9,365
      1.392
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      2,590
$  35,747   $  61,357
Effluent Quality:

  Effluent Constituents
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  Dissolved Iron, mg/1

  PH	....
    25
   200
   600
   6-9
Resulting Effluent Levels

      25      	

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 pickling rinses.
                                     358

-------
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-------
                                    TABLE 73
                         WATER EFFLUENT TREATMENT COSTS
                                 STEEL INDUSTRY

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

Annual Costs:

  Capital

  Depreciation

  Operation & Maintenance

  Sludge Disposal

  Energy & Power

  Chemical Costs

TOTAL
$ 242.245   $1,055,013





10,416
24,225
8,479
15,670
3,000
45,366
105^501
36,925
11,143
60,000
20,732
$
61,790
$ 279,667
Effluent Quality:

  Effluent Constituents
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   400          400
   120
   360
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                                     360

-------














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-------
                                    TABLE 74
                         WATER EFFLUENT TREATMENT COSTS
                                 STEEL INDUSTRY

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

Annual Costs:

  Capital

  Depreciatic-a

  Operation & Maintenance

  Sludge Disposal

  Energy & Power

  Chemical Costs

TOTAL
$ 269,856   $1,083,235
   11,603

   26,986

    9,445

   19,500
    3,750
 46,579
108.323
 37.913

 13,920

 60,000

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

  Effluent Constituents
  Parameters  -  units

  Flow, gal./ton	

  Suspended Solids, mg/1

  Oil and Grease, mg/1

  Dissolved Iron, mg/1

  PH	
          Resulting Effluent Levels

   1000         1000
     80
    200
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  6-9
*This load allowed only when these wastes are treated in combination with
 pickling rinses.
                                      362

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                                    TABLE 75
                         WATER EFFLUENT TREATMENT COSTS
                                 STEEL INDUSTRY

                           HOT COATINGS - GALVANISING
Treatment or Control Technologies
 Identified under Item III o^ the
 Scope of Work:
Investment                       9	

Annual Costs:

  Capital                        	

  Depreciation                   	

  Operation r-. Maintenance        	

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  Energy & Power                 	

  Oil Disposal                   	

  Chemical Costs                 	

TOTAL                            £_

Effluent Quality:

  Effluent Constituents
  Parameters  -  units

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

  Suspended Solids, mg/1

  Oil and Grease, mg/1

  Chromium, Total, mg/1

  Chromium, Cr+6, mg/1

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                  BPCTCA
              25,169

              58,533

              20,436
               7,500
             9.718
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           $  585,333   $ 225,995   $ 193,336
              8.314
            22,599
             7,909
             2,250

             2,548

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

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                                         257
              3.750
         Resulting Effluent Levels
    600
   1200
   600
  1200
 600
1200
120-200
 25-75
 12-16
 10-12
 75-140
                                    2-6
50-100
15-30
 5-10
 4-6
15-75
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                                        TABLE 76
                             WATER EFFLUENT TREATMENT COSTS
                                     STEEL INDUSTRY
    
                                  HOT COATINGS - TERNE
    treatment or Control Technologies
     Ide-itif ie i under Item III of the
     Scope of Work:
    Invescment
    
    Annual Costs:
    
      Capital
    
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      Oil Disposal
    
      Chemical Costs
    
    TOTAL
    
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    20,486
    
    7,500
    
    
    $ 111,688 $
    
    C 1 1
    208,538 $
    8,967
    20,854
    7,299
    
    1,500
    2,548
    12,124
    53,292 $
    Resulting Effluent Levels
    600 600
    1200 1200
    50-100
    15-30
    0.75-1.5
    5-15
    3-5
    50
    15
    0.5
    5
    6-9
    BATEA
    D I
    193,336
    8,314
    .19,333
    6,767
    257
    3,750
    
    
    38,421
    100
    250
    25
    10
    0.25
    2
    6-9
                                             368
    

    -------
                             SECTION IX
    
              EFFLUENT QUALITY ATTAINABLE THROUGH THE
            APPLICATION OF THE BEST PRACTICABLE CONTROL
                   TECHNOLOGY CURRENTLY AVAILABLE
             LIMITATIONS GUIDELINES
    
    The effluent limitations which must be achieved July 1, 1977
    are to specify the effluent quality attainable  through  the
    application  of  the  Best  Practicable  Control  Technology
    Currently Available.  Best  Practicable  Control  Technology
    Currently  Available  is generally based upon the average of
    the best existing performance by plants  of  various  sizes,
    ages,  and unit processes within the industrial subcategory.
    This average is not based  upon  a  broad  range  of  plants
    within the steel industry, but based upon performance levels
    achieved   by   plants  purported  by  the  industry  or  by
    regulatory agencies to be equipped with the  best  treatment
    facilities.   Experience demonstrated that in some instances
    these facilities were exemplary only in  the  control  of  a
    portion   of   the   waste  parameters  present.   In  those
    industrial categories where present  control  and  treatment
    practices  are  uniformly  inadequate,  a  higher  level  of
    control than any currently in place may be required  if  the
    technology  to  achieve such higher level can be practicably
    applied by July 1, 1977.
    
    Conversely, where limitations based on the "average  of  the
    best  plants"  would involve the application of a technology
    not considered at this time to be cost-effective, the BPCTCA
    limitations were set on the  basis  of  the  application  of
    other   technologies  which  were  considered  to  be  cost-
    effective.  For example, filtration following  clarification
    increases  the  capital  investment  in  a  manner  which is
    disproportionate to the additional solids removal achieved.
    
    Considerations must also be given to:
    
    1.  The size and age of equipment and facilities involved
    
    2.  The processes employed
    
    3.  Non-water quality environmental impact (including energy
    requirements)
    
    H.  The engineering aspects of the  application  of  various
    types of control techniques
                                369
    

    -------
    5.  Process changes
    
    6.  The total cost of application of technology in  relation
    to  the effluent reduction benefits to be achieved from such
    application
    
    Also,  Best   Practicable   Control   Technology   Currently
    Available  emphasizes  treatment  facilities at the end of a
    manufacturing process, but includes the control technologies
    within the process itself when the latter are considered  to
    be normal practice within an industry.
    
    A  further  consideration  is  the  degree  of  economic and
    engineering reliability which must be  established  for  the
    technology  to  be  "currently  available."   As a result of
    demonstration projects, pilot plants and general use,  there
    must  exist  a  high degree of confidence in the engineering
    and economic practicability of the technology at the time of
    commencement of construction or installation of the  control
    facilities.
    
    RATIONALE FOR SELECTION OF BPCTCA
    
    The   following  paragraphs  summarized  factors  that  were
    considered in selecting the categorization, water use rates,
    level  of  treatment  technology,  effluent   concentrations
    attainable by the technology, and hence the establishment of
    the effluent limitations for BPCTCA.
    
    Size   and   Age   of   Facilities   and  Land  Availability.
    Considerations
    
    As discussed in Section  IV,  the  age  and  size  of  steel
    industry   facilities  has  little  direct  bearing  in  the
    quantity or quality of wastewater generated.  Thus, the  ELG
    for  a  given subcategory of waste source applies equally to
    all plants regardless of size or age.  Land availability for
    installation of add-on treatment  facilities  can  influence
    the  type of technology utilized to meet the ELG's.  This is
    one of the considerations which can account for a  range  in
    the costs that might be incurred.
    
    Consideration of Processes Employed
    
    All  plants  in  a given subcategory use the same or similar
    production methods, giving similar discharges.  There is  no
    evidence that operation of any current process or subprocess
    will substantially affect capabilities to implement the best
    practicable control technology currently available.  At such
    time   that   new   processes   appear  imminent  for  broad
                               370
    

    -------
    application, the ELGs should be amended to cover  these  new
    sources.   No  changes in process employed are envisioned as
    necessary for implementation of this technology  for  plants
    in  any  subcategory.  The treatment technologies to achieve
    BPCTCA are end-ofprocess methods which can be added onto the
    existing treatment facilities.
    
    Consideration of Non-Water Quality Environmenta1 Impact
    
    Impact  of  Proposed  Limitations  on  Air   Quality.    The
    increased  use  of  recycle  systems  has  the potential for
    increasing  the  loss  of   volatile   substances   to   the
    atmosphere.   Recycle  systems  are so effective in reducing
    wastewater volumes, and  hence  waste  loads,  to  and  from
    treatment systems, and in reducing the size and cost of such
    treatment   systems  that  a  trade-off  must  be  accepted.
    Recycle systems requiring the use  of  cooling  towers  have
    contributed  significantly  to reductions of effluent loads,
    while contributing only minimally to air pollution problems.
    Careful operation of these systems can avoid or minimize air
    pollution problems.
    
    Impact of Proposed  Limitations  on  Solid  Waste  Problems.
    Consideration has also been given to the solid waste aspects
    of water pollution controls.  The processes for treating the
    wastewaters  from this industry produce considerable volumes
    of sludges.  Much of this material is inert iron oxide which
    can be  reused  profitably  in  melting  operations.   Other
    sludges  not  suitable  for  reuse  must  be  disposed of to
    landfills, since they are mainly chemical precipitates which
    could   be   little   reduced   by   incineration.     Being
    precipitates,  they  are  by nature relatively insoluble and
    nonhazardous substances requiring minimal custodial care.
    
    In order to ensure long-term protection of  the  environment
    from harmful constituents, special consideration of disposal
    sites should be made.  All landfill sites should be selected
    so  as to prevent horizontal and vertical migration of these
    contaminants to ground or surface waters.   In  cases  where
    geologic conditions may not reasonably ensure this, adequate
    mechanical  precautions   (e.g., impervious liners) should be
    taken to ensure long-term protection to the environment.   A
    program   of  routine  periodic  sampling  and  analysis  of
    leachates is advisable.  Where appropriate, the location  of
    solid   hazardous   materials   disposal   sites  should  be
    permanently recorded in  the  appropriate  office  of  legal
    jurisdiction.
    
    Impact  of Proposed Limitations on Energy. Requirements.  The
    effect  of  water  pollution  control  measures  on   energy
                                371
    

    -------
    requirements  has  also  been  determined.    The  additional
    energy required in the form of electric power to achieve the
    effluent limitations proposed for BPCTCA and  BATEA  amounts
    to less than 3X of the 51.6 billion kwh of electrical energy
    used by the steel industry in 1972.
    
    The  enhancement  to  water  quality  management provided by
    these proposed effluent limitations substantially  outweighs
    the impact on air, solid waste, and energy requirements.
    
    Consideration  of the Engineering Aspects of the Application
    of Various Types of Control Techniques
    
    The level of technology selected as  the  basis  for  BPCTCA
    limitations  is  considered  to  be  practicable in that the
    concepts  are  proven  and  are  currently   available   for
    implementation,  and  may be readily applied as "add-ons" to
    existing treatment facilities.
    
    Consideration of Process Changes
    
    No in-process changes will be required to achieve the BPCTCA
    limitations, although  recycle  water  quality  changes  may
    occur  as  a  result of efforts to reduce effluent discharge
    rates.  Many plants are employing recycle, cascade uses,  or
    treatment  and  recycle  as a means for minimizing water use
    and the volume of effluents discharged.  The limitations are
    load limitations  (unit weight of  pollutant  discharged  per
    unit   weight   of   product)   only,   and  not  volume  or
    concentration limitations.  The limitations can be  achieved
    by   extensive   treatment   of  large  flows;  however,  an
    evaluation of  costs  indicates  that  the  limitations  can
    usually be achieved most economically by minimizing effluent
    volumes.
    
    Consideration of Costs Versus Effluent Reduction Benefits
    
    In  consideration  of  the  costs of implementing the BPCTCA
    limitations relative to the  benefits  to  be  derived,  the
    limitations  were  set  at  values which would not result in
    excessive capital or operating costs to the industry.
    
    To accomplish this economic evaluation, it was necessary  to
    establish  the  treatment technologies that could be applied
    to each subcategory  in  an  add-on  fashion,  the  effluent
    qualities  attainable  with  each technology, and the costs.
    In order to determine the added costs, it was  necessary  to
    define  what  treatment  processes were already in place and
    currently being utilized by most  of  the  plants  within  a
                                 372
    

    -------
    given  subcategory.   This  was established as the reference
    level of treatment.
    
    Treatment systems were then envisioned which, as add-ons  to
    existing  facilities,  would  achieve significant waste load
    reductions.  Capital and operating costs for  these  systems
    were  then  developed  for  the  average size facility.  The
    average size was determined by dividing the  total  industry
    production  by  the  number  of  operating  facilities.  The
    capital  costs  were   developed   from   a   quasi-detailed
    engineering  estimate  of the cost of the components of each
    of the systems.  The annual operating cost for each  of  the
    facilities  was  determined  by summing the capital recovery
    (basis ten year straight line depreciation) and capital  use
    (basis  7%  interest)  charges,  operating  and  maintenance
    costs, chemical costs, and utility costs.
    
    Cost effectiveness diagrams were then prepared to  show  the
    pollution  reduction  benefits derived relative to the costs
    incurred.  As expected, the diagrams show an increasing cost
    for treatment per percent reduction obtained as the  percent
    of  the  initial  pollutional load remaining decreased.  The
    BPCTCA limitations were set at the point where the costs per
    percent pollutant reduction took a sharp break upward toward
    higher costs per percent of pollutant removed.   These  cost
    effectiveness diagrams are presented in Section X.
    
    The  initial  capital  investment  and  annual  expenditures
    required of the industry to achieve BPCTCA were developed by
    multiplying the costs  (capital or annual)  for  the  average
    size facility by the number of facilities operating for each
    subcategory.   These  costs  are  summarized in Table 108 in
    Section X.
    
    After selection was made of the treatment technology  to  be
    designated  as  one  means to achieve the BPCTCA limitations
    for each subcategory, a sketch of each treatment  model  was
    prepared.   The  sketch  for  each  subcategory is presented
    following the table presenting the  BPCTCA  limitations  for
    the subcategory.
    
    IDENTIFICATION   Of   BEST  PRACTICABLE  CONTROL  TECHNOLOGY
    CTORENTLY AVAILABLE - BPCTCA
    
    Based on the information contained in Sections  III  through
    VIII  of this report, a determination has been made that the
    quality of effluent attainable through  the  application  of
    the  Best Practicable Control Technology Currently Available
    is as listed in Tables 77 throug 92.  These tables set forth
                                  373
    

    -------
    the ELGs for the  following  process  subcategories  of  the
    steel industry:
    
       I.  Hot Forming Primary
      II.  Hot Forming Section
     III.  Hot Forming Flat
      IV.  Pipe and Tubes
       V.  Pickling - Sulfuric Acid - Batch Concentrated
      VI.  Pickling - Sulfuric Acid - Batch Rinse
     VII.  Pickling - Hydrochloric Acid - Concentrated -
           Alternate I
    VIII.  Pickling - Hydrochloric Acid - Rinses - Alternate I
      IX.  Pickling - Hydrochloric Acid - Concentrates and
           Rinses - Alternate II
       X.  Cold Rolling - Recirculation
      XI.  Cold Rolling - Combination
     XII.  Cold Rolling - Direct Application
    XIII.  Hot Coatings - Galvanizing
     XIV.  Hot Coatings - Terne
    
    In  establishing  the subject guidelines, it should be noted
    that the resulting limitations or standards  are  applicable
    to  aqueous  waste  discharge  only, exclusive of noncontact
    cooling  waters.   In  the  section  of  this  report  which
    discusses  control and treatment technology for the iron and
    steelmaking industry as a whole, a qualitative reference has
    been given regarding "the environmental  impact  other  than
    water" for the subcategories investigated.
    
    The effluent guidelines established herein take into account
    only  those  aqueous  constituents  considered  to  be major
    pollutants in each of the  subcategories  investigated.   In
    general,  the  critical  parameters  were  selected for each
    subcategory on the basis of those waste  constituents  known
    to  be  generated in the specific manufacturing process, and
    also known to be  present  in  sufficient  quantitiy  to  be
    inimical  to  the  environment.  Certain general parameters,
    such as suspended solids, naturally include  the  oxides  of
    iron and silica, however, these latter specific constituents
    were  not  included  as  critical parameters, since adequate
    removal of the general parameter  (suspended solids) in  turn
    provides   for   adequate   removal  of  the  more  specific
    parameters indicated.  This does not hold true when  certain
    of  the  parameters  are in the dissolved state; however, in
    the  case  of  iron  oxides  generated  in  the   iron   and
    steelmaking  processes, they are for the most part insoluble
    in the  relatively  neutral  effluents  in  which  they  are
    contained.    The   absence   of   apparent  less  important
    parameters  from  the  guidelines   in   no   way   endorses
    unrestricted discharge of same.
                                   374
    

    -------
    The  recommended  effluent limitations guidelines for BPCTCA
    resulting from this study are summarized in Tables 77 to 92.
    These tables also list the control and treatment  technology
    applicable  or  normally  utilized  to reach the constituent
    levels  indicated.   These  effluent  limitations   proposed
    herein are by no means the absolute lowest values attainable
    (except  where  no discharge of process wastewater pollutant
    is recommended)  by the indicated  technology,  but  moreover
    they represent values which can be readily controlled around
    on a day by day basis.
    
    It should be noted that these effluent limitations represent
    values  not to be exceeded by any 30 continuous day average.
    The maximum daily effluent  loads  per  unit  of  production
    should  not  exceed  these  values  by a factor of more than
    three.  In the absence of sufficient performance  data  from
    the  industry  to  establish  these factors on a statistical
    basis, the factor of three was chosen  in  consideration  of
    the  operating  variations  allowed  for in selecting the 30
    continuous day average limitations.
    
    DISCUSSION BY SUBCATEGOJIES
    
    The  rationale  used  for  developing  the  BPCTCA  effluent
    limitations  guidelines  is summarized below for each of the
    subcategories.   All  effluent  limitations  guidelines  are
    presented  on a "gross" or absolute basis since for the most
    part,  removals  are  relatively  independent   of   initial
    concentrations  of  contaminants.  The ELGs are in kilograms
    of pollutant per metric ton  of  product  or  in  pounds  of
    pollutant  per 1,000 Ibs of product and in these terms only.
    The ELGs are not a limitation on flow, type of technology to
    be utilized, or concentrations to be achieved.  These  items
    are  listed  only  as a guide to show the basis for the ELGs
    and may be varied as the discharger desires so long  as  the
    ELG loads per unit of production are met.
    
    Hot Forming - Primary
    
    Following  is a summary of the factors used to establish the
    BPCTCA effluent limitation guidelines (ELGs)  applying to the
    Hot Forming Primary subcategory.  As far  as  possible,  the
    stated  limits are based upon performance levels attained by
    the selected  plants  surveyed  during  this  study.   Where
    treatment   levels   can   be  improved  by  application  of
    additional  currently  available   control   and   treatment
    technology,  the  anticipated  reduction  of waste loads was
    included in the estimates.
                                 375
    

    -------
    The BPCTCA ELGs for the Hot Forming Primary subcategory, and
    the  control  and  treatment  technology  to  achieve  these
    limits, are summarized in Table 77.
    
    Flow.  The five plants surveyed in this study, four of which
    operated  essentially  on  a once-through basis, had average
    process water applied flows of 2,427 1/kkg (582 gal./ton) of
    product, with an additional flow of 842 1/kkg (202 gal./ton)
    where hot scarfing was practiced.   The  recommended  BPCTCA
    limits  are  based on flows of 2,500 1/kkg (600 gal./ton) of
    product.  An additional waste volume from  hot  scarfing  is
    provided for those facilities so equipped, equivalent to 833
    1/kkg  (200 gal./ton) of product.
    
    guspended   Solids.    The  five  plants  surveyed  in  this
    subcategory had  effluent  suspended  solids  concentrations
    ranging between 2 and 23 mg/1.  The plants utilized chemical
    flocculation  or  deep  bed  filtration to achieve these low
    levels.
    
    It is felt that these  plants  are  practicing  control  and
    treatment  technology  superior  to  that expected under the
    BPCTCA  ELGs.   However,  analysis  of  the  feeds  to   the
    filtration   systems,   following  clarification  techniques
    closely approximating BPCTCA  treatment  technology,  showed
    suspended  solids  concentrations ranging from 8 to 55 mg/1.
    Therefore, the BPCTCA ELG  for  suspended  solids  for  this
    subcategory  has  been  conservatively  set at 0.2150 kg/kkg
    (0.2500 Ibs of solids per ton of product), equivalent to  50
    mg/1.   An additional load of 0.0417 kg/kkg (0.0834 Ibs/ton)
    is provided for those plants practicing hot scarfing.   This
    value  is  justified  on  the  basis that all plants will be
    capable of achieving this value by 1977 in a cost  effective
    manner with technology currently available and in use.
    
    Oil and Grease
    
    The  five  plants  surveyed in this subcategory had effluent
    oil concentrations ranging between 2 and 8 mg/1.  The plants
    utilized skimming and deep bed filtration to  achieve  these
    low levels.
    
    Again,  it  is felt that most of these plants are practicing
    control and treatment technology superior to  that  expected
    under  the  BPCTCA  ELGs.  Considering the fact that the oil
    concentrations in the feed to the filtration  systems  ranged
    from   7  to  12  mg/1, the BPCTCA ELG for oil and grease for
    this subcategory  has  been  conservatively   set  at  0.0375
    kg/kkg  (0.075  Ibs of oils per ton of product), equivalent to
    15  mg/1  at the recommended discharge flow rate.  Again, an
                                   376
    

    -------
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    additional allowance of 0.0125 kg/kkg  (0.0250  Ibs/ton)   is
    provided  for  hot scarfing.  This value is justified on the
    basis that all plants will  be  capable  of  achieving  this
    value  by  1977  in  a cost effective manner with technology
    currently available.
    
    2H.  All plants surveyed fell within the pH constraint range
    of 6.0  to  9.0.   Both  for  filter  feeds  and  for  final
    effluents,  thus  providing  a  basis  for establishing this
    range as the EPCTCA ELG.  Any  plant  falling  outside  this
    range   can   easily   remedy   the  situation  by  applying
    appropriate neutralization procedures to the final effluent.
    
    Hot Forming - Section
    
    Following is a summary of the factors used to establish  the
    BPCTCA  effluent  limitation  guidelines applying to the Hot
    Forming Section subcategory.  As far as possible, the stated
    limits are based upon performance  levels  attained  by  the
    selected plants surveyed during this study.  Where treatment
    levels   can   be  improved  by  application  of  additional
    currently available control and  treatment  technology,  the
    anticipated  reduction  of  waste  loads was included in the
    estimates.
    
    The BPCTCA ELGs for the Hot Forming Section subcategory, and
    the  control  and  treatment  technology  to  achieve  these
    limits, are summarized in Table 78.
            Four  of the ten plants surveyed in this subcategory
    treated wastewater on a once-through basis and had  effluent
    flow rates ranging between 20,900 1/kkg (5,010 gal. /ton) and
    51,870  1/kkg (12,440 gal. /ton) of product, although the two
    highest flows discharged into  the  plant  intake  well  for
    reuse  throughout  the  mills.   Four  other plants surveyed
    operated on a recycle basis with blowdown, and had  effluent
    flow  rates between 580 1/kkg  (140 gal. /ton)  and 1,460 1/kkg
    (350  gal. /ton)   of  product.   The  remaining  two   plants
    surveyed   had  total  recycle  systems  with  zero  aqueous
    discharge.  The average water application rate for these ten
    mills was 25,870 1/kkg (6440 gal/ton).
    
    The BPCTCA ELG's are based on  a  raw  waste  volume  (water
    application rate)  of 27,105 1/kkg (6500 gal/ton), recycle of
    14,595  1/kkg   (3500  gal/ton) of scale pit effluent back to
    the flume as scale flushing water,  and  a  discharge  after
    treatment  of  12,510 1/kkg  (3000 gal/ton) of product.  This
    rate is well within the capability of current technology  to
    achieve,  as  evidenced  by  those plants already well below
    this level by utilizing partial recycle to scale  flumes  as
                                  379
    

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    flushing  water.   At the same time, this value will provide
    the impetus for once-through water users to develop  recycle
    systems while at the same time allowing them to achieve this
    end by 1977 in a cost effective manner.
    
    Suspended  Solids.  Suspended solids concentrations from the
    eight plants having discharges ranged from  2  to  71  mg/1.
    The  plants  utilizing  total  recycle  had  41  and 47 mg/1
    suspended matter in the recycle  water  from  the  treatment
    plant.   In  achieving  these  suspended  solids levels, the
    plants    surveyed    practiced     plain     sedimentation,
    clarification,  centrifugal  separation, filtration, or some
    combination of two or more of these treatment processes.
    
    The average concentration value of suspended solids achieved
    by the eight plants having discharges from  their  treatment
    processes is 40 mg/1.  Eliminating the benefits derived from
    filtration  processes,  the  average concentration for these
    plants is 43 mg/1.  Based upon this value,  the  BPCTCA  ELG
    for  suspended  solids  has been set at 0.6251 kg/kkg  (1.251
    Ibs/ton) of product,  equivalent  to  50  mg/1  in  a  3,000
    gal./ton  flow.   This  value is currently being achieved by
    six of the ten plants surveyed.  The remaining plants  would
    be  able  to  achieve  this concentration by the addition of
    additional solids removal  equipment  or,  on  an  alternate
    basis,  by  providing a tighter recycle than dictated by the
    BPCTCA ELG flow, thus meeting the standard on the  basis  of
    pounds of suspended matter discharged.
    
    Oil  and  Grease.   Oil  and  grease concentrations from the
    eight plants having discharges ranged from  2  to  18  mg/1.
    The  plants  utilizing  total recycle were achieving oil and
    grease levels of 7 .to  18  mg/1  in  their  treated  recycle
    water.   All  plants surveyed used either underflow baffles,
    or oil  skimming  along  with  clarification,  or  deep  bed
    filtration equipment to achieve these concentrations.
    
    Eliminating   the  beneficial  effects  of  filtration,  the
    average concentration of oil  and  grease  achieved  by  all
    plants  surveyed from their treatment processes was 11 mg/1.
    Based upon thi,s value, the BPCTCA ELG for oil and grease was
    conservatively set  at  0.1875  kg/kkg   (0.371  Ibs/ton)  of
    product,  equivalent  to  15  mg/1.   This  concentration is
    currently  being  achieved  by  eight  of  the  ten    plants
    surveyed.
    
    Eg.    All  of  the  plants  surveyed  fell  within  the  pH
    constraint range of 6.0 to 9.0, thus providing a  basis  for
    establishing  this  range  as  the  BPCTCA  ELG.   Any plant
    falling  outside  of  this  range  can  readily  remedy  the
                                  382
    

    -------
    situation  by applying appropriate neutralization procedures
    to the final effluent.
    
    Hot Forming - Flat
    
    Following is a summary of the factors used to establish  the
    BPCTCA effluent limitation guidelines (ELGs)  applying to the
    Hot  Forming  Flat  subcategory.   As  far  as possible, the
    stated limits are based upon performance levels attained  by
    the  selected  plants  surveyed  during  this  study.  Where
    treatment  levels  can  be  improved   by   application   of
    additional   currently   available   control  and  treatment
    technology, the anticipated reduction  of  waste  loads  was
    included in the estimates.
    
    The  BPCTCA  ELGs  for the Hot Forming Flat subcategory, and
    the  control  and  treatment  technology  to  achieve  these
    limits, are summarized in Table 79 for sheet and strip mills
    and in Table 80 for plate mills.
    
    Flow.   Two  of the five plants surveyed in this subcategory
    provided wastewater treatment on a  once-through  basis  and
    had effluent flow rates of 32,150 1/kkg (7,710 gal./ton) and
    35,190  1/kkg (8,440 gal./ton) of product.  Two other plants
    (one being a plate mill and one  being  a  hot  strip  mill)
    operated  on  a  tight  recycle basis with limited blowdown.
    Their effluent flow rates were 634 1/kkg  (152 gal./ton)  and
    204  1/kkg  (49  gal./ton)  of  product.   The  fifth  plant
    surveyed had  a  total  recycle  system  with  zero  aqueous
    discharge.  The water application rate on the four hot strip
    mills  averaged 32,380 1/kkg  (7765 gal/ton) and on the plate
    mill the water application  rate  was  23,000  1/gkkg   (5533
    gal/ton).
    
    The BPCTCA ELG's for hot strip mills are based on an applied
    rate  of 32,526 1/kkg (7800 gal/ton), recycle of 9,591 1/kkg
    (2300 gal/ton) of scale pit effluent back to the flume,  and
    a  dsicharge  after treatment of 22,935 1/kkg (5500 gal/ton)
    of product.  The BPCTCA ELG's for plate mills are  based  on
    an  applied  rate of 22,935 1/kkg (5500 gal/ton), recycle of
    6255 1/kkg (1500 gal/ton) of scale pit effluent back to  the
    flume, and a discharge after treatment of 16,680 1/kkg  (4000
    gal/ton)  of  product.   These  rates  are  well  within the
    capability of current technology to achieve,  as evidenced by
    those plants already below this level.  At  the  same  time,
    these  values will provide the impetus for oncethrough water
    users to develop recycle systems, while  at  the  same  time
    allowing  them  to  achieve  this  end  by  1977  in  a cost
    effective manner.
                                 383
    

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    -------
    

    -------
    Suspended Solids.  Suspended solids concentration  from  the
    four  plants  having  discharges  were 8, 4, 30, and 5 mg/1.
    The plant utilizing total  recycle  had  40  mg/1  suspended
    matter  in  the  recycle water from the treatment plant.   In
    achieving these suspended solids levels, all of  the  plants
    surveyed   practiced   plain  sedimentation,  clarification,
    filtration, or some combination of  two  or  more  of  these
    treatment processes.  The average concentration of suspended
    solids actually achieved by five plants from their treatment
    processes  is  17 mg/1.  Even after eliminating the benefits
    derived  from  higher  technology  (filters)   the   typical
    concentrations  after  treatment  ranged  from 5 to 54 mg/1,
    with an average value of 32 mg/1.
    
    Based upon the above data,  the  BPCTCA  ELG  for  suspended
    solids  has  been  conservatively  set  at 0.8335 and 1.1461
    kg/kkg (1.667 and 2.2922 Ibs/ton) of product, equivalent  to
    50   mg/1,   for   plate   mills   and   sheet/strip  mills,
    respectively.  This effluent value is justified since it  is
    currently being achieved by all five plants surveyed.
    
    Oil and Grease.  Oil and grease concentrations from the four
    plants  surveyed  having  discharges were 6, 6.3, 7, and 7.9
    mg/1.  The plant utilizing total recycle  was  achieving  an
    oil  and  grease  level  of  21  mg/1 in its treated recycle
    water.  All plants surveyed used either underflow baffles or
    oil  skimming,  along  with  clarification   or   deep   bed
    filtration to achieve these concentrations.
    
    The  average concentration of oil and grease achieved by all
    five plants from their  treatment  processes  was  10  mg/1.
    Even  after  eliminating  the  benefits from filtration, oil
    concentrations averaged 12 mg/1.  Based upon this value, the
    BPCTCA ELG for oil and  grease  was  conservatively  set  at
    0.250  and  0.3438  kg/kkg   (0.500  and  0.6876  Ibs/ton) of
    product,  equivalent  to  15  mg/1,  for  plate  mills   and
    sheet/strip   mills,   respectively.   This  final  effluent
    concentration is currently being achieved by all five of the
    plants surveyed in this subcategory.
    
    pH.   All  of  the  plants   surveyed  fell  within  the   pH
    constraint range of 6.0 to 9.0, thus providing  the basis for
    establishing  this  range  as  the  BPCTCA  ELG.   Any plant
    falling  outside  of  this   range  can  readily remedy  the
    situation  by applying appropriate neutralization procedures
    to the final effluent.
    
             Tube
                                   388
    

    -------
    As was discussed in Section V - Pipe and Tube Mills, contact
    process waters generally emanate from roll  cooling  sprays,
    pipe  cooling  baths, and pipe cooling spray quenches.  This
    water usually contains scale and oil which must  be  removed
    before  the effluent is discharged.  The BPCTCA ELGs for the
    Pipe and Tubes subcategory are summarized in Table 81.
    
    Four of the six plants surveyed had waste loads comprised of
    from 30-70% noncontact cooling water with total waste  loads
    ranging from 2,148 to 53,250 1/kkg  (515 to 12,770 gal./ton).
    The  flow  from  one  plant,  including an unknown volume of
    noncontact cooling water, was five  time  the  average  flow
    from  the other five mills  (on a gallon per ton basis).   The
    average water applied rate on the remaining five  mills  was
    10,283  1/kkg  (2466  gal/ton)   but  this also included some
    noncontact cooling water.
    
    The BPCTCA ELG's are based on  an  applied  rate  of  10,425
    1/kkg  (2500  gal/ton), recycle of 5212 1/kkg (1250 gal/ton)
    of scale pit effluent back to the  flume,  and  a  discharge
    after treatment of 5213 1/kkg  (1250 gal/ton)  of product.
    
    Suspended  Solids.   Of  the six plants surveyed, only three
    had effluent discharges.  Their  effluent  suspended  solids
    concentration  varied  from  10  to 116 mg/1 and the average
    effluent waste  load  was  0.434  kg/kkg  (0.0869  Ibs/ton).
    Suspended   solids   concentrations,  including  the  solids
    returned to  the  process  by  the  total  recycle  systems,
    averaged  32  mg/1, following treatment.  The BPCTCA ELG for
    suspended solids  has  been  set  conservatively  at  0.2605
    kg/kkg  (0.521  Ibs/ton), equivalent to 50 mg/1 in a flow of
    5,210 1/kkg (1,250 gal./ton) of product.
    
    Only one of the three plants discharging  treated  effluents
    is  presently  achieving  a  lower pollutant level than that
    which is proposed.   However,  all  three  could  meet  this
    limitation  if contact and noncontact water segregation were
    practiced,  thus  improving  the   efficiencies   of   their
    treatment  plants.   And  three  other  plants achieve these
    limitations by practicing zero or very low discharge rates.
    
    Oil and Grease.  The effluent oil and grease  concentrations
    varied from 2 to 10 mg/1 with an average waste load of 0.189
    kg/kkg (0.378 Ibs/ton).  Using the same reasoning as applied
    to  suspended solids above, the expected effluent waste load
    (and therefore, the  BPCTCA  limitation)  is  0.0781  kg/kkg
    (0.1562  Ibs/ton)   based  on  15 mg/1 and 5,210 1/kkg (1,250
    gal./ton)  of product.
                                    389
    

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    10 a.
    

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    Besides the three zero discharge plants, two  of  the  three
    plants  discharging  treated  effluents  were achieving this
    limitation, and the third would  likewise  achieve  it  with
    proper   contact  and  noncontact  water  segregation,  thus
    improving oil removal efficiency.
    
    t>H.  Generally, the pH of the  effluent  from  this  process
    should  always  fall  well within the range of 6.0-9.0 which
    was established as the BPCTCA permissible range.  Data  from
    all  of  the plants surveyed bear this cut, with no effluent
    pH1s outside these limits.
    
    Pickling Subcategories
    
    Following is a summary of  factors  used  to  establish  the
    BPCTCA  Effluent  Limitations  Guidelines  applying  to  all
    pickling subcategories.  Most of the recommended limitations
    are based on performance levels attained  during  the  plant
    survey portion of this study and represent actual operations
    and  waste  treatment  techniques  currently  used  in  this
    industry.  Where no operating plants were found to serve  as
    models  for  BPCTCA treatment systems, data from plants in a
    similar pickling  subcategory  were  used  as  guides.   For
    example,  in  the  batch  hydrochloric  acid  - concentrated
    subcategory, both of the plants  surveyed  were  eliminating
    spent  pickle  baths  by  contract  hauling,  so "treatment"
    technology was not being practiced on the  site.   For  this
    reason,   the   treatment   sequence   for   the  continuous
    hydrochloric   acid   -   concentrated   subcategory    and,
    subsequently,   the   BPCTCA  levels  recommended  for  that
    subcategory were applied to batch hydrochloric acid.
    
    It  was  impractical  to  reduce  the  number  of   pickling
    subcategories.  Even though final concentrations of critical
    parameters  after treatment were essentially the same across
    all subcategories,  the  variations  in  normal  flow  rates
    between  batch and continuous operations; concentrated spent
    pickling solutions and diluted rinse waters;  and  differing
    requirements  for  fume  scrubbing  for  hydrochloric versus
    sulfuric  pickling  lines   necessitates   individual   load
    limitations   for   each   of   six  pickling  subdivisions.
    Discussion by subcategory follows.
    
    Pickling - Sulfuric Acid - Batch Concentrated
    
    The BPCTCA ELGs for this subcategory are presented in  Table
    82.
    
    Six  plants  in  this  subcategory  were surveyed, including
    three pickling rod and wire products; two  pickling  bundles
                                  392
    

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    of  pipes  and tubing; and one pickling bar product.  At one
    of the rod and wire mills, two pickling lines were surveyed.
    Production rates and, consequently, acid consumption  rates,
    are   relatively   small  compared  to  continuous  pickling
    operations.  Of  the  six  plants,  only  one  (the  largest
    producer)   was discharging a treated effluent from the batch
    sulfuric  acid  pickling  -   concentrated   process   after
    equalization and blending with rinses and alkaline cleaners.
    Two  of  the other plants paid an outside contractor to haul
    spent concentrates off the premises for subsequent  disposal
    elsewhere,   while   the   remaining  three  plants  operate
    efficient acid recovery plants on site to recover  unreacted
    sulfuric acid for reuse in pickling operations, along with a
    ferrous sulfate heptahydrate crystalline solid which is sold
    as a by-product.  Two of these latter plants have no aqueous
    discharges from their processes, since even the rinse waters
    and fume scrubber effluents are recovered.
    
    Since  there  may  not  be sufficient time for industry-wide
    application of the acid recovery technology by July 1, 1977,
    and due to other considerations as well, it was  decided  to
    set  recommended  BPCTCA Limitations Guidelines based on the
    one plant actually discharging treated spent pickle  liquor,
    leaving  the  no  discharge  acid  recovery systems stand as
    BATEA.  The flow rate of spent  sulfuric  acid  concentrates
    discharged by the one plant treating such wastes, a pipe and
    tube  mill,  averaged  5.54 gallons of spent acid per ton of
    product batch pickled.  This was blended at ratios of six or
    seven to one with spent alkaline cleaners and  alkaline  and
    acid  rinse  waters  in  an  equalization tank, treated with
    acetylene sludges (an alkaline waste material), and  allowed
    to  settle in lagoons for one to two days prior to discharge
    of supernatants.  Effluent quality was used to establish the
    recommended BPCTCA limits which follow.
    
    Suspended Solids.  A BPCTCA limits of 0.0073 kg/kkg   (0.0146
    Ibs  of  solids  per ton)  of steel pickled is recommended as
    the contribution from the treated spent pickle liquor  after
    addition of neutralizing agents, equivalent to 50 mg/1 based
    on  a 146 1/kkg  (35 gal./ton)  flow rate.  The one plant with
    a waste discharge was attaining  a  total  suspended  solids
    loading  of  25%  of  the  combined  recommended  limit  for
    concentrates and  rinses,   although  the  concentration  did
    exceed  50  mg/1  because  the total combined discharge flow
    attributable to the spent pickle liquor and rinse waters was
    15% of the flows used as the basis for settling  concentrate
    and  rinse  water  ELGs.   A  treatment  sequence  utilizing
    equalization of wastes, mixing and aeration, lime  or  other
    alkaline treatment, polymer addition, and long-term settling
                                395
    

    -------
    may  be  used  to  attain  the  recommended BPCTCA suspended
    solids level.
    
    Dissolved Iron.  A BPCTCA limit of 0.00015  kg/kkg  (0.00030
    Ibs   of  dissolved  iron  per  ton)   of  steel  pickled  is
    recommended as the contribution from the spent pickle liquor
    concentrates, equivalent to 1.0 mg/1 based on a flow rate of
    146 1/kkg (35 gal./ton) of steel pickled.  The  plant  above
    discharged dissolved iron at 4X of this level, mainly due to
    the  successful  alkaline  treatment  and long-term settling
    provided for the raw waste loads.  The sequence of treatment
    required  for  attaining  the  recommended  total  suspended
    solids  limits  will  enable  plants  to  achieve the BPCTCA
    dissolved iron limits also.
    
    Pickling - Batch gulfuric Acid - Rinse Waters
    
    The BPCTCA ELGs for this subcategory are presented in  Table
    83.
    
    The same six plants reported above for batch sulfuric acid -
    concentrated  were  surveyed  for current practices of rinse
    water control and treatment technology.  One of the rod  and
    wire  operations was running two separate pickling lines, so
    there was actual operating data from seven lines.  Of these,
    three achieved no discharge of rinse waters or fume scrubber
    effluents by reusing these flows to make up fresh batches of
    pickling solution or by total recycle of rinse  waters  with
    lime  treatment  within  the  loop  to  precipitate out iron
    salts, which then were settled out in a  lagoon  within  the
    loop.  The remaining four rinse water discharges ranged from
    16.9 to 464 gallons of rinse water per ton of steel pickled.
    Treatment  of  the waste discharges varied from no treatment
    other than  minimizing  flows   (the  16.9  gal./ton  plant),
    through  systems  for  mixing  and  diluting  with  alkaline
    wastes,  to  the  treatment  sequence  discussed  above  for
    pickling  concentrates.   Recommended  BPCTCA limitations on
    critical parameters follows.
    
    Suspended. Solids.  A BPCTCA limit of 0.0417  kg/kkg   (0.0834
    Ibs  of  solids  per  ton)  of steel pickled is recommended,
    equivalent to 50 mg/1 based on a discharge flow rate of  833
    1/kkg   (200  gal./ton)  of  steel pickled.  Suspended solids
    loads from the  four  plants  which  discharged  treated  or
    untreated  pickling rinse waters ranged from 0.0185 to 0.151
    Ibs/ton, and three of the  four  lines  were  achieving  the
    recommended  limit.  The remaining line provided no treatment
    other  than  tight flow control.  The same treatment sequence
    recommended  for batch  sulfuric acid  -  concentrated  BPCTCA
    limitations, namely, equalization of wastewaters, mixing and
                                 396
    

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    aeration,  lime treatment (preferably with a polymer added),
    and long-term settling may be used to treat rinse waters  at
    the same time.
    
    Dissolved  Iron.   A BPCTCA limit of 0.00083 kg/kkg (0.00167
    Ibs  of  dissolved  iron  per  ton)   of  steel  pickled   is
    recommended,  equivalent  to  1.0  mg/1 based on a 833 1/kkg
    (200 gal./ton) flow rate.  Data from the  four  rinse  lines
    discharging  wastes  showed  a  range from 0.000012 to 0.915
    Ibs/ton,  but  three  of  the  four  were  less   than   the
    recommended  BPCTCA limit both in load and in concentration.
    Again, the exception was the  line  providing  no  treatment
    other  than  flow  reduction.   The  sequence  of treatments
    described  above  will  achieve   the   recommended   BPCTCA
    limitation for dissolved iron.
    
    Pickling - Continuous Sulfuric Acid - Concentrates and Rinse
    Waters
    
    The BPCTCA ELGs for this subcategory are as yet undeveloped,
    awaiting  the  completion  of  additional  plant  surveys to
    provide an expanded data base.
    
    Only one plant in this subcategory has  been  surveyed  thus
    far - a 300 ton per day continuous strip pickling operation.
    This   unit  was  practicing  a  high  degree  of  treatment
    technology and was producing no aqueous discharge.  However,
    further examples of sulfuric acid pickling using  continuous
    processes   will   have   to   be  surveyed  to  insure  the
    applicability of this technology to the entire subcateogory.
    Temporarily deferred pending completion of the survey.
    Pickling -  Hydrochloric  Acid  -  Batch  and  Continuous  -
    Concentrates
    
    The  BPCTCA ELGs for this subcategory are presented in Table
    84.  If regeneration is practiced the BPCTCA ELG's for  this
    subcategory are presented in Table 85.  If neutralization is
    practiced   the   BPCTCA  ELG's  for  this  subcategory  are
    presented in Table 87.
    
    Batch Pickling Operations.  A  relatively  small  number  of
    pickling  operations, predominantly rod and wire processors,
    use hydrochloric acid in batch pickling systems.  Production
    rates  on  these  units  are  about  half   of   those   for
    corresponding  sulfuric  acid lines, so most batch operators
    do not generate enough spent hydrochloric acid pickle liquor
    to make acid recovery units practical.  Instead, the general
    practice has been  contract  hauling  of  batches  of  spent
                                 399
    

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    pickle  baths  to  treatment and ultimate disposal off-site,
    where they may be blended with alkaline  wastes  from  other
    industrial  sources.  Two plants of this type were surveyed,
    and these were either neutralizing to a level acceptable  to
    the  municipal  sanitary  authority,  or were using contract
    hauling  services  to   dispose   of   spent   concentrates.
    Technology  for  treatment  of spent concentrates from batch
    hydrochloric acid  pickling  does  exist,  however,  and  is
    discussed   more   fully   under  the  individual  pollutant
    parameters which follow.  In  most  instances,  it  is  more
    practical to treat spent concentrates jointly with rinses in
    one unified treatment system.
    Continuous    Picklinjg    Operations.     Plants   utilizing
    hydrochloric acid for continuous pickling,  primarily  sheet
    and  strip  lines,  are  relatively new when contrasted with
    continuous sulfuric acid pickling lines.  As a result,  they
    practice  more  modern control and treatment technology than
    their sulfuric acid counterparts.   Emphasis  is  placed  on
    recovery  of  reusable  hydrochloric  acid  from  all  spent
    pickling concentrated solutions.  Typical lines run at  high
    production  rates, on the order of 1,270 to 5,440 kkg  (1,400
    to 6,000 tons) per day,  with  an  average  production  near
    2,720  kkg  (3,000  tons) per day.  Many plants operate more
    than one line at a given location.  Spent  concentrates  are
    generated  at  a  typical  rate  of 42 to 65 1/kkg  (10 to 15
    gal. /ton) .
    
    The three continuous HCl regeneration systems  surveyed  are
    using  the  same basic acid recovery process.  Spent acid is
    evaporated in a gas-fired roaster.  Iron  oxide  is  removed
    from  the  bottom of the roaster while HCl vapors pass on to
    an absorber where they are  converted  into  reusable  acid.
    The inert combustion products pass through the absorber to a
    final  water  scrubber for removal of any residual HCl vapor
    and fine particulates prior to venting to  atmosphere.   The
    vent  scrubber  discharge  is the only liquid waste from the
    acid recovery system, averaging approximately 830 1/kkg  (200
    gal. /ton)  in  flow  rate.   For  those  hydrochloric   acid
    pickling   operations   not  practicing  acid  regeneration,
    treatment alternatives for spent  concentrates  ranged  from
    deep    well   disposal   to   carefully   controlled   lime
    neutralization, jointly with the more  dilute  acidic  rinse
    waters.   Of  the  seven  continuous HCl pickling operations
    surveyed, three were regenerating  their  spent  acids,  two
    were  practicing  deep well disposal, one was using contract
    hauling disposal services, and one was blending concentrates
    and rinse waters  prior  to  treatment  via  aeration,  lime
    neutralization,   polymer   addition,  clarification  via  a
    thickener, with vacuum filtration  of  thickener  underflows
                                 406
    

    -------
    and  discharge  of  a  clear,  neutral,  iron-free effluent.
    Individual  recommendations  for  each  critical   parameter
    follow, and are summarized in Table 85.
    
    Suspended   Solids.    For   those   plants   utilizing  HCl
    regeneration systems, a BPCTCA limitation of  0.0417  kg/kkg
    (0.0834   Ibs  of  solids  per  ton)  of  steel  pickled  is
    recommended, equivalent to 50 mg/1 based on an absorber vent
    scrubber water flow of 834 1/kkg (200 gal./ton).  All  spent
    concentrated  HCl pickle liquors are regenerated in the acid
    recovery unit; all iron is converted to oxides for reuse  in
    the  steelmaking processes.  The only contaminants remaining
    in the gas stream and, consequently, in  the  absorber  vent
    scrubber  effluent are residual hydrochloric acid vapors and
    fine  particulates,  including  extremely  fine  iron  oxide
    particles and other inert combustion products.  All three of
    the  plants surveyed are equipped with cyclone separators to
    remove the oxide dust from the HCl gas stream prior  to  the
    HCl  absorber.   An  additional unit at one of the plants is
    equipped with an electrostatic precipitator.  The effect  of
    these  dust  collectors  is  quite  noticeable  in the final
    scrubber discharge water which contained from 70 to 130  ppm
    of  suspended  matter for those units equipped with cyclones
    and only 7 mg/1 suspended  matter  for  the  unit  with  the
    electrostatic precipitator.
    
    At  present,  most  plants  discharge  their  absorber  vent
    scrubber waters once-through with no treatment.   The  plant
    using  an  electrostatic  precipitator achieves solids loads
    low enough to meet the BPCTCA limit, but  the  other  plants
    would  require  a  short-term  sedimentation  pond to reduce
    solids  loads  to  the  recommended  levels.   Since   these
    scrubber  wastes  are  often  acidic  enough to require lime
    neutralization  particularly  if  the  HCl   absorbers   are
    operated inefficiently allowing residual acid vapors to pass
    on to the final scrubber at too high a rate, a sedimentation
    pond would be required to settle out iron precipitates prior
    to discharge.
    
    For  those  plants  not  practicing  acid  regeneration, the
    recommended BPCTCA limitations are based on joint  treatment
    of spent concentrates and rinse waters and are summarized in
    Table  87.   The  total  suspended solids effluent loads for
    concentrates and rinses together are limit to 0.0480  kg/kkg
    (0.0960  Ibs/ton)  of  steel  pickled, equivalent to 50 mg/1
    based on a combined flow of  959  1/kkg   (230  gal./ton)  of
    product.   For  those plants using wet scrubbers for control
    of fumes in hoods over the  pickling  tanks,  an  additional
    allowance of 0.0104 kg/kkg (0.0208 Ibs/ton)  of steel pickled
    is  provided,  equivalent  to  50  mg/1 based on a fume hood
                               407
    

    -------
    scrubber flow of 209 1/kkg (50 gal./ton)  of  product.   The
    one   continuous   pickling  operation  surveyed  which  was
    practicing joint treatment of spent concentrates and  rinses
    was  attaining  an effluent suspended solids load equivalent
    to only 43X of the BPCTCA limit.
    
    Dissolved Iron.  For  those  plants  utilizing  regeneration
    systems,  a BPCTCA limitation of 0.00083 kg/kkg (0.00167 Ibs
    of dissolved iron per ton) of steel pickled is  recommended,
    equivalent  to  1  mg/1,  based on an absorber vent scrubber
    effluent flow of 834 1/kkg (200 gal./ton)  of steel  pickled.
    Most  of  the  iron  carried  through  either  of  the  dust
    collection systems is in the particulate form.   Unless  the
    HCl  absorber  is  functioning inefficiently, it will remain
    undissolved, contributing little or nothing to the dissolved
    iron loads.  However,  neutralization  with  lime  or  other
    alkali,  plus  sedimentation  will  be  necessary to prevent
    discharge of excessive dissolved  iron  during  those  times
    when  high  concentrations  of  HCl  vapors  pass out of the
    absorber.  For the plants surveyed, dissolved iron  loadings
    were at 10 to 75% of the limit at pH 7 or above, but were as
    high  as  18  times  over  the  BPCTCA  limit  as  pH levels
    decreased to pH 2 or lower.
    
    For those plants not generating spent HCl concentrates,  the
    recommended limitations for joint treatment systems handling
    concentrates and rinses allow a total dissolved iron load of
    0.00096   kg/kkg    (0.00192   Ibs/ton)   of  steel  pickled,
    equivalent to 1 mg/1, based on a total combined flow of  959
    1/kkg  (230 gal./ton) of product.  An additional allowance of
    0.00021  kg/kkg   (0.00042  Ibs/ton)  is  provided  for those
    plants using wet fume hood  scrubbers  in  conjunction  with
    pickling  operations.   The plant practicing joint treatment
    of rinses and concentrates achieves a dissolved iron loading
    of only 0.000317 Ibs/ton, equivalent to less than 15X of its
    permitted loading.
    
    QH.  As in all other subcategories, the BPCTCA ELG for pH is
    the range 6.0 to 9.0.  Since treatment with alkalies will be
    necessary to achieve the BPCTCA dissolved iron  limitations,
    the  attainment  of  the pH limitations will not require any
    additional equipment or expense.
    
    Pickling - Hydrochloric Ac^d - Batch and Continuous - Rinses
    
    A total of  nine  hydrochloric  acid  pickling  plants  were
    examined  for rinse water quality during the survey, and six
    of these were large tonnage strip and sheet mills.   Of  the
    nine   operations,  three  were  presently providing no rinse
    water  treatment;  attain  some   concentration   reductions
                                  408
    

    -------
    through  partial neutralization or dilution; two treat rinse
    waters effectively using  conventional  lime  treatment  and
    sedimentation/clarification;   and   the   remaining   plant
    cascades dilute rinse waters toward  the  head  end  of  the
    pickling  line,  thereby  concentrating iron and acid levels
    until the rinse waters resemble  dilute  (1-2X)  spent  acid
    concentrated solutions.  At present, this plant injects this
    waste  and  the  spent  concentrate to a deep well, but this
    mixture is amenable to acid recovery  by  systems  described
    previously in the sections on Pickling - Hydrochloric Acid -
    Concentrates.   Following  is  a  summary of factors used to
    establish the BPCTCA Effluent Limitations Guidelines as they
    apply to rinse waters.  They are presented in Table 86.
    
    Suspended Solids.  For pickling installations treating rinse
    waters separately, either because they operate  regeneration
    or  separate  treatment of concentrates, a BPCTCA limitation
    of 0.0a17 kg/kkg  (0.0834 Ibs of suspended solids per ton) of
    steel pickled is recommended, equivalent to 50 mg/1 based on
    a rinse water flow rate of 833 1/kkg (200 gal./ton) of steel
    pickled.  An additional allowance of 0.0104  kg/kkg   (0.0208
    Ibs/ton), equivalent to 50 mg/1 based on a flow of 209 1/kkg
    (50  gal./ton)  is provided for pickling lines equipped with
    wet fume hood scrubbers.  Seven plants  are  attaining  this
    limit, including those that are depending on dilution alone.
    The  average solids load discharged by these plants was less
    than  40%  of  the  basic  allowance  above.   The   typical
    treatment   sequence   would   include   equalization,  lime
    addition,   mixing,   aeration,   polymer   addition,    and
    sedimentation  in  a  thickener  with  vacuum  filtration of
    underflow sludges.
    
    For pickling  operations  treating  spent  concentrates  and
    rinse  waters jointly, the BPCTCA limitations were discussed
    previously in the sections on Pickling - Hydrochloric Acid -
    Concentrates.
    
    Dissolved Iron.   For  pickling  operations  treating  rinse
    waters  separately,  a  BPCTCA  limitation of 0.00083 kg/kkg
    (0.00167  Ibs  of  dissolved  iron  per  ton)  of  steel  is
    recommended,  equivalent  to  1  mg/1 based on a rinse water
    flow rate of 833 1/kkg  (200 gal./ton)  of steel pickled.   An
    additional  allowance  of  0.00021 kg/kkg (0.00042 Ibs/ton),
    equivalent to 1 mg/1 based  on  a  flow  of  209  1/kkg  (50
    gal./ton)  is  provided for pickling lines equipped with wet
    fume hood scrubbers.  Only  three  of  the  plants  surveyed
    attain dissolved iron levels significantly below this limit,
    but  the  plants  that  fail  to  are  not controlling their
    neutralization steps adequately.  The sequence of treatments
    described above for suspended  solids  removal  succeeds  in
                                 409
    

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                                                           410
    

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    meeting  the  recommended limitation for dissolved iron when
    carefully practiced.
    
    For pickling operations practicing joint treatment of  spent
    concentrates and rinses, the BPCTCA limitations on dissolved
    iron were discussed previously in the sections on Pickling -
    Hydrochloric Acid - Concentrates. .
    
    pH.  As in all other subcategories, the BPCTCA ELG for pH is
    the  range  6.0  to  9.0.   Since treatment with alkalies is
    required to achieve the BPCTCA dissolved  iron  limitations,
    the  attainment  of  the pH limitations will not require any
    additional equipment or expense.
    
    Oil and Grease.  Several plants have found  it  advantageous
    to  treat  pickling  rinse  waters jointly with cold rolling
    mill wastewaters utilizing the acidity  and  dissolved  iron
    content  of  the  former  to assist in emulsion breaking and
    clarification/flocculaticn  of  the  latter.    The   BPCTCA
    limitation for oil and grease from such treatment operations
    is  set  at 0.0083 kg/kkg  (0.0167 Ibs/ton), equivalent to 10
    mg/1, based on a flow rate of 833 1/kkg   (200  gal./ton)  of
    product.   The  one  plant  surveyed  practicing  such joint
    treatment was discharging oil  and  grease  at  65%  of  the
    recommended   limitation.    For   plants   treating   spent
    concentrates and rinse waters  from  pickling  jointly  with
    cold  rolling mill wastes, the BPCTCA limitations are set at
    0.0095 kg/kkg  (0.0190 Ibs/ton), equivalent to 10 mg/1  based
    on  a  combined  flow  rate  of  959 1/kkg  (230 gal./ton) of
    product.
    
    Cold Rolling Subcateggries
    
    Waste treatment practices in cold rolling operations  center
    primarily on the removal of oils and suspended solids.  Most
    mills have gone to recycle systems, at least on some stands,
    on their rolling solutions primarily due to the high cost of
    rolling  oils  as  well  as  to  meet  increasingly  tighter
    pollution control requirements.
    
    Recirculation Systems.  Four of the five mills  sampled  had
    recirculation  systems.   Spent rolling oils are pumped to a
    separate storage tank and  metered  into  an  oil  separator
    along  with  oily  wastewater  (spillage, pump leakage, etc.)
    from the oil cellar and machine shop,  associated  with  the
    cold  mill  operation.   Discharges from these plants ranged
    from 67 1/kkg to 760 1/kkg (16 to 182 gal./ton)  of  product
    rolled.   The  volume of discharge per ton of product rolled
    is highly dependent upon the width, thickness, and type of a
    product, the speed of the rolling mill, the condition of the
                                   411
    

    -------
    rolls and wipers, and will vary  considerably  on  different
    days for the same mill, depending on the product rolled.  In
    spite  of  the wide variation in flows shown above, three of
    the four plants achieved average discharge rates between  67
    and  75  1/kkg   (16 and 18 gal./ton), and 4 to 6 mg/1 of oil
    and grease was  readily  attained  in  the  treatment  plant
    effluent,  partly  due  to  the  dilution  effect  caused by
    treating  cold  rolling  mill  wastewaters  in   a   central
    treatment plant along with wastewaters from other processes.
    
    The BPCTCA ELGs are presented in Table 88, and are discussed
    individually below:
    
    Suspended  Solids.   Four plants surveyed were operating all
    rolling  stands  using  tight  recycle  systems,  and   were
    discharging  suspended  solids  in  their  treated effluents
    ranging from 2 to 22 mg/1.  In all cases, small  volumes  of
    rolling  mill  waste  are  mixed with large volumes of other
    wastewaters  whose  characteristics  are   predominant   and
    overshadow the rolling mill waste.  Taking into account this
    dilution  and  realizing  the  load  will  vary considerably
    according to the mill, the BPCTCA limitation  for  suspended
    solids  from  recirculation  systems has been established as
    0.0026 kg/kkg  (0.0052 Ibs of suspended solids  per  ton)  of
    steel  rolled,  equivalent  to  25  mg/1  at  104  1/kkg (25
    gal./ton).  Three of the four plants surveyed are  operating
    within this load limitation at the present time.
    
    Oil  and  Grease.  The four plants surveyed were discharging
    oil concentrations in the treatment plant effluents  from  4
    to 6 mg/1.  In all cases, dilution by large volumes of other
    wastewaters  being  treated  in  the  same central treatment
    plant overshadowed the impact effect  of  the  rolling  mill
    waste  discharge.   These concentrations are also too low to
    be  accurately  measured  by  the  most  readily   available
    analytical  techniques  for oil content.  The BPCTCA ELG for
    oil and grease from recirculation  systems  has,  therefore,
    been  set  at 0.00104 kg/kkg  (0.00206 Ibs of oil per ton) of
    steel, equivalent to 10 mg/1 based on a  discharge  flow  of
    104  1/kkg  (25  gal./ton).  Two of the four plants surveyed
    are operating within this  load  limitation  currently,  and
    three  out  of  four  reach concentration less than 10 mg/1,
    indicating that the treatment  technology  is  available  to
    maintain that level.
    
    Dissolved  Iron.   For  those  cold  rolling - recirculation
    plants treating their wastewaters jointly  with  those  from
    pickling  operations, a BPCTCA dissolved iron limitation has
    been set at 0.000104 kg/kkg  (0.000208  Ibs/ton),  equivalent
    to  1  mg/1  at  a  flow of  104 1/kkg  (25 gal./ton) of steel
                                  412
    

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    produced.   Data  were  available  from  two  such   plants,
    indicating  an  average  dissolved iron concentration of 0.1
    mg/1 after treatment.
    
    Combination Systems.  Although recent trends in cold rolling
    practice  have  aimed  at  increased  use  of  recirculation
    systems  wherever possibly, many plants must continue to run
    one or more stands on a once-through basis.   This  need  is
    dictated   by  special  customer  requirements,  control  of
    dissolved solids, or the need to remove a previously applied
    oily coating which may  be  incompatible  with  the  rolling
    solutions   used.    Plants  using  such  a  combination  of
    recirculation  and  direct   application   stands   generate
    considerably  more wastewater than recirculation alone.  For
    example, the one combination plant visited on two  different
    occasions during this survey consisted of two different cold
    rolling  lines  and a temper mill using various combinations
    of recirculation and  direct  application,  with  wastewater
    flows  averaging 1551 1/kkg (372 gal/ton) at the time of the
    visits.  Data reported by this plant  for  a  representative
    period of operations confirmed the above average, indicating
    a  28-day  average  flow  of  1,530  1/kkg (367 gal./ton)  to
    treatment.  For this reason, the BPCTCA ELGs for combination
    cold rolling operations has been  based  on  flow  rates  of
    1,668 1/kkg (400 gal./ton) of steel produced.
    
    The  BPCTCA  ELGs  for the cold rolling - combination plants
    are presented in Table 89, and discussed individually below.
    
    Suspended Solids.  During the  plant  visits  the  one  cold
    rolling - combination plant surveyed was discharging 6 to 10
    mg/1  of  suspended solids after treatment via oil skimming,
    equalization,  emulsion breaking, air flotation, and chemical
    treatment at a central treatment plant together with coating
    wastewaters.  The BPCTCA  limitation  for  suspended  solids
    from  cold rolling - combination plants has been established
    at  0.0417  kg/kkg   (0.0834  Ibs/ton)    of   steel   rolled,
    equivalent  to  25  mg/1  at  a  flow  of  1,668  1/kkg (400
    gal./ton).  The plant surveyed is currently averaging 28% of
    this load.
    
    Oil   and   Grease.    During   the   plant   surveys,   oil
    concentrations after treatment ranged between 4 and 20 mg/1,
    and  averaged  12  mg/1.  The BPCTCA limitations for oil and
    grease from cold rolling - combination operations  has  been
    set  at  0.0167  kg/kkg   (0.0334  Ibs/ton)  of steel rolled,
    equivalent to  10  mg/1  at  a  flow  of  1,668  1/kkg  (400
    gal./ton).   The  plant  surveyed was discharging an average
    load slightly exceeding this  value,  but  sampling  records
    indicate that a short-term upset occurred during one of five
                                 415
    

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    sampling   shifts,   which  yielded  a  higher  than  normal
    concentration for that period, but  still  well  within  the
    maximum  daily limit.  The plant effluent reverted to normal
    within a few hours, and the average  concentration  for  the
    subsequent shift was below 10 mg/1.
    
    Dissolved Iron.  For those cold rolling - combination plants
    treating  their wastewaters jointly with those from pickling
    operations, a BPCTCA dissolved iron limitation has been  set
    at  0.00167 kg/kkg  (0.0034 Ibs/ton), equivalent to 1 mg/1 at
    a flow of 1,668 1/kkg  (400 gal./ton) of  steel  rolled.   No
    dissolved  iron  data was collected during the survey of the
    one plant treating cold rolling and coating (including light
    pickling) wastes jointly,  but even total iron averaged less
    than 1 mg/1.
    
    Direct   Application   Systems.    A   few   cold    rolling
    installations will continue to operate without recirculation
    on  any  rolling  stand,  providing only once-through direct
    application of rolling solutions.   Although  no  plants  of
    this  type  were surveyed, a review of the application rates
    utilized by  the  recirculation  and  combination  types  of
    operation in the cold rolling subcategory indicate a typical
    water   requirement  of  approximately  4,170  1/kkg   (1,000
    gal./ton) of product rolled.  Thus this flow, together  with
    the  treatment technology utilized on the other cold rolling
    wastewaters   (namely,  equalization,   chemical   treatment,
    flocculation,  dissolved air flotation, surface skimming and
    long-term settling) form a basis for BPCTCA EUGs for  direct
    application   plants.    The   individual   limitations  are
    discussed below, and are summarized in Table 90.
    
    Suspended Solids.  The  recommended  BPCTCA  limitation  for
    suspended   solids   from  direct application systems has been
    set at 0.1042 kg/kkg  (0.2084  Ibs/ton)  of  steel  produced,
    equivalent  to  25  mg/1, based on a total discharge flow of
    4,170 1/kkg  (1,000 gal./ton).  Although no plants  utilizing
    direct  application on all stands were surveyed, and thus no
    treatment data was available,  the  technology  required  to
    attain these limitations has been adequately demonstrated on
    the other cold rolling systems, as discussed above.
    
    Oil  and Grease.  The  recommended BPCTCA limitations for oil
    and grease  from direct application systems has been  set  at
    0.0417 kg/kkg  (0.0834  Ibs/ton) of steel produced, equivalent
    to  10  mg/1  at  a  flow  of  4,170 1/kkg  (1,000 gal./ton).
    Again, despite the  non-availability of data, the  technology
    has   been  adequately demonstrated  by  treatment  systems
    handling  cold  rolling  wastewaters  using  the  other  two
    solution systems.
                                  418
    

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    Dissolved Iron.  For those cold rolling - direct application
    plants  treating  their  wastewaters jointly with those from
    pickling operations, a BPCTCA dissolved iron limitation  has
    been   set  at  0.0042  kg/kkg  (0.0084  Ibs/ton)  of  steel
    produced, equivalent to 1 mg/1 at  a  flow  of  4,170  1/kkg
    (1,000 gal./ton) of product.
    
    Hot Coatings - Galvanizing Operations
    
    Four  plants  in  the hot coatings subcategory were visited.
    Two of these were rod and wire  mills  producing  galvanized
    wire, but one had no process wastewaters in contact with the
    coated   product   and,  consequently,  no  raw  waste  load
    attributable to the coating step.   Waste loads from the  rod
    mill  and  the  pickling  operations  associated  with  this
    production line are covered under the  hot  forming  section
    and the pickling - hydrochloric acid subcategories.
    
    The  remaining  three  mills  included  two large continuous
    strip galvanizing  operations  and   (including  one  running
    three  coating  lines  side  by  side)  one  continuous wire
    galvanizing operation.   Wastewater  flow  rates  for  these
    three  lines ranged from 557 to 2,195 gal./ton for the strip
    galvanizing lines, to 4,600 gal./ton for the wire mill.  All
    lines included varying portions of noncontact cooling  water
    from  furnace  cooling  and  from temperature control of the
    molten metal baths.
    
    The BPCTCA ELGs for this subcategory are presented in  Table
    91.
    
    Suspended  Solids.   A BPCTCA limit of 0.1250 kg/kkb (0.2500
    Ibs per ton)  of coated steel is recommended,  equivalent  to
    50 mg/1 based on a 2,500 1/kkg  (600 gal./ton) flow rate.  An
    additional  allowance  of  0.1251 kg/kkg  (0.2502 Ibs/ton) is
    provided for those plants utilizing a wet fume hood scrubber
    in  conjunction  with  the  process.   One  of   the   strip
    galvanizing  plants   (the  one  with  three lines)  currently
    discharges 0.04  Ibs/ton,  while  the  other  line  slightly
    exceeds  the BPCTCA limitation at 0.268 Ibs/ton.  This waste
    receives additional treatment in a central treatment  plant,
    so the final effluent meets the limitation.
    
    On  the  basis  of these actual plant operations, the BPCTCA
    limitation is consistently attainable using standard mixing,
    polymer addition, and settling equipment and techniques.
    
    Oil and Grease.  A BPCTCA limit  of  0.0375  kg/kkg  (0.0750
    Ibs/ton)   is  recommended,  equivalent to 15 mg/1 based on a
    2,500  1/kkg   (600  gal./ton)  flow  rate.   An   additional
                               421
    

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    allowance  of 0.0375 kg/kkg (0.0750 Ibs/ton)  is provided for
    those  plants  utilizing  wet   fume   hood   scrubbers   in
    conjunction  with  the  coating operations.  The galvanizing
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    of 0.10 Ibs of oil per ton of galvanized product, 67% of its
    appropriate limitations.   The  BPCTCA  limitation  is  thus
    readily  attainable  using standard oil skimming and removal
    equipment  and  techniques.   The  other  galvanizing  plant
    exceeds   the  limitation  by  onethird,  but  this  treated
    wastewater receives additional aeration, sedimentation,  and
    oil  skimming  in  a  central  treatment plant, so the final
    effluent  also  meets  the  limit.   The  wire   galvanizing
    operation  was discharging its treated wastes to a municipal
    sanitary authority at 9 mg/1 oils and greases, but this  was
    equivalent to 0.3 Ibs/ton.
    
    Zinc.   A  BPCTCA limit of 0.0125 kg/kkg (0.0250 Ibs/ton) of
    galvanized product is  recommended,  equivalent  to  5  mg/1
    based  on  a  2,500  1/kkg  (600  gal./ton)  flow  rate.  An
    additional allowance of 0.0125 kg/kkg   (0.0250  Ibs/ton)  is
    provided  for those plants utilizing wet fume hood scrubbers
    in conjunction with the coating operations.  Both continuous
    galvanizing plants surveyed achieve zinc levels considerably
    below this limit, averaging 0.0078 Ibs of zinc  per  ton  of
    coated   product.    Allowances   were   made   because  the
    recommended  BPCTCA  limit   is   based   upon   using   the
    comparatively simpler mixing, polymer addition, and settling
    equipment  and  techniques  needed  to  attain the suspended
    solids limits, while the two  continuous  galvanizing  lines
    surveyed have equipment more appropriate for attaining BATEA
    limitations as discussed in Section X.
    
    Hexavalent Chromium.  A BPCTCA limit for hexavalent chromium
    of   0.00005   kg/kkg   (0.00010  Ibs/ton)   is  recommended,
    equivalent  to  0.02  mg/1  based  on  a  2,500  1/kkg   (600
    gal./ton)  flow  rate.   An  additional allowance of 0.00005
    kg/kkg   (0.00010  Ibs/ton)  is  provided  for  these  plants
    utilizing  wet  fume  hood scrubbers in conjunction with the
    coating  operations.   Both  continuous  galvanizing  plants
    surveyed  were discharging treated effluents containing less
    than 60% of the stated BPCTCA limits, utilizing the reducing
    capability  of  dilute   pickling   solutions   to   convert
    hexavalent  chromium  to  trivalent.  In some operations, it
    may be necessary to provide separate chromium reduction  via
    addition  of  other reducing agents.  The trivalent chromium
    is then precipitated along with zinc and iron.
    
    Total Chromium.  A BPCTCA limit for total chromium of 0.0075
    kg/kkg  (0.0150 Ibs/ton) is recommended, equivalent to 3 mg/1
                               424
    

    -------
    based on a 2,500 1/kkg  (600 gal./ton) discharge  flow  rate.
    An additional allowance of 0.0075 kg/kkg (0.0150 Ibs/ton) is
    provided  for  those  plants  with  wet fume hood scrubbers.
    Both continuous galvanizing operations were discharging less
    than 30* of the BPCTCA  limits for total chromium, but  sinc^
    these  treatment  sequences  were more appropriate for BATEA
    than BPCTCA limitations, allowances were made to justify use
    of simpler treatment techniques.
    
    p_H.  As in all other subcategories, the  BPCTCA  limitations
    for  pH  require  discharges  to be in the range 6.0 to 9.0.
    Since treatment is required to  achieve  BPCTCA  limitations
    for zinc and chromium, the attainment of pH limitations will
    not require any additional equipment or expense.
    
    Hot Coatings - Terne Operations
    
    Two  plants operating terne plating lines were surveyed, and
    both of these were  practicing  tight  control  to  minimize
    drag-out  of  solutions  from  process  tanks.  As a result,
    neither   plant   produced    sufficient    quantities    of
    objectionable   pollutants  to  require  special  treatment.
    Process water flow rates ranged from 2,150  to  4,115  1/kkg
    (516  to  987  gal./ton),  and  fume  hood  scrubber  waters
    contributed an equivalent load at one of the plants.  Due to
    the lack of data from operating  treatment  systems,  BPCTCA
    limitations  for  all   parameters  were  set  at  the  level
    anticipated  in  effluents  from  simple   mixing,   polymer
    addition  and  settling  equipment  as  discussed in the hot
    coatings - galvanizing  subcategory.
    
    The BPCTCA ELGs for this subcategory are presented in  Table
    92.
    
    Suspended  Solids.   A  BPCTCA limit of 0.1251 kg/kkg (0.2502
    Ibs/ton) of coated product is recommended, equivalent to  50
    mg/1  based  on  a 2,500 1/kkg  (600 gal./ton) discharge flow
    rate.  An additional  allowance  of  0.1251  kg/kkg  (0.2502
    Ibs/ton)  is  provided  for those plants utilizing a wet fume
    hood  scrubber  system  in  conjunction  with  the   coating
    operations.   Despite   lack of treatment, both terne plating
    lines  surveyed  were   meeting   the   recommended   limits,
    discharging  0.11  and  0.08  kg/kkg  (0.22 and 0.16 Ibs/ton)
    suspended solids loads  in their plant effluents.
    
    Oil and  Grease.   A  BPCTCA  limitation  of  0.0375  kg/kkg
    (0.0750   Ibs/ton)   is  recommended  for  oil  and  grease,
    equivalent to 15 mg/1 based on a 2,500 1/kkg  (600  gal./ton)
    flow rate.  An additional allowance of 0.0375 kg/kkg (0.0750
    Ibs/ton)  is  provided  for  those plants utilizing wet fume
                                 425
    

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    hood scrubbers in conjunction with coating operations.  Both
    lines  surveyed  were  meeting  the  required   limitations,
    averaging  oil  and grease loadings equivalent to 35X of the
    limits.
    
    Lead.  A BPCTCA limit for lead  of  0.00125  kg/kkg   (0.0025
    Ibs/ton)  of coated product is recommended, equivalent to 0.5
    mg/1 based on a flow rate of 2,500 1/kkg  (600 gal./ton).  An
    additional  allowance  of 0.00125 kg/kkg  (0.0025 Ibs/ton)  is
    provided for plants utilizing wet  fume  hood  scrubbers  in
    conjunction   with   the   coating  operations.   Data  were
    available from both of the terne lines visited,  which  were
    discharging  lead at an average rate of 0.0005 kg/kkg (0.001
    Ibs/ton)  of coated product.  Due to the  limited  number  of
    samples,  the recommended BPCTCA limit was conservatively set
    at  the  level  expected  in  the  effluent  from the simple
    mixing, polymer addition, and  settling  equipment  used  to
    attain BPCTCA suspended solids limits.
    
    Tin.   A  BPCTCA limitation for tin of 0.0125 kg/kkg  (0.0250
    Ibs/ton)  of coated product is recommended, equivalent  to  5
    mg/1 based on a flow rate of 2,500 1/kkg  (600 gal./ton).  An
    additional  allowance  of  0.0125 kg/kkg  (0.0250 Ibs/ton)  is
    provided for those plants utilizing wet fume hood  scrubbers
    in  conjunction  with  coating operations both terne  plating
    lines  surveyed  were  successfully  attaining  this   level
    despite  lack  of treatment, discharging loads of 0.0043 and
    0.0183 kg/kkg (0.0086 and 0.0366 Ibs/ton).  The latter plant
    was credited with the additional allowance  because   it  was
    operating  wet  fume  hood  scrubbers.  Again, BPCTCA limits
    were set at levels expected from simple,  readily  available
    treatment technology.
    
    pH.   As in all subcategories, the BPCTCA limitations for pH
    require final discharges in the range  6.0  to  9.0.   Since
    treatment is required to achieve BPCTCA limitations for lead
    and  tin,  the attainment of pH limitations will not  require
    any additional equipment or expense.
    
    Miscellaneous Runoffs - Storage Piles - Coal^ StoneA  and Ore
    
    These three miscellaneous  runoffs  are  discussed  together
    since at a minimum, all three runoffs would require the same
    general type of treatment; namely collection, sedimentation,
    and  pH  adjustment.   This is not meant to imply that these
    runoffs  should  necessarily  be   collected   and    treated
    together, although that possibility need not be specifically
    excluded  either.   Nor  should  this  analysis  necessarily
    preclude that the above treatment is all that is  needed   in
    every  case.   For  coal  pile  runoffs   in  particular, the
                                   428
    

    -------
    presence of other undesirable contaminants (as discussed  in
    Section  V)   due  to  their  presence  in  the coal would be
    heavily dependent on the area where the coal  is  mined  and
    the particular mineral makeup of the soil in that area.
    
    Thus, based upon a minimum treatment concept, these fugitive
    runoffs could generally be treated via:
    
    Collection
    
    Installation of an impervious liner (vinyl, rubber, etc.) at
    the  base  of  the  pile to prevent subsurface runoff.  This
    technology has been used to a minor extent in steam electric
    power plants to minimize their coal pile subsurface runoffs.
    Generally, a 6 in. layer of sand or  earth  must  be  placed
    between  the  liner  and  the stockpiled material to prevent
    damage to the liner.  The use of this technology  may  also,
    in most cases, be limited to installations where a stockpile
    has  yet  to  be  placed.  At many locations, because of the
    logistics of unloading, storage, and end use facilities,  it
    will  not  be possible to change the location of a stockpile
    or move it temporarily while a liner is being installed.
    
    Installation of  a  perimeter  collection  system  to  dra'.n
    subsurface  runoff  stopped  by the liner and surface runolf
    from the pile surface.  These  collected  wastewaters  would
    then  be  routed to a holding facility, probably a pond, for
    treatment,  storage  before  treatment,  or  treatment   and
    storage before further treatment.
    
    Treatment
    
    The  wastewaters  collected in the holding facility can then
    be treated at that point or stored for treatment at  another
    point,  or  both.   Whatever  method  employed,  the general
    treatment  provided  should  consist  of,  at   a   minimum,
    sedimentation and pH adjustment.
    
    Due  to  the  high capital investment required to accomplish
    the  above  control  and  treatment  technology,  no  BPCTCA
    limitations  for  this segment of the industry are proposed.
    Capital investments and operating  costs  will  be  deferred
    until such time as BATEA limits apply.
    
    Misce 1 Ianeous Runoffs - Casting and Slagging
    
    i23°i  Casting.   Ingot  casting  operations  employ minimal
    amounts of water for mold spray cooling.  Water usage is  so
    minimal  that  there  is  rarely  any  runoff  from the area
    proper.  In addition, any excess spray water would generally
                                 429
    

    -------
    contain only suspended matter in the form  of  larger  scale
    particles which would settle in the immediate spray area.  A
    runoff  that might exist at a specific site due to excessive
    spray water usage could best be resolved by tightening up on
    spray water usage.
    
    Based upon the minimal water use requirements for ingot mold
    spray cooling operations, and the fact that current industry
    practice controls this usage to a point  where  no  overland
    runoff  normally  exists,  it is recommended that the BPCTCA
    and BATEA  Guidelines  for  discharges  from  ingot  casting
    operations  be  set at zero aqueous discharge of pollutants.
    The additional costs associated with achieving these  levels
    are zero since they represent current general practice.
    
    Pig  Casting.   As in the case of ingot casting, spray water
    usage is generally so minimal in the pig  casting  operation
    that  no  runoff  is expected.  Thus, it is recommended that
    the limitations for BPCTCA and BATEA be set at zero  aqueous
    discharge.   Since the technology to achieve this is already
    generally  in  practice,  there  are  no  additional   costs
    required to achieve these standards.
    
    Slagging.  There are seldom any overland discharges from the
    slag quenching operations within a steel mill.  The majority
    of  the  quench  water  is  evaporated during quenching, the
    remainder permeates through to the base of the  quench  pit,
    where,  upon removal of the quenched slag, it sits in a pool
    until evaporated by the next hot slag charge.
    
    Also, these slag quench pits are normally graded to  prevent
    overland  runoff  from the pit and promote the collection of
    excess quench water in the bottom of the pit.   Thus,  there
    is  generally  no  overland  runoff  from the slag quenching
    area.
    
    The  recommended  BPCTCA  and  BATEA  Guidelines  for   slag
    quenching  are  established  as  zero  aqueous  discharge of
    pollutants.  The technology used to achieve these  standards
    will  employ  the current practice generally used to prevent
    overland runoffs and the  installation  of  impervious  base
    liners to prevent subsurface runoff.
    
    Noncontact Cooling Water fiecirculation System Slowdown
    
    The  use  of a recirculating noncontact cooling water system
    in steelmaking or finishing processes provides a method  for
    significantly  reducing  aqueous thermal discharges from the
    plant site.  These recirculating systems are usually part of
    an evaporative cooling system  which  provides  for  maximum
                                  430
    

    -------
    heat  rejection to the surrounding air.  These recirculating
    systems are normally associated with  newer  or  refurbished
    older mills.
    
    Because   these   systems  utilize  evaporative  cooling  to
    regenerate  cool  water  for  reuse,  a  certain  amount  of
    blowdown  from  the  system  is  required to maintain stable
    operating conditions.  This blowdown, in certain  instances,
    may itself be a potential pollutional discharge.
    
    The   volume   of   these  blowdown  wastewaters  will  vary
    significantly, depending upon the size of the  recirculating
    system  and  the design and operating characteristics of the
    evaporative cooling system.  Thus, it  is  not  possible  to
    predict  the  general  magnitude  of  these discharges on an
    industry-wide basis.  Quantities of blowdown discharges will
    be very site specific and cannot easily be related to  plant
    production.
    
    The  potential pollutants in these discharges generally come
    from those additives that are used to inhibit  corrosion  in
    the  recirculating  system.   Of  primary  concern are those
    plants that use hexavalent  chrome-zinc  inhibitor  systems.
    This  treatment  provides  the greatest corrosion protection
    but, unfortunately, also the greatest pollution potential.
    
    Another  possible  contaminant  of   importance   could   be
    suspended   matter   in   the  recirculation  system.   This
    contaminant can be introduced into the cooling system either
    through the  makeup  water  supply  or  by  the  washing  of
    airborne  contaminants  by  the  evaporative cooling system.
    Although  the   potential   deleterious   affect   of   this
    contaminant   in  the  recirculating  water  system  can  be
    controlled through the use  of  dispersants,  it  still  may
    constitute a potential pollutant in the blowdown stream.
    
    Because  the  quantity  and quality of these blowdown wastes
    are so site specific, it is not possible  to  establish  raw
    waste  or  plant  effluent  loads  for these discharges on a
    pounds per ton of product basis.
    
    It is recommended that,  where  possible,  the  wastes  from
    cooling system blowdown be collected and combined with other
    process wastes which require removal of chrome and suspended
    solids.
    
    Where  this is not possible, it is recommended that separate
    treatment facilities for these wastes be provided  to  treat
    them  before  discharge.  The technology exists and has been
    utilized in achieving the ELG's for other  subcategories  in
                                 431
    

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    this  study  to  remove these contaminants before discharge.
    Hexavalent  and  total   chromium   can   be   removed   via
    acidification,  reduction  to  the  trivalent  state  with a
    strong reducing agent, and  precipitation  with  lime.   The
    lime  precipitation  step  will  also  precipitate  zinc, if
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    BPCTCA:   Suspended Solids    -    50 mg/1
              Total Chromium      -    3.0 mg/1
              Hexavalent Chromium -    0.02 mg/1
              Zinc                -    5.0 mg/1
              Phosphorous         -    8.0 mg/1
              pH                  -    6.0 to 9.0
    
    Utility, Area Wastewaters
    
    In  the  steel  mill, those areas where water is treated and
    prepared for use in the plant, or where steam or electricity
    are generated are generally referred  to  as  the  utilities
    areas.
    
    During  the  preparation  of  raw  water for use, wastes are
    generated which constitute a wastewater discharge  from  the
    utility area.  These wastes include clarifier blowdown, sand
    and carbon filter backwash, spent softener and demineralizer
    regenerants, and steam system blowdown.
    
    Although the character of these wastes are more specifically
    discussed  in  another  section  of this report, the overall
    character of these combined wastes are discussed  here  with
    the  intent  to  establish  practical  ELG's  to control the
    quantity and quality of discharges from the utilities area.
    
    The quantity of wastes generated  from  utilities  areas  in
    general  is not a predictable value.  The quantity of wastes
    is site specific and depends  upon  the  particular  utility
    operations in service, the size of these operations, and the
    quality  of  the  raw  intake  water to be treated and used.
    Because the magnitude of the wastes are  so  dependent  upon
    the above factors, they are not predictable on a gallons per
    ton of product basis.
                                 433
    

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    The overall quality of utility area discharges is also quite
    variable,  again because of the above mentioned factors, and
    thus are not predictable on an overall basis.
    
    However,  from  a  basic  knowledge  of  the  utility   area
    operations,  it is known that possible contaminants in these
    wastes include suspended  solids,  alkalinity,  or  acidity.
    The  technology exists to insure that these contaminants are
    present in acceptable concentrations before discharge.  Such
    treatment technology  has  already  been  applied  to  other
    subcategory  steel  industry processes to produce acceptable
    effluent concentrations.
    
    Based upon the technology available to treat  these  wastes,
    (neutralization  and  sedimentation)  and the application of
    this technology to this subcategory,  the  BPCTCA  ELGs  for
    utility area wastewaters are as follows:
    
              Suspended Solids    -    50 mg/1
              pH                  -    6.0 to 9.0
    
    Maintenance Department Wastes
    
    The   only   liquid  wastes  generated  in  the  maintenance
    operations of a steel mill that are directly dependent  upon
    the tons of steel produced are those wastes generated during
    maintenance  on  the rolling mills.  The greater the tonnage
    rolled, the  more  frequently  rolls  must  be  changed  and
    refaced  and  the  more wastes generated during the refacing
    operation.  The roll shop is normally  located  adjacent  to
    the  rolling  mill  and  a common waste treatment system may
    serve both operations.  It is, therefore,  impracticable  to
    separate the maintenance waste load from that of the rolling
    operation   and  to  establish  a  waste  load  attributable
    exclusively to the maintenance operation.  This waste  would
    therefore  be  included  with  the  waste  from  the rolling
    operation.
    
    Most  other  liquid  wastes   resulting   from   maintenance
    operations are independent of the tons of steel produced and
    the  type  of  product.   It  is,  therefore,  impossible to
    estimate a waste load for maintenance generated  wastes  and
    to  establish a waste load per ton of product.  As a general
    rule, the normal daily maintenance wastewater discharge will
    have little overall effect  on  the  quality  of  the  plant
    effluent.   However,  problems  can  arise  when  even small
    volumes of oil are improperly disposed of in the plant sewer
    system.
                                   437
    

    -------
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    -------
    Effluent  guidelines  for  the  regulation  of   maintenance
    wastewater based upon production rates would be impractical,
    as there would either be no waste or an undetermined amount.
    The  guidelines  should, therefore, stress the reduction and
    control of these wastes by  establishing  good  housekeeping
    procedures, central collecting stations for small volumes of
    oily  wastes,  and  the education of employees on the proper
    methods of disposal of these wastes.
    
    It is further recommended that where it is  not  practicable
    or  feasible to combine maintenance department wastes with a
    process  waste  treatment  system,  a   separate   treatment
    facility   should   be   installed   for   the   maintenance
    wastewaters.  As discussed in the preceding paragraphs,  the
    discharge limitations should be established on concentration
    only.   Based  on  technology  available and consistent with
    numbers established for the Phase I study, the  BPCTCA  ELGs
    have been set as follows:
    
              Suspended Solids    -    50 mg/1
              Oil and Grease      -    15 mg/1
              pH                       6.0 to 9.0
    
    Central Treatment
    
    In   some   instances,  plants  will  combine  two  or  more
    wastewater flows from  different  process  subcategories  or
    from  sources  for which regulations have not been proposed,
    and treat the combinations in  a  central  treatment  plant.
    One  such example is the joint treatment of wastewaters from
    pickling and cold rolling  operations,  for  which  specific
    regulations  have  been  written  under those subcategories.
    For all  other  central  treatment  systems,  the  allowable
    BPCTCA loads for discharge will be the sum of the loads from
    regulated  sources,  plus the loads determined from the flow
    rates of the unregulated sources multiplied by the following
    allowable concentrations:
    
              Suspended Solids    -    50 mg/1
              Oil and Grease      -    15 mg/1
              Total Chromium      -    3.0 mg/1
              Hexavalent Chromium -    0.02 mg/1
              Phosphorus          -    8 mg/1
              Zinc                -    5 mg/1
              pH                       6.0 to 9.0
                                     439
    

    -------
                             SECTION X
    
                EFFLUENT QUALITY ATTAINABLE THROUGH
          THE APPLICATION OF THE BEST AVAILABLE TECHNOLOGY
                      ECONOMICALLY ACHIEVABLE
    EFFLUENT LIMITATIONS GUIDELINES
    
    The effluent limitations which must be achieved by  July  1,
    1983  are  to  specify  the  degree  of  effluent  reduction
    attainable through the application  of  the  best  available
    technology    economically   achievable.    Best   available
    technology  is  not  based  upon  an  average  of  the  best
    performance  within  an  industrial  category,  but is to be
    determined  by  identifying  the  very  best   control   and
    treatment  technology  employed  by  a specific point source
    within the industrial category or subcategory, or  where  it
    is  readily  transferable from one industry to another, such
    technology may be identified as BATEA technology.   However,
    where  limitations  based  on  the  very  best  control  and
    treatment technology employed would involve the  application
    of   a   technology  not  considered  at  this  time  to  be
    cost-effective,the BATEA limitations  were  based  on  other
    technologies  which  were  considered  to be cost-effective.
    For example, filtration  following  clarification  increases
    the capital investment in a manner which is disproportionate
    to  the  additional  solids  removal  achieved.   A specific
    finding must be made  as  to  the  availability  of  control
    measures   and  practices  to  eliminate  the  discharge  of
    pollutants,  taking  into   account   the   cost   of   such
    elimination.
    
    Consideration must also be given to:
    
    1.  The size and age of equipment and facilities involved.
    
    2.  The processes employed.
    
    3.  Non-water guality environmental impact (including energy
    requirements) .
    
    4.  The engineering aspects of the  application  of  various
    types of control techniques.
    
    5.  Process changes.
    
    6.  The cost of achieving the effluent  reduction  resulting
    from application of BATEA technology.
                                     441
    

    -------
    Best  available  technology  assess  the availability in all
    cases of in-process changes or controls which can be applied
    to reduce waste  loads,  as  well  as  additional  treatment
    techniques  which  can be applied at the end of a production
    process.  Those plant  processes  and  control  technologies
    which  at  the pilot plant, semi-works, or other level, have
    demonstrated both  technological  performance  and  economic
    viability  at  a  level  sufficient  to  reasonably  justify
    investing in such facilities may be considered in  assessing
    best available technology.
    
    Best  available  technology is the highest degree of control
    technology that has been achieved or has  been  demonstrated
    to be capable of being designed for plant scale operation up
    to  and  including  "no  discharge" of pollutants.  Although
    economic factors are considered in the development, the cost
    for this level of control is intended to be the  top-of-the-
    line  current  technology  subject to limitations imposed by
    economic and engineering feasibility.  However,  this  level
    may  be characterized by some technical risk with respect to
    performance  and  with  respect  to  certainty   of   costs.
    Therefore,   the  BATEA  limitations  may  necessitate  some
    industrially  sponsored  development  work  prior   to   its
    application.
    
    RATIONALE FOR THE SELECTION OF BATEA
    
    The  following  paragraphs  summarize  the factors that were
    considered in selecting the categorization, water use rates,
    level  of  treatment  technology,  effluent   concentrations
    attainable by the technology, and hence the establishment of
    the effluent limitations for BATEA.
    Size   and   Age   of   Facilities   and  Land  Availability
    Considerations
    
    As discussed in Section  IV,  the  age  and  size  of  steel
    industry   facilities  has  little  direct  bearing  on  the
    quantity or quality of wastewater generated.  Thus, the  ELG
    for  a  given subcategory of waste source applies equally to
    all plants regardless of size or age.  Land availability for
    installation of add-on treatment  facilities  can  influence
    the  type  of technology utilized to meet the ELGs.  This is
    one of the considerations which can account for a wide range
    in the costs that might be incurred.
    
    Consideration of Processes Employed
    
    All plants in a given subcategory use the  same  or  similar
    production  methods, giving similar discharges.  There is no
                                     442
    

    -------
    evidence that operation of any current process or subprocess
    will substantially affect capabilities to implement the best
    available control technology  economically  achievable.   At
    such  time  that  new  processes  appear  imminent for broad
    application, the ELGs should be amended to cover  these  new
    sources.  The treatment technologies to achieve BATEA assess
    the  availability  of in-process controls as well as control
    or additional treatment techniques employed at the end of  a
    production process.
    
    Consideration of Non-Water Quality Environmental Impact
    
    Impact  of  Proposed Limitations on Air Quality.  The impact
    of BATEA limitations upon  the  non-water  elements  of  the
    environment  has  been  considered.   The  increased  use of
    recycle systems have the potential for increasing  the  loss
    of  volatiles  to  the  atmosphere.   Recycle systems are so
    effective in reducing wastewater volumes,  and  hence  waste
    loads  to  and  from  treatment systems, and in reducing the
    size and cost of treatment systems that a trade-off must  be
    accepted.   Recycle  systems  requiring  the  use of cooling
    towers  have  contributed  significantly  to  reductions  of
    effluent  loads  while  contributing  only  minimally to air
    pollution problems.  Careful operation of such a system  can
    avoid or minimize air pollution problems.
    
    Imgact  of  Proposed  Limitations  on  Solid Waste Problems.
    Consideration has also been given to the solid waste aspects
    of water pollution controls.  The processes for treating the
    wastewaters from this industry produce considerable  volumes
    of sludges.  Much of this material is inert iron oxide which
    can  be  reused  profitably  in  melting  operations.  Other
    sludges not suitable  for  reuse  must  be  disposed  of  to
    landfills,  since  most  of  them  are chemical precipitates
    which  could  be  little  reduced  by  incineration.   Being
    precipitates  they  are  by  nature relatively insoluble and
    nonhazardous substances requiring minimal custodial care.
    
    Impact of Proposed Limitations Due to  Hazardous  Materials.
    In  order  to ensure long-term protection of the environment
    from harmful constituents, special consideration of disposal
    sites should be made.  All landfill sites should be selected
    so as to prevent horizontal and vertical migration of  these
    contaminants  to  ground  or surface waters.  In cases where
    geologic conditions may not reasonably ensure this, adequate
    mechanical precautions  (e.g., impervious liners)  should  be
    taken  to ensure long-term protection to the environment.  A
    program  of  routine  periodic  sampling  and  analysis   of
    leachates  is advisable.  Where appropriate, the location of
    solid  hazardous  materials   disposal   sites   should   be
                            443
    

    -------
    permanently  recorded  in  the  appropriate  office of legal
    jurisdiction.
    
    Impact of Proposed Limitations on Energy Requirements.   The
    effect   of  water  pollution  control  measures  on  energy
    requirements  has  also  been  determined.   The  additional
    energy required in the form of electric power to achieve the
    effluent  limitations  proposed for BPCTCA and BATEA amounts
    to less than 2% of the electrical energy used by  the  steel
    industry in 1972.
    
    The  enhancement  to  water  quality  management provided by
    these proposed effluent limitations substantially  outweighs
    the impact on air, solid waste, and energy requirements.
    
    Consideration  of the Engineering Aspects of the Application
    of Various Tyjges of Control Techniques
    
    The BATEA level of technology is considered to be  the  best
    available  and  economically achievable in that the concepts
    are proven and available  for  implementation,  and  may  be
    readily applied through adaptation or as add-ons to proposed
    BPCTCA treatment facilities.
    
    Consideration of Process Changes
    
    No process changes are envisioned for implementation of this
    technology  for  plants  in  any subcategory.  The treatment
    technologies to achieve BATEA assess the availability of in-
    process controls as well as control or additional  treatment
    techniques employed at the end of a production process.
    
    Consideration  of_  Costs of Achieving the Effluent Reduction
    Resulting from the Application of BATEA Technology
    
    The costs of implementing the BATEA limitations relative  to
    the  benefits to be derived is pertinent, but is expected to
    be higher per unit  reduction  in• waste  load  achieved  as
    higher  quality  effluents are produced.  The overall impact
    of capital and operating costs relative to the value of  the
    products   produced   and   gross   revenues  generated  was
    considered in establishing the BATEA limitations.
    
    The technology evaluation, treatment facility, costing,  and
    calculation  of  overall capital and operating costs, to the
    industry as described in Section IX and which  provided  the
    basis for the development of the BPCTCA limitations was also
    used   to  provide  the  basis  for  determining  the  BATEA
    limitations, the costs therefore, and the  acceptability  of
    those costs.
                               444
    

    -------
    The initial capital investment and total annual expenditures
    required  of  the  industry to achieve BATEA limitations are
    summarized in Table
    
    After selection of the treatment technology to be designated
    as one means to  achieve  the  BATEA  limitations  for  each
    subcategory  was  made, a sketch of each treatment model was
    prepared.  The sketch  for  each  subcategory  is  presented
    following  the  tables  presenting the BATEA limitations for
    the subcategory.
    
    IDENTIFICATION OF THE BEST AVAILABLE TECHNOLOGY ECONOMICALLY
    ACHIEVABLE - BATEA
    
    Based on the information contained in Sections  III  through
    VIII  of this report, a determination has been made that the
    quality of effluent attainable through  the  application  of
    the  Best Available Technology Economically Achievable is as
    listed in Tables    through   .  These tables set forth  the
    ELGs  for  the  following process subcategories of the steel
    industry:
    
       I.  Hot Forming Primary
      II.  Hot Forming Section
     III.  Hot Forming Flat
      IV.  Pipe and Tubes
       V.  Pickling - Sulfuric Acid - Batch Concentrates
      VI.  Pickling - Sulfuric Acid - Batch Rinse
     VII.  Pickling - Hydrochloric Acid - Concentrates -
           Alternate I
    VIII.  Pickling - Hydrochloric Acid - Rinses - Alternate I
      IX.  Pickling - Hydrochloric Acid - Concentrates and
           Rinses - Alternate II
       X.  Cold Rolling - Recirculation
      XI.  Cold Rolling - Combination
     XII.  Cold Rolling - Direct Application
    XIII.  Hot Coatings - Galvanizing
     XIV.  Hot Coatings - Terne
    
    In establishing the subject guidelines, it should  be  noted
    that  the  resulting limitations or standards are applicable
    to aqueous waste discharges only,  exclusive  of  noncontact
    cooling  waters.   In  the  section  of  this  report  which
    discusses control and treatment technology for the iron  and
    steelmaking industry as a whole, a qualitative reference has
    been  given  regarding  "the environmental impact other than
    water" for the subcategories investigated.
    
    The  effluent  guidelines  established  herein  taken   into
    account  only  those  aqueous  constituents considered to be
                               445
    

    -------
    major pollutants in each of the subcategories  investigated.
    In  general,  the critical parameters were selected for each
    subcategory on the basis of those waste  constituents  known
    to  be  generated  in the specific manufacturing process and
    also known to  be  present  in  sufficient  quantity  to  be
    inimical  to  the  environment.   Certain general parameters
    such as suspended solids naturally  include  the  oxides  of
    iron   and   silica.    However,   these   latter   specific
    constituents were not included as critical parameters, since
    adequate  removal  of  the  general  parameters   (suspended
    solids)  in  turn  provides for adequate removal of the more
    specific parameters indicated.  This does not hold true when
    certain of  the  parameters  are  in  the  dissolved  state;
    however,  in  the  case of iron oxides generated in the iron
    and steelmaking  processes,  they  are  for  the  most  part
    insoluble  in the relatively neutral effluents in which they
    are contained.   The  absence  of  apparent  less  important
    parameters   from   the   guidelines   in  no  way  endorses
    unrestricted discharge of the same.
    
    The  recommended  BATEA  effluent   limitations   guidelines
    resulting  from  this  study  are summarized in Tables 93 to
    107.  These tables  also  list  the  control  and  treatment
    technology  applicable  or  normally  utilized  to reach the
    constituent levels indicated.   These  effluent  limitations
    set  herein  are  not necessarily the absolute lowest values
    attainable  (except where no discharge of process  wastewater
    pollutants  to  navigable  waters  is  recommended)   by  the
    indicated technology, but rather they represent values which
    can be readily controlled around on a day by day basis.
    
    It should be noted that these effluent limitations represent
    values not to be exceeded by any 30 continuous day  average.
    The  maximum  daily  effluent  loads  per unit of production
    should not exceed these values by  more  than  a  factor  of
    three as discussed in Section IX.
    
    Cost Versug Effluent Reduction Benefits
    
    Estimated  total  costs on a dollars per ton basis have been
    included for each subcategory as a whole.  These costs  have
    been  based  on  the  wastewaters  emanating  from a typical
    average  size  production   facility   for   each   of   the
    subcategories  investigated.   In arriving at these effluent
    limitations  guidelines,  due  consideration  was  given  to
    keeping  the  costs  of implementing the new technology to a
    minimum.  Specifically, the effluent limitations  guidelines
    were  kept  at  values  which  would not result in excessive
    capital or operating costs to the industry.  The capital and
    annual  operating  costs  that  would  be  required  of  the
                                446
    

    -------
    industry  to  achieve  BATEA  was  determined  by a six-step
    process  for  each  of  the  subcategories.   It  was  first
    determined  what  treatment  processes were already in place
    and  currently  being  utilized  by  most  of  the   plants.
    Secondly,  a  hypothetical  treatment  system was envisioned
    which, as an add-on to existing facilities would  treat  the
    effluent  sufficiently  to  meet  BATEA  ELGs.  Thirdly, the
    average plant size was  determined  by  dividing  the  total
    industry  production  by the number of operation facilities.
    Fourth, a quasi-detailed engineering estimate  was  prepared
    on  the cost of the components and the total capital cost of
    the add-on facilities for the  average  plant.   Fifth,  the
    annual  operating,  maintenance,  capital recovery (basis 10
    years straight line depreciation) and capital use  (basis  7%
    interest)  charges  were  determined.   And sixth, the costs
    developed for the average facility were  multiplied  by  the
    total  number  of  facilities to arrive at the total capital
    and annual costs to the industry for each subcategory.   The
    results are summarized in Table 108.
    
    BATEA EFFLUENT LIMITATIONS GUIDELINES
    
    The  BATEA  limitations  have been established in accordance
    with the policies and definitions set forth at the beginning
    of  this  section.   Further  refinements  of  some  of  the
    technologies  and the ELGs discussed in the previous Section
    IX of this  study  will  be  required.   The  subject  BATEA
    limitations  are summarized in Tables  93 to 107, along with
    their projected costs and treatment technologies.
    
    Discussion by Subcategorj.es
    
    The rationale used for developing BATEA effluent limitations
    guidelines  is  summarized  below  for  each  of  the  major
    subcategories.   All  effluent  limitations  guidelines  are
    presented on a "gross" or absolute basis since for the  most
    part,   removals   are  relatively  independent  of  initial
    concentrations of contaminants.  The ELGs are  in  kilograms
    of  pollutant  per  metric  ton  of  product or in pounds of
    pollutant per thousand pounds of product and in these  terms
    only.   The  ELGs  are  not  a  limitation  on flow, type of
    technology to be utilized, or concentrations to be achieved.
    These items are listed only as a guide to show the basis for
    the ELGs and may be varied as the discharger desires so long
    as the ELGs per unit of production are met.
    
    Hot Forming - Primary
    
    Following is a summary of the factors used to establish  the
    BATEA Effluent Limitations Guidelines (ELGs) applying to the
                                447
    

    -------
    Hot  Forming  Primary  subcategory.  As far as possible, the
    stated limits are based upon performance levels attained  by
    at  least  one  of  the selected plants surveyed during this
    study.   Where  treatment  levels   can   be   improved   by
    application  of  additional  currently available control and
    treatment technology, the  anticipated  reduction  of  waste
    loads was included in the estimates.
    
    The  BATEA ELGs for the Hot Forming Primary subcategory, and
    the  control  and  treatment  technology  to  achieve  these
    limits, are summarized in Table 93.
    
    Flow.  The five plants surveyed under this subcategory, four
    of  which  operated essentially on a once-through basis, had
    effluent flows ranging from 217 1/kkg (52 gal./ton) to 3,248
    1/kkg  (779 gal./ton)  of product,  for  an  average  flow  of
    1,923 1/kkg (460 gal./ton).  Although most plants sampled in
    this  subcategory  were  operating  on a once-through basis,
    evidence  persists  from  plants  sampled  under  other  Hot
    Forming  categories,   that Hot Forming plants in general can
    operate using tight recycle system with  blowdown  rates  of
    10%  or less than their once-through flow.  Even within this
    subcategory,  the  plant  discharging  only  217  1/kkg  (52
    gal./ton)  was  blowing down at 8.5% of its application flow
    rate.
    
    Therefore, based upon  evidence  from  this  and  other  Hot
    Forming  subcategory  plants visited, the BATEA ELGs for the
    Hot Forming Primary subcategory are based upon  a  discharge
    flow rate of 417 1/kkg (100 gal./ton) of product which would
    be  the  blowdown  rate  from a recycle system providing all
    contact   water   requirements   including   hot   scarfing.
                Solids.    The  five  plants  surveyed  in  this
    subcategory had  effluent  suspended  solids  concentrations
    ranging  from  2  to  23  mg/1.  The plants utilize chemical
    flocculation or deep bed filtration  to  achieve  these  low
    levels.   In  particular,  the plant operating with the high
    degree of recycling was attaining 5 to 16  mg/1  of  TSS  in
    water  recirculated  to  the  mill without using filtration.
    This high level of quality resulted from  well-run  chemical
    flocculation and clarification steps.
    
    Based  upon  the  performance of these plants, the BATEA ELG
    for suspended solids has been set at 0.0104  kg/kkg   (0.0208
    Ibs  of  suspended solids per ton) of product, equivalent to
    25 mg/1  based  on  a  discharge  flow  of  417  1/kkg   (100
    gal./ton) .   The  recycle  plant  effluents contained 33% of
    this limit.  It is anticipated that the industry can achieve
    the control and treatment technology necessary to meet  this
                                 448
    

    -------
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    standard  in  a  cost effective manner by 1983, and in fact,
    exemplary plants currently attain this level.
    
    Oil  and  Grease.   The  five  plants   surveyed   in   this
    subcategory  had  effluent  oil  and  grease  concentrations
    ranging between 2 and 8 mg/1.  The plants  utilize  skimming
    and  deep  bed  filtration  to  achieve  these  low  levels.
    However, the skimming systems were efficiently run  so  that
    oil  concentrations  in  the  feed to the filtration systems
    ranged between 7 and 12 mg/1.  In particular, the  plant  on
    tight  recycle  was  attaining an average concentration of 8
    mg/1 via clarification/flocculation.
    
    Based upon the performance of these plants,  the  BATEA  ELG
    for oil and grease has been set at 0.0042 kg/kkg  (0.0083 Ibs
    of oil and grease per ton) of product, equivalent to 10 mg/1
    based  on  a  discharge  flow  of  417 1/kkg (100 gal./ton).
    Again, the plant on tight recycle is  currently  discharging
    only 62% of this limit.  It is anticipated that the industry
    can  provide  the control and treatment technology necessary
    to meet this standard in a cost effective  manner  by  1983,
    and in fact, exemplary plants currently attain this level.
    
    pH.  All plants surveyed fell within the pH constraint range
    of  6.0  to  9.0,  both  for  filter  feeds  and  for  final
    effluents, thus providing  a  basis  for  establishing  this
    range  as  the  BATEA  ELG.   Any plant falling outside this
    range  can  easily  remedy   the   situation   by   applying
    appropriate neutralization procedures to the final effluent.
    
    Hot Forming - Section
    
    Following  is a summary of the factors used to establish the
    BATEA effluent limitation guidelines  (ELGs) applying to  the
    Hot  Forming  Section  subcategory.  As far as possible, the
    stated limits are based upon performance levels attained  by
    the  selected  plants  surveyed  during  this  study.  Where
    treatment  levels  can  be  improved   by   application   of
    additional   currently   available   control  and  treatment
    technology, the anticipated reduction  of  waste  loads  was
    included in the estimates.
    
    The  BATEA ELGs for the Hot Forming Section subcategory, and
    the  control  and  treatment  technology  to  achieve  these
    limits, are summarized in Table 94.
    
    Flow.    Of   the   ten  process  lines  surveyed  for  this
    subcategory, four were  practicing  either  tight  or  total
    recycle.   Two  of  these  plants  had effluent flows of  584
    1/kkg  (140 gal./ton)  and  1,555  1/kkg   (373  gal./ton)  of
                                 452
    

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                MODEL  COST £-/-"F
    -------
    product.   The  third plant containing two process lines had
    zero aqueous discharge, with the only "blowdown"  being  the
    water  content of the wet sludges generated by the treatment
    processes.
    
    Because those plants utilizing tight or  total  recycle  are
    discharging significantly less water than those operating on
    a  once-through  basis, it is felt that these four lines are
    all practicing BATEA technology.  Therefore, the BATEA  ELGs
    are  based  on  flows  set  at  626  1/kkg  (150 gal./ton) of
    product, excluding all noncontact cooling water.  This value
    is justified based upon the fact that several of the section
    subcategory plants surveyed are already  practicing  recycle
    technology.   In fact, one plant operating two bar mills was
    recycling so effectively that  no  aqueous  discharges  were
    required.  This high degree of load reduction was considered
    to  be  a special case, difficult to apply across the entire
    section  subcategory.   For  this   reason,   zero   aqueous
    discharge was not recommended as the BATEA ELG.
    
    Suspended  Solids.  Suspended solids concentrations from the
    two plants surveyed which  were  using  tight  recycle  with
    blowdown  were  29  and  10  mg/1.   Treatment technology to
    achieve  these  levels  is  sedimentation/clarification  and
    sedimentation/clarification/filtration, respectively.
    
    Based  upon  the  effluent  concentrations  achieved and the
    treatment technology used at these  and  other  Hot  Forming
    subcategory  plants,  it  is  felt  that  several plants are
    employing  BATEA  technology.   Thus  the  BATEA   ELG   for
    suspended  solids  is  set  at  0.0156 kg/kkg  (0.0312 Ibs of
    suspended solids per ton) of product, equivalent to 25  mg/1
    in  a  626  1/kkg   (150 gal./ton) discharge flow rate.  This
    value is  justified since two of  the  three  recycle  plants
    surveyed   (including  the zero discharge lines) already meet
    this standard, the third exceeds the limit by only 8%, and a
    fourth plant on a relatively loose  recycle   (60%  blowdown)
    achieves  the limit by using filtration of the blowdown down
    to 2 mg/1 suspended solids.
    
    In  determining  this  standard,  the  total  recycle  plant
    recirculated water quality was purposely excluded in setting
    effluent   treatment   levels.    This   plant   carries   a
    concentration of 47 mg/1 suspended matter back to the  mills
    in  its recycle loop.  However, since there is no discharge,
    that concentration is irrelevant from a  discharge  standard
    point  of  view  and  is  limited  only  by  a plant process
    equipment's ability to  handle  higher  concentrations.   In
    fact,  as  a  plant  goes to total recycle, they may find it
    advantageous   to   carry   a   higher   suspended    solids
                                  456
    

    -------
    concentration  in the recycle stream, so as to minimize size
    of treatment equipment.
    
    Oil and Grease.  Oil and grease concentrations from the  two
    plants surveyed which were using tight recycle with blowdown
    were 8.3 and 9.8 mg/1.  Treatment technology used to achieve
    these      values      is     skimming/clarification     and
    skimming/clarification/ filtration, respectively.
    
    Based upon the effluent  concentrations  achieved,  and  the
    treatment  technology  used,  it is felt that several plants
    are employing BATEA technology.  Thus, the BATEA ELG for oil
    and grease is set at 0.0063 kg/Jckg  (0.0125 Ibs  of  oil  per
    ton)  of  product, equivalent to 10 mg/1 in a discharge flow
    of 626 1/kkg (150 gal./ton).  This value is justified  since
    three of the five plants visited already meet this standard.
    
    Again, in determining this standard, the total recycle plant
    was  excluded from the evaluation, since the level of oil it
    carries in the recycle loop is irrelevant as long  as  there
    is no discharge.  However, the plant was utilizing efficient
    oil  skimmers, and the water recycled to the mills contained
    only 2 to 5 mg/1 oils and greases.
    
    pH.   All  of  the  plants  surveyed  fell  within  the   pH
    constraint  range  of 6.0 to 9.0, thus providing a basis for
    establishing the range as the BATEA ELG.  Any plant  falling
    outside  of  this  range can readily remedy the situation by
    applying appropriate neutralization procedures to the  final
    effluent.
    
    Hot Forming - Flat
    
    Following  is a summary of the factors used to establish the
    BATEA effluent limitation guidelines  (ELGs) applying to  the
    Hot  Forming  Flat  subcategory.   As  far  as possible, the
    stated limits are based upon performance levels attained  by
    the  selected  plant  surveyed  during  this  study.   Where
    treatment  levels  can  be  improved   by   application   of
    additional   currently   available   control  and  treatment
    technology, the anticipated reduction  of  waste  loads  was
    included in the estimates.
    
    The BATEA ELGs for the Hot Forming Flat, Hot Strip and Sheet
    subcategory,  and  the  control  and treatment technology to
    achieve these limits, are summarized in Table 95.  The BATEA
    ELG's for the Hot Forming - Flat -  Plate  subcategory,  and
    the  control  treatment  technology to achieve these limits,
    are summarized in Table 96.
                                    457
    

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    Flow.  Of the five plants surveyed,  three  were  practicing
    either tight or total recycle.  Two of these plants, a plate
    mill  and a wide strip mill, had effluent flows of 634 1/kkg
    (152 gal./ton) and  204  1/kkg  (49  gal./ton)  of  product,
    respectively.  The third recycle plant, a narrow strip mill,
    has zero aqueous discharge.
    
    Because  those  plants  utilizing tight or total recycle are
    discharging significantly less water than those operating on
    a once-through basis, it is felt that these three plants are
    all practicing BATEA technology.  Therefore, the BATEA  ELGs
    for  plate and strip/sheet mills are based on discharge flow
    rates set at 626 1/kkg (150 gal./ton) of product,  excluding
    all  noncontact  cooling  water.  This value is justified on
    the basis  that  three  of  the  five  plants  surveyed  are
    currently  practicing  the  technology  necessary to achieve
    this discharge flow, and are also achieving the  guidelines.
    In addition, it is anticipated that all once-through or more
    limited recycle systems have sufficient time to achieve this
    standard in a cost effective manner by 1983.
    
    Suspended  Solids.  Suspended solids concentrations from the
    two plants practicing tight recycle, but with blowdown  were
    4  and  5  mg/1.  Treatment technology used to achieve these
    levels        was        sedimentation/filtration        and
    sedimentation/clarification, respectively.
    
    Based  upon  the  effluent  concentrations  achieved and the
    treatment technology used it is felt that several plants are
    employing  BATEA  technology.   Thus,  the  BATEA  ELG   for
    suspended  solids  is  set  at  0.0156 kg/kkg  (0.0312 Ibs of
    suspended solids per ton) of product, equivalent to 25  mg/1
    in a discharge flow of 626 1/kkg  (150 gal./ton).  This value
    is justified since three of the five plants surveyed already
    meet this standard.
    
    In  determining  this  standard,  the  total  recycle  plant
    recirculated water quality was purposely excluded in setting
    effluent   treatment   levels.    This   plant   carries   a
    concentration  of  54 mg/1 suspended matter back to the mill
    in its recycle loop.  However, since there is no  discharge,
    that  concentration  is irrelevant from a discharge standard
    point of view  and  is  limited  only  by  a  plant  process
    equipment's ability to handle the higher concentrations.  In
    fact,  as  a  plant  goes to total recycle, they may find it
    advantageous   to   carry   a   higher   suspended    solids
    concentration  in the recycle stream, so as to minimize size
    of treatment equipment.
                                    464
    

    -------
    Oil and Grease.  Oil and grease concentrations from the  two
    plants  surveyed  using tight recycle with blowdown were 6.3
    and 7.9 mg/1.  Treatment technology used  to  achieve  these
    values  were skimming/filtration and skimming/clarification,
    respectively.
    
    Based upon the effluent  concentrations  achieved,  and  the
    treatment  technology  used,  it is felt that several plants
    are employing BATEA technology.  Thus, the BATEA ELG for oil
    and grease is set at 0.0063 kg/kkg  (0.0126 Ibs  of  oil  per
    ton)  of  product, equivalent to 10 mg/1 in a discharge flow
    of 626 1/kkg (150 gal./ton).  This value is justified  since
    three of the five plants surveyed already meet this standard
    and  there is sufficient time for all plants to achieve this
    limit in a cost effective manner by 1983.
    
    Again, in determining this standard, the  water  quality  of
    the  total  recycle  plant  was excluded from the evaluation
    since the level of oil it carries in  the  recycle  loop  is
    irrelevant as long as there is no discharge.
    
    pH.    All  of  the  plants  surveyed  fell  within  the  pH
    constraint range of 6.0 to 9.0, thus providing the basis for
    establishing the range as the BATEA ELG.  Any plant  falling
    outside  of  this  range can readily remedy the situation by
    applying appropriate neutralization procedures to the  final
    effluent.
    
         and Tubes
    
    Currently,   three  of  the  six  exemplary  pipe  and  tube
    installations surveyed practice very  low  or  zero  aqueous
    discharge.    The   recommended  BATEA  limitation  is  not,
    however, "no discharge of  process  wastewater  pollutants,"
    since  control  and  treatment  technology required would be
    highly  dependent  upon  available  space  and  a   suitable
    climate.   Emphasis  should  be  placed  upon  attaining the
    minimum possible discharge flow through extensive recycle as
    in the BATEA technologies for the Hot Forming subcategories.
    The BATEA limitations have been based on  a  discharge  flow
    rate  of  626  1/kkg  (150 gal/ton) of product which would be
    the blowdown from a recycle  system  providing  all  contact
    water  requirements  of  the operation.  The BATEA ELG's for
    the Pipe and Tubes subcategory and the control and treatment
    technology to achieve these limits are summarized  in  Table
    97.
    
    Suspended  Solids.   Based on the effluent loadings achieved
    through the use of tight recycle systems, and  treatment  of
    blowdowns  via  flocculation  and  clarification for the Hot
                                   465
    

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    -------
                                          B
    MODEL COST
         P/PE f:  TUBE '3
                                           GNS'3S O/AGGAM
    ANNUAL COSTS'GASED  ON 7SN VEAte  CAP/TAL RECOVERY
                    + IN ;•<£•/< ES T S^A T£ 7 %
                    + OPERA7/NG COSTS /NCLUDE LABOR^HEMlCfUS t UTILITIES
                    + MAINTENANCE CQ27S BASED O.Vf?.5% OA CAP/TAL COSTS
      COSTS BASED ON 3(t>3 MXGJCAY (4OO TO/\'5/DAY) PRQOVC7/OW
          S GRAPH CAN^T BE U-Sc/D fO/Z  /KTER. 1 EDI AT I™ \'A LUES
       O
         O
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                               468
    

    -------
    Forming subcategories, the BATEA for suspended  solids  from
    Pipe  and Tube subcategory operations has been set at 0.0156
    kg/kkg (0.0312 Ibs/ton) of product, equivalent to 25 mg/1 in
    a discharge flow of 626 1/kkg (150 gal./ton).  Although none
    of the plants currently  discharging  wastewater  approaches
    this  limit,  the  three  plants  without  discharges are in
    compliance.  In addition, one of these plants  is  recycling
    water  containing only 19 mg/1, while the river water intake
    suspended  solids  concentration  averages  56  mg/1.   This
    plant,   and   others   from   Hot   Forming  subcategories,
    demonstrate   the   applicability   of    the    recommended
    technologies  and  the  attainability  of  the  limits  with
    currently available equipment.
    
    Oil and Grease.  Recommended BATEA limitations for  oil  and
    grease  from  Pipe and Tube subcategory operations have been
    established at 0.0063 kg/kkg  (0.0126  Ibs/ton)  of  product,
    equivalent  to  10  mg/1  in a discharge volume of 626 1/kkg
    (150 gal./ton).  The  three  plants  currently  using  tight
    recycle  systems  without  blowdown  are recirculating water
    containing from 3.0 to 4.3 mg/1 oil and  grease,  while  the
    three  plants operating once-through systems also skim their
    wastewaters to attain concentrations of less than  10  mg/1,
    albeit in much higher flows than the BATEA limits permit.
    
    Thus,   it  is  evident  that  the  recommended  limits  are
    attainable   with   currently   available   equipment    and
    technology.
    
    pH.   The  BATEA  limitations  for  pH  require all effluent
    discharges to be in the 6.0 to 9.0 range.  Any plant falling
    outside this range can  remedy  the  situation  by  applying
    appropriate neutralization procedures to the final effluent.
    All  surveyed  plants  having discharges were meeting the pH
    limitations.
    
    Pickling. - Batch Sulfuric  Acid  -  Concentrates  and  Rinse
    Water Subcategories
    
    Of  the  six  surveyed  plants utilizing batch sulfuric acid
    pickling, three were practicing recovery  of  sulfuric  acid
    via atmospheric or vacuum crystallization using commercially
    available recovery systems.  Furthermore, two of these three
    plants  were consuming all rinse waters internally.  In both
    cases, fresh water is used as final spray rinse water  only.
    It  is  collected  in  a  spray rinse tank, transferred to a
    standing rinse or dip tank where  it  tends  to  concentrate
    somewhat,  and  ultimately  is  used  to make up evaporative
    losses at the main pickling tank, or as dilutant water  when
    each  fresh  batch  of  pickling  solution is made up.  Each
                                 469
    

    -------
    batch of spent pickle liquor, containing its  share  of  the
    rinse  waters,  is  in turn transferred to the acid recovery
    system for treatment  and  recovery  of  unreacted  sulfuric
    acid.
    
    The  waste treatment practices for the recovery and reuse of
    spent sulfuric  acid  pickle  solutions  center  around  the
    removal  of ferrous sulfate heptahydrate from the liquor via
    crystallization.  Two systems are used.  In one  system  hot
    spent  acid  is  agitated in an open top vessel to evaporate
    surplus water and cool the spent acid.   Refrigerated  water
    is then circulated through indirect cooling coils to further
    cool   the   acid   and   crystallize  the  ferrous  sulfate
    heptahydrate from the  now  super-saturated  solution.   The
    crystals  are allowed to settle and are removed.  Fresh acid
    is added to raise the  acid  concentration  to  the  desired
    level  and  the  acid returned to the pickle tank for reuse.
    There is no liquid discharge from this system.
    
    In the second system, spent hot sulfuric acid is pumped into
    a  vacuum  evaporator  where  the  solution  is  cooled  and
    concentrated,  and crystallization takes place.  The acid is
    then pumped to a thickener to concentrate the crystals prior
    to  removal  via  a  centrifuge.   The  recovered  acid   is
    discharged  into a storage tank where fresh acid is added to
    raise the concentration to the desired level  for  pickling.
    The  liquid  discharge  from this system is comprised of the
    condensate from the evaporator, which  is  of  such  quality
    that  it  may be mixed with the noncontact cooling water and
    reused as rinse water.  A sample of this  mixture  collected
    at  the  only  plant  of  this type surveyed was of a higher
    quality than of the cooling water alone.  The end result  is
    a zero waste load for this operation also, provided that the
    condensate is reused as described.
    
    One  of  the major problems of sulfuric acid recovery plants
    is the sale or disposal of the recovered crystalline ferrous
    sulfate heptahydrate.  A  market  for  this  product  exists
    among  chemical processors, paint and pigment manufacturers,
    and sewage  treatment  plants,  but  this  market  currently
    consumes  only  a  fraction of the potential ferrous sulfate
    heptahydrate  production  if  this  technique  becomes  more
    widespread.   It  is  not possible to accurately predict the
    extent to which this market will expand in  response  to  an
    increased  supply.   The  high  degree  of solubility of the
    crystals makes their disposal by landfill undesirable unless
    the material is first converted to an insoluble form such as
    the monohydrate or is placed in a lined and drained disposal
    area.  What may be required to best recover values from this
    by-product is a commercially feasible  means  of  converting
                                470
    

    -------
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                                       472
    

    -------
                 MOJEL COST EF
                 PICKLING, ~5u
       COSTS BASED ON 227  HHG/OAV (flBQ TON^lGAV] OF 5TE~-L P.'CrfL CO
       THIS GRAPH CANfi'Q~BE L/3E& i-Q'Z /A/7CG '. ! ED/ ATE
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         * TOTAL. COST FOR  LEVEL D  INCLUDE  CKEDITS  FOR ACID
           AND IRON SALT RECOVERY, AND AL'^O REFLECT SAV/NS
           DUE TO ELIMINATION OF SLUDGE DiSPOSAL COSTS  AND
           CHEMICAL' COSTS WHICH WERE INCLUDED IN LEVEL C.
            • — DOLLARS SPENT  FOR COLLECTION Sf'STETM
               AND HAULING  WASTES FOR Of-'P-FiTE DISPOSAL
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                                  473
    

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                        FI6LJGE
                  P/ChLING ^ULFURIC/iLin-B/UCH  -&MSS
    COSTS
                                                          Recovesy
                     - BASSO cw r
    -------
    the   ferrous  sulfate  heptahydrate  to  ferric  oxide  and
    sulfuric acid, possibly  in  independent  chemical  recovery
    plants  serving  many individual picklers.  But the existing
    acid   recovery   plants   currently   in   operation   have
    successfully   eliminated  all  aqueous  discharges  to  any
    receiving stream.  For this reason,  the  recommended  BATEA
    effluent  limitations  for  both  the  Batch Sulfuric Acid -
    Concentrates,  and  the  Batch   Sulfuric   Acid   -   Rinse
    subcategories  are  established  as no aqueous discharges of
    process wastewaters to receiving  streams.   The  means  for
    achieving  this  level are currently available and in use in
    these subcategories.  The BATEA ELGs  for  this  subcategory
    and  the  control  and treatment technology to achieve these
    limits are summarized in Tables 98 and 99.
    
    Pickling - Continuous Sulfuric Acid - Concentrates and Rinse
    Water Subcategories
    
    The BATEA ELGs for this subcategory are as yet  undeveloped,
    awaiting  the  completion  of  additional  plant  surveys to
    provide an expanded data base.  The only continuous sulfuric
    acid pickling  operation  surveyed  was  practicing  a  high
    degree  of treatment technology and was producing no aqueous
    discharge.  However, additional examples must be surveyed to
    insure the applicability of this technology  to  the  entire
    subcategory,  especially  since  the  selected  plant  is  a
    comparatively small continuous strip pickling line producing
    300 tons/day of product.  As a result, BATEA limitations for
    this subcategory are temporarily deferred pending completion
    of the additional plant surveys.
    
    Pickling - Continuous Hydrochloric Acid - Concentrates
    
    The most modern pickling installations in use today  utilize
    hydrochloric   acid  continuous  pickling,  with  continuous
    regeneration of spent  pickle  liquor  to  produce  reusable
    hydrochloric   acid  and  sinterable  ferric  oxides.   Such
    systems are  discussed  in  Section  IX,  where  the  BPCTCA
    limitations  were  set  using such a system to recover spent
    concentrated acid, discharging only the wastewaters from the
    absorber vent scrubber.
    
    A significant reduction in discharge flows from this  system
    can  be  obtained  by  adding a recycle loop on the absorber
    vent scrubbers, and treating the blowdown from  this  system
    via  aeration,  lime  neutralization  and  sedimentation.  A
    system such as this has not been tested; however, the key to
    the system is keeping the water flows in  balance.   Systems
    similar   to   this   are   in  use  in  the  sulfuric  acid
    subcategories with considerable success.
                                 477
    

    -------
    Based on the above, the BATEA limits for pickling operations
    utilizing HCl regeneration have been  established  for  each
    critical  parameter  as discussed below.  The BATEA ELGs for
    this subcategory and the control and treatment technology to
    achieve these limits are summarized in Table 100.
    
    For  those  hydrochloric  acid   pickling   operations   not
    practicing  acid  regeneration,  joint  treatment  of  spent
    concentrates and rinse waters was recommended to achieve the
    BPCTCA limitations.  This  technology  is  further  advanced
    through  use  of countercurrent rinsing to reduce flows from
    that source to less than 209 1/kkg (50 gal./ton), which when
    taken  together  with  the  wastewater   flow   from   spent
    concentrates  gives  a  total flow to the treatment plant of
    333 1/kkg (80 gal./ton of product).  Although the only plant
    surveyed which was discharging flows approximately twice  as
    large as the recommended flows, two of the other plants, one
    using  regeneration  and  the other deep well disposal, were
    successfully concentrating rinse water flows to 50  gal./ton
    or  less.   In  fact,  the  plant  using  deep well disposal
    methods achieves flow rates of only 3.3  gal./ton  of  spent
    pickle  liquor,  plus  5.9  gal./ton  of rinse water using a
    cascade system, indicating how efficiently such rinse  water
    conservation  practice  may  be.   The BATEA limitations for
    this subcategory  (without regeneration of concentrates)  and
    the   control   and  treatment  technology  to  achieve  the
    recommended  limits  are  summarized  in   Table   100.    A
    discussion  of  these  limitations  parameter  by  parameter
    follows.
    
    Suspended  Solids.    For   those   plants   utilizing   HCl
    regeneration  systems,  a  BATEA  limitation of 0.0031 kg/kkg
    (0.0062 Ibs/ton) of steel pickled is established as the load
    from regenerating the  spent  concentrates.   This  load  is
    equivalent  to 25 mg/1 in an absorber vent scrubber system's
    blowdown at a rate of 125 1/kkg  (30  gal./ton).   Currently,
    none  of  the three plants using HCl regeneration systems is
    recycling  or  treating   their   absorber   vent   scrubber
    discharges,   so   none   are   attaining   the  recommended
    limitation.  The nearest  approach  is  made  by  the  plant
    equipped   with   electrostatic   precipitators  rather  than
    cyclones, since the untreated  discharge  from  that  source
    exceeds  the  limit  by 34X.  Even a minor degree of recycle
    and minimum treatment of blowdowns would  suffice  to  bring
    that  plant  into compliance.  Correspondingly higher levels
    of treatment would be required to control wastes from  other
    plants, but the technology is available and demonstrated for
    other iron and steel industry subcategories.
                                478
    

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              FIGURE:
    
    MODEL  CC^T E
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                                            PlA&RAM
    
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    -------
    For  those  plants  practicing joint treatment of rinses and
    concentrate  without  recourse  to  HCl  regeneration,   the
    recommended  BATEA limitation for total suspended solids are
    presented in Table 102 and are set at 0.0083 kg/kkg   (0.0167
    Ibs/ton)   of steel pickled, equivalent to 25 mg/1 based on a
    combined flow of 333 1/kkg  (80  gal./ton).   An  additional
    load  of 0.0052 kg/kkg (0.0104 Ibs/ton) is allowed for those
    plants utilizing wet fume hood scrubbers in conjunction with
    pickling operation, equivalent to 25 mg/1 in a flow  of  209
    i/kkg  (50  gal./ton).   The one plant treating these wastes
    jointly was exceeding the recommended BATEA suspended solids
    limit by a factor of three, but if tighter control of  rinse
    water flows were practiced, superior solids removal would be
    expected  from the existing treatment system.  As it is, the
    effluent concentrations leaving the system  during  sampling
    ranged  from 21 to 56 mg/1 suspended solids, indicating that
    control of certain factors can  lead  to  improved  effluent
    quality.   Also  worthy of note, this plant was treating its
    wastes to  attain  levels  suitable  for  discharge  to  the
    municipal  sanitary  authority  for  further  treatment.  As
    such, their TSS standard would  have  no  limitations  other
    than local plant requirements.
    
    Dissolved   Iron.   For  those  hydrochloric  acid  pickling
    operations  using  HCl   regeneration   systems,   a   BATEA
    limitation  for  dissolved  iron  of 0.00013 kg/kkg  (0.00026
    Ibs/ton) of steel pickled is recommended,  equivalent  to  1
    mg/1 in a discharge flow of 125 1/kkg  (30 gal./ton).  Of the
    three  plants  surveyed,  two  were  successful  in treating
    wastes to this degree as long as careful attention was  paid
    to  pH  control.  However, one of the plants, whose load was
    only 62% of the BATEA limit at pH 7.0 or  above,  discharged
    as much as 120 times the limit as the pH went down to 5.1.
    
    For  plants  practicing  joint treatment of concentrates and
    rinses, rather than HCl regeneration, the  BATEA  limitation
    for  dissolved  iron  are  set  at  0.00034  kg/kkg  (0.00068
    Ibs/ton) of  steel  pickled,  equivalent  to  1  mg/1  in  a
    combined  discharge  flow  of  333  1/kkg  (80 gal./ton).  An
    additional load  of  0.00021  kg/kkg   (0.00042  Ibs/ton)  is
    allowed for those plants using wet fume hood scrubbers.  The
    one  plant  surveyed  treating  spent concentrates and rinse
    water jointly was achieving a dissolved iron  load  of  less
    than  50%  of  the  recommended effluent load through use of
    aeration,  lime  neutralization,   thickening   and   vacuum
    filtration  of underflows demonstrating the effectiveness of
    this system for handling such wastes.
    
    gH.  As in all other subcategories, the BATEA ELG for pH  is
     he  range  6.0  to  9.0.   Since  the treatment required to
                                  482
    

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                                  F'/&Urt!:  /<'•>/&
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    achieve the BATEA dissolved iron  limitations  involves  the
    use  of  alkalies  to  raise  the  pH  values, no additional
    equipment or expense is required to insure  meeting  the  pH
    constraints.
    
    Pickling - Hydrochloric Acid - Rinse Waters
    
    One  of  the  two  plants  providing  more  or less complete
    treatment of rinse waters in this subcategory has been  used
    as the basis for establishing all BATEA Effluent Limitations
    Guidelines.   This  plant  provides  equalization, blending,
    lime addition to pH 8.0, mixing, aeration in dual  chambers,
    polymer  addition,  clarification in either of two identical
    thickeners  used  in  parallel  with  vacuum  filtration  of
    underflows,  and  final  settling  in  a  large  lagoon with
    discharge of overflow to a receiving stream.  An effluent of
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    Suspended Solids.  For separate treatment of rinse waters, a
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    solids per ton) of steel pickled is recommended,  equivalent
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    conjunction  with  the  pickling  operations.    The   plant
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    loading, but has a longer final lagoon detention  time  than
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    effluent  (prior to lagooning) meets the limits.
    
    For pickling operations treating rinse waters in conjunction
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    Pickling - Hydrochloric Acid - Concentrates.
    
    Dissolved  Iron.   For  pickling  operations  treating rinse
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    flow   of  209  1/kkg   (50  gal./ton).   Three  hydrochloric
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    complete  treatment  system which is the model for all BATEA
    treatment stages, the joint treatment system with the single
    thickener, and the small wire pickling operation  associated
    with  the  Hot  Coatings  -  Galvanizing subcategory.  These
    three widely different pickling operations deomonstrate that
                                 486
    

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    -------
    given proper lime treatment, the  BATEA  limitation  can  be
    consistently met.
    
    For  pickling operations utilizing joint treatment of rinses
    along with spent concentrates, the  BATEA  limitations  were
    discussed   previously  in  the  paragraphs  on  Pickling  -
    Hydrochloric Acid -Concentrates.
    
    Oil and Grease.  As discussed in  Section  IX,  some  plants
    find  it advantageous to treat pickling rinse waters jointly
    with cold rolling wastes.  The BATEA limitation for oil  and
    grease from such joint treatment operations is set at 0.0021
    kg/kkg   (0.0042  Ibs/ton),  equivalent  to  10  mg/1  in  a
    discharge flow of 209 1/kkg (50  gal./ton).   An  additional
    load  of  0.0021  kg/kkg  (0.0042 Ibs/ton)  is allowed if the
    plant  operates  in  wet  fume  hood  scrubber   system   in
    conjunction  with  the  pickling  operations.  The one plant
    surveyed practicing such joint treatment discharges  on  oil
    loading  of  87%  of  this  limit at the thickener overflow,
    indicating  that  the  limit  is  attainable  using  present
    equipment   and   technology.   For  plants  treating  spent
    concentrates and rinse waters  from  pickling  jointly  with
    cold  rolling  wastewaters,  the  BATEA  limits  for oil and
    grease are set at 0.0034 kg/kkg (0.0068 Ibs/ton), equivalent
    to 10 mg/1 in a discharge flow of 333 1/kkg   (80  gal./ton).
    An additional allowance of 0.0021 kg/kkg (0.0042 Ibs/ton) is
    provided if a wet fume hood scrubber system is used over the
    pickling tanks.
    
    pH.   As  in  all other subcategories, the BATEA ELGs for pH
    require it to be in the range 6.0 to 9.0.   Since  treatment
    with  alkalies  is  required to attain the recommended BATEA
    limits for dissolved iron, no further equipment  or  expense
    will be required to maintain the proper pH values.
    
    Cold Rolling Subcategory Operations
    
    The  degree  of  effluent  load  reductions achieved via the
    treatment and control  technology  required  to  attain  the
    BPCTCA limitations for recirculation, combination and direct
    application  cold rolling operations as described in Section
    IX  is  equivalent  to   the   best   available   technology
    economically achievable at this time.  To achieve additional
    reductions   would   require  expenditures  of  capital  and
    operating costs out of line with the benefits derived.   For
    this  reason,  the  BATEA  limitations  for the cold rolling
    operations are identical with the BPCTCA limitations in  all
    cases.   The  BATEA limitations for this subcategory and the
    control and treatment technology to achieve the  recommended
    limits are summarized in Tables 103, 104 and  105.
                               490
    

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