DRAFT
DEVELOPMENT DOCUMENT
for
EFFLUENT LIMITATIONS GUIDELINES
and
STANDARDS OF PERFORMANCE
MINERAL MINING AND PROCESSING INDUSTRY
VOLUME III
Clay, Ceramic, Refractory and Miscellaneous Minerals
USB
a
t
Contract No. 68-01-2633
December 1974
DRAFT
-------
Notice
The attached document is a DRAFT CONTRACTOR'S REPORT. It includes
technical information and recommendations submitted by the contractor
to the United States Environmental Protection Agency ("EPA") regarding
the subject industry. It is being distributed for review and comment
only. The report is not an official EPA publication and it has not
been reviewed by the Agency.
The report, including the recommendations, will be undergoing
extensive review by EPA, Federal and States agencies, public interest
organizations, and other interested groups and persons during the
coming weeks. The report and in particular the contractor's
recommended effluent limitations guidelines and standards of
performance is subject to change in any and all respects.
The regulations to be published by EPA under Section 304 (b) and 3C6
of the Federal Water Pollution Control Act, as amended, will be based
to a large extent on the report and the comments received on it.
However, pursuant to Sections 304 (b) and 306 of the Act, EPA will
also consider additional pertinent technical and economic information
which is developed in the course of review of this report by the
public and within EPA. EPA is currently performing an economic impact
analysis regarding the subject industry, which will be taken into
account as part of the review of the report. Upon completion of the
review process, and prior to final promulgation of regulations, an SPA
report will be issued setting forth EPA's conclusions concerning the
subject industry, effluent limitation guidelines and standards of
performance applicable to such industry. Judgments necessary to
promulgation of regulations under Sections 304 (b) and 306 of the Act,
of course, remain the responsibility of EPA. Subject to these
limitations, EPA is making this draft contractor's report available in
order to encourage the widest possible participation of interested
persons in the decision making process at the earliest possible time.
The report shall have standing in any EPA proceeding or court
proceeding only to the extent that it represents the views of the
Contractor who studied the subject industry and prepared the
information and recommendations. It cannot be cited, referenced, or
represented in any respect in any such proceedings as a statement of
EPA's views regarding the subject industry.
U. S. Environmental Protection Agency
Office of Water and Hazardous Materials
Effluent G^'felines Division
Washington, D. C. 20460
-------
DRAFT
DEVELOPMENT DOCUMENT
for
EFFLUENT LIMITATIONS GUIDELINES
and
STANDARDS OF PERFORMANCE
MINERAL MINING AND PROCESSING INDUSTRY
VOLUME III
Clay, Ceramic, Refractory and Miscellaneous Minerals
Contract No. 68-01-2633
December 1974
DRAFT
-------
DRAFT
ABSTRACT
This document presents the findings of an extensive study of
selected minerals in the clay, ceramic, refractory and
miscellaneous minerals segment of the mineral mining
industry for the purpose of developing effluent limitations
guidelines for existing point sources and standards of
performance and pretreatment standards for new sources, to
implement Sections 304, 306 and 307 of the Federal Water
Pollution Control Act, as amended (33 U.S.C. 1551, 1314,
and 1316, 86 Stat. 816 et. seq.) (the "Act").
Effluent limitations guidelines contained herein set forth
the degree of effluent reduction attainable through the
application of the best practicable control technology
currently available (BPCTCA) and the degree of effluent
reduction attainable through the application of 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 and pretreatment standards for new sources
contained herein set forth the degree of effluent reduction
which is achievable through the application of the best
available demonstrated control technology, processes,
operating methods, or other alternatives.
Based on the application of best practicable technology
currently available, 15 of the 22 production subcategories
(comprising 18 minerals) under study can be operated with no
discharge of process wastewater pollutants to navigable
waters. With the best available technology economically
achievable, 17 of the 22 production subcategories can be
operated with no discharge of process wastewater pollutants
to navigable waters. No discharge of process wastewater
pollutants to navigable waters is achievable as a new source
performance standard for all production subcategories except
kaolin (wet), feldspar (wet), talc minerals (flotation),
garnet, and graphite.
Supporting data and rationale for development of the
proposed effluent limitations guidelines and standards of
performance are contained in this report.
xix
DRAFT
-------
DRAFT
CONTENTS
Section
Abstract iii
I Conclusions 1-1
II Recommendations II-1
III Introduction III-1
Purpose and Authority III-1
Summary of Methods Used for
Development of Effluent
Limitations Guidelines and
Standards of Performance III-2
General Description of Industry
by Product III-8
Production of Minerals in
this Segment III-35
IV Industry Categorization IV-1
Introduction IV-1
Industry Categorization IV-1
Factors Considered IV-3
V Water Use and Waste Characterization v-1
Introduction V-1
Specific Water Uses V-1
Process Water Characterization v-U
VI Selection of Pollutant Parameters VI-1
Introduction VI-1
Significance and Rationale for
Selection of Pollution Para-
meters VI-1
Significance and Rationale for
Rejection of Pollution Para-
meters VI-8
VII Control and Treatment Technology VII-1
DRAFT
-------
DRAFT
CONTENTS
Introduction VII-1
Vii Problem Areas in the Clay,
Ceramic, Refractory and Miscel-
laneous Minerals Industries VII-2
Control Practices VII-5
Suspended Solids VII-8
Dissolved Material Treatments VII-13
Summary of Treatment Technology
Applications, Limitations and
Reliability VII-15
Pretreatment Technology VII-17
Non-Water Quality Environmental
Aspects, Including Energy
Requirements VII-18
VIII Cost Energy and Non-Water
Quality Aspects VIII-1
Summary VIII-1
Cost References and Rationale VIII-4
Individual Mineral Wastewater
Treatment and Disposal Costs VIII-9
Industry Statistics Vin-30
IX Effluent Reduction Attainable Through
the Application of the Best Prac-
ticable Control Technology Currently
Available IX-1
Introduction IX-1
General Water Guidelines IX-2
Process Wastewater Guidelines
and Limitations for the Clay,
Ceramics, Refractory and
Miscellaneous Minerals Point
Source Subcategories IX-6
X Effluent Reduction Attainable Through
Application of the Best Available
Technology Economically Achievable x-1
Introduction X-1
General Water Guidelines X-3
VI
DRAFT
-------
DRAFT
CONTENTS
Process Wastewater Guidelines
and Limitations for the Clay,
Ceramics, Refractory and
Miscellaneous Minerals Point
Source Subcategories X-6
XI New Source Performance standards and
Pretxeatment standards XI-1
Introduction XI-1
General Water Guidelines XI-2
Effluent Reduction Attainable by
the Best Available Demonstrated
Control Technologies, Processes,
Operating Methods or Other
Alternatives XI-2
Pretreatment Standards XI-4
XII Acknowledgements XII-1
XIII References XIII-1
XIV Glossary XIV-1
Vil
DRAFT
-------
DRAFT
CONTENTS
LIST OF FIGURES
Figure No. P3S§_E2-
TTT-3 1 1 supply-Demand Relationships for
Clays - 1968 111-10
III-3.5.1 supply-Demand Relationships for
Feldspar - 1968 111-15
III-3.6.1 Production and Uses of Kyanite and
Related Minerals III-17
111-3.9.1 production and Uses of Talc Minerals 111-24
111-3]11.1 Domestic Consumption of Diatomite 111-31
HI-3.12.1 supply-Demand Relationships for
Graphite - 1968 111-34
V-3.1.1 Bentonite Mining and Processing v_5
V-3.2.1 Fire clay Mining and Processing V_Q
V-3.3.1 Attapulgite Mining and Processing v-10
V-3.3.2 Montmorillonite Mining and Processing v-14
V-3.4.1 Kaolin {dry) Mining and Processing y-17
V-3.4.2 Kaolin (wet) Mining and Processing v-19
V-3.4.3 Ball Clay Mining and Processing v-23
V-3.5.1 Feldspar (wet) Mining and Processing v-27
V-3.5.2 Feldspar (dry) Mining and Processing v-3 4
V-3.6.1 Kyanite Mining and Processing v-36
V-3.7.1 Magnesite Mining and Processing v-'O
V-3.8.1 Shale Mining and Processing V-n
V-3.8.2 Aplite Mining and Processing v_,i(,
V-3.9.1 Talc (dry) Mining and Processing v-r)0
V-3.9.2 Talc (log washing) Mining and Processing v-51
V-3.9.3 Talc (wet screening) Mining and Processing v-52
V-3.9.4 Talc (flotation! Mining and Processing v-5G
V-3.9.5 Talc (impure ore) Mining and Processing V-j3
V-3.9.6 Pyrophyllite (heavy media) Mining and
Processing V-59
V-3.10.1 Garnet Mining and Processing v-64
V-3.10.2 Tripoli Mining and Processing V-67
V-3.11.1 Diatomite Mining and Processing V-70
V-3.12.1 Graphite Mining and Processing v_74
viii
DRAFT
-------
DRAFT
CONTENTS
V-3.13.1 Jade Mining and Processing Y-7C
V-3.13.2 Novaculite Mining and Processing v-GO
V-U.1 Daily/monthly Ratio of Several Plants v-33
DRAFT
-------
DRAFT
CONTENTS
LIST OF TABLES
Table No.
1-1 List of Clay, Ceramic, and Refractory
Minerals
II-1 summary of BPCTCA and BATEA
II-2 Recommended New Source
Performance Standards
III-1 1972 Production and Employment
Figures for Minerals in this Segment
IV-1 Industry Categorization
V-4.1 Ratio of Maximum Daily/Monthly Average
Effluent Data
V-5.1 Mine Water Pumpout Data
VII-1 Settling Characteristics of Suspended
Suspended Solids
VII-2 Comments on Treatment Technologies
Used in this Industry
VIII-1 Present Capital Investment and Energy
Consumption of Wastewater Treatment
Facilities
VIII-2 Treatment Costs for Representative
Attapulgite Plant
VIII-3 Treatment Costs for Representative
Montmorillonite Plant
VIII-4 Treatment Costs for Representative
Wet Process Kaolin Plant
VIII-5 Treatment Costs for Representative
Ball Clay Plant
VTII-6 Treatment Costs for Representative
Wet Process Feldspar Plant
VTII-7 Treatment Costs for Representative
Kyanite Plant
VIII-8 Treatment Costs for Representative
Wet Process Talc Minerals Plant
XIV-1 Conversion Table
No.
1-2
II-3
111-36
IV-3
V-58
V-]G
VII-4
VII-1G
VIII-3
VIII-10,
VI IT- 11
VTTI-'I 'J
VI I I- 16
VIII-19
VIII-22
VIII-26
XIV- 9
DRAFT
-------
DRAFT
SECTION I
CONCLUSIONS
For purposes of establishing effluent limitations guidelines
and standards of performance, and for ease of presentation,
the mineral mining industry has been divided into three
segments to be published in three volumes: minerals for the
construction industry; minerals for the chemical and
fertiliser industries; and clay, ceramic, refractory and
miscellaneous minerals. This division reflects the end use
of the mineral after mining and beneficiation. In this
volume covering clay, ceramic, refractory, and miscellaneous
minerals, the 13 minerals were grouped into 22 production
subcategories for reasons explained in Section IV.
Based on the application of best practicable technology
currently available, 15 of the 22 production subcategories
under study can be operated with no discharge of process
wastewater pollutants to navigable x^aters. With the best
available technology economically achievable, 17 of the
22 production subcategories can ;be operated with no
discharge of process wastewater pollutants to navigable
waters. No discharge of process wastewater pollutants to
navigable waters is achievable as a new source performance
standard for all production subcategories except kaolin.
(wot), feldspar (wet), talc minerals (flotation), garnet,
and graphite. Mine water discharge is not considered process
wastewater and is addressed separately.
This study included 13 clay, ceramic, and refractory
minerals of SIC categories, 1452, 1453, 1454, 1455, 1459,
1496 and 1499 with significant waste discharge potential.
Table 1-1 lists the minerals studied in this report.
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INEORI 1ATION IN THIS REPORT AND ARE SUBJECT TO CilAI.'GL BASED
UPON COn:-"ENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
1-1
DRAFT
-------
DRAFT
TABLE 1-1
LIST OF CLA*. CERAMIC. AND REFRACTORY MINERALS
1. Berrtonite
2. Fire Clay
3. Fuller's Earth
A. Attapulgite
B. Montmorillonite
4. Kaolin and Ball Clay
5. Feldspar
6. Kyanite
7. Magnesite (Naturally Occurring)
8. Shale and other Clay Minerals
A. Shale
B. Aplite
9. Talc, Soapstone, and Pyrophyllite
10. Natural Abrasives
A. Garnet
B. Tripoli
11. Diatomite
12. Graphite
13. Miscellaneous Non-Metallic Minerals
A. Jade
B. Novaculite
NOTICE: THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
1-2
DRAFT
-------
DRAFT
SECTION II
RECOMMENDATIONS
The recommended effluent limitations guidelines based on
best practicable control technology currently available
(BPCTCA), are no discharge of process wastewater pollutants
(defined in Section IX) to navigable waters for the
following minerals/processes:
bentonite
fire clay
fuller's earth (montmorillonite)
kaolin (dry process)
feldspar (dry process)
kyanite
magnesite (naturally occurring)
shale
aplite
talc minerals group (dry)
talc minerals group (ore mining and washing)
tripoli
diatomite
jade
novaculite
The above effluent limitations guidelines are also
recommended as the best available technology economically
achievable (BATEA) and the new source performance standards
(NSPS) for those minerals/processes listed.
The recommended effluent limitations guidelines based on
best practicable control technology currently available for
the remaining subcategories (not listed above) of the clay,
ceramic, refractory, and miscellaneous minerals segment of
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
II-1
DRAFT
-------
DRAFT
the mineral mining and processing industry are listed in
Table II-1.
The recommended effluent limitations guidelines based on
best available technology economically achievable are no
discharge of process wastewater pollutants to navigable
waters for the following minerals/processes:
ball clay
Fuller's earth (attapulgite)
The effluent limitations guidelines based on best available
technology economically available for the remaining
subcategories (not listed above) of this segment of the
mineral mining and processing industry are also listed in
Table II-1.
The new source performance standards for those subcategories
other than for those for which no discharge of pollutants in
process wastewater has been recommended (listed above) are
listed in Table II-2.
The recommended mine water discharge limitations for all
throe levels are a pH of G-9 and TSS of 21 rig/liter fo.r all
3ubcal:ogories in this segment of the industrv except
bontonite and fuller's earth (riontnorillonite) .
NOTICE: THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
II-2
DRAFT
-------
DRAFT
TABLE ll-l. Recommended BPCTCA and BATEA for the Cloy, Ceramic,
Refractory, ond Miscellaneous Minerals Segment of the
Mineral Mining and Processing Industry, far Process Water Only
Recommended
BPCTCA Guide-
Subcotegcry line (tcg/kkg) ** BPCTCA
TSS other
Bentonite none none *1
Fir* Clay none none 1
Fuller'i Earth
Atrapulgite 0.017 none 2
Montfnorillonire none none 3
Kaolin
Dry none none 1
Wet .0.1 Zn 0.002 4;2
Recommended
BATEA Guide-
KneflajAkg) ** BATEA
TSS other
none none Some as BPCTCA
none none Same as BPCTCA
none none 2+12+8
none none Same as BPCTCA
none none Same as BPCTCA
0.06 none 2+Sodium hydrosulfite
OS bleaching agent
Ball Clay 0.17 none 5;2Tfwet none none Same as BPCTCA
scrubbers
Feldspar
Dry none none 11
Wet 0.6 F'0.15 8;7;2
Kyanite none none 8;2
Magneslte none none 8; 2
(not. occurring)
Shale none none 1
Apllte none none 8;2
Talc Minerals Group
Dry none none 1
Ore Mining &
Washing none none 8;2
Flotation 0.5 none 7;2and/
or 10
Garnet 0.4 none 7;2
Tripoli none none 1
Dlatomite none none 9 and/or
B
Graphite 1.6 Mn 0.03 7;2
Fe 0.16
BOD 1.6
COD 2.3
Jade none none 2;9
Novaculite none none 3
* LEGEND
1 No process water used in mining or processing
2 Settling pond
3 Recycle scrubber water
4 Lime treatment (ppt.zinc)
5 Dry bog dust collector
6 Segregation of plant waste streams
7 pH monitoring and adjustment
8 Recycle
9 Evaporation pond
10 Clarification pond
11 Natural evaporation ||-3
12 Flocculants
13 Sond bed filtration ,«»«
DRAFT
+recycle of scrubber
water, where required.
none none Some as BPCTCA
0.6 F~Q. 1 Same as BPCTCA +
additional F~ reduction
none none Sane as BPCTCA
none none Sams as BPCTCA
none none Same as BPCTCA
none none Same as BPCTCA
none none Some as BPCTCA
none none Same as BPCTCA
0.3 none Same as BPCTCA
+converaion to 5
+oddit!anal 2
0.25 none Same as BPCTCA
+ 13 where necessary
none none Same os BPCTCA
none none Some as BPCTCA
Same m BPCTCA Sams as BPCTCA
No proven tech-
nology exists to
lower levels
none none Some as BPCTCA
none none Same as BPCTCA
**Kg/fclcg of product in all cases
except feldspar (wet) which is
fcg/kkg of ore processed .
NOTICE: THESE ARE TENTATIVE RECOM-
MENDATIONS BASED UPON
INFORMATION IN THIS REPORT
AND ARE SUBJECT TO CHANGE
BASED UPON COMMENTS RECEIVED
AND FURTHER INTERNAL REVIEW
BY EPA.
-------
DRAFT
TABLE II-2
RECOMMENDED NEW SOURCE PERFORMANCE STANDARDS
Subcategorv
Kaolin (wet)
Feldspar (wet)
Talc Minerals
(Flotation)
Garnet
Graphite
Limitations
kg/metric ton gibs/ton) of product*
Monthly average Daily maximum
Same as BATEA
TSS O.H (0.8)
fluoride 0.05 (0.1)
Same as BATEA
Same as BATEA
Same as BATEA
Same as BATEA
2.0 (4.0)
0.1 (0.2)
Same as BATEA
Same as BATEA
Same as BATEA
* For feldspar (wet) only, the limitations are expressed as
kg/metric ton (Ibs/ton) of ore processed.
2 ARE TENTATIVE RECOMMENDATIONS BASED UPON
TTPMMIN THIS REP°RT ™D *** SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA
DRAFT
-------
DRAFT
SECTION III
INTRODUCTION
1.0 PURPOSE AND AUTHORITY
The United States Environmental Protection Agency (EPA) is
charged under the Federal Water Pollution Control Act
Amendments of 1972 with establishing effluent limitations
which must be achieved by point sources of discharge into
the navigable water of the United States.
Section 301(bJ of the Act requires the achievement by not
later than July 1r 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 effluent reduction
attainable through the application of the best practicable
control technology currently available and the degree of
effluent reduction attainable through the application of the
best control measures and practices achievable including
DRAFT
-------
DRAFT
treatment techniques, process and procedure innovations,
operation methods and other alternatives. The regulations
proposed herein set forth effluent limitations guidelines
pursuant to Section 304(b) of the Act for the Mining of
Clay, Ceramic, Refractory and Miscellaneous Minerals segment
of the Mineral Mining and Processing Industry point source
category. 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 Administration published in the
Federal Register of January 16, 1973 (38 F.R. 1624), a list
of 27 source categories. Publication of an amended list
will constitute announcement of the Administrator's
intention of establishing, under Section 306, standards of
performance applicable to new sources within the mineral
mining and processing industry. The list will be amended
when proposed regulations for the Mineral Mining and
Processing Industry are published in the Federal Register.
2.0 SUMMARY OF METHODS USED FOR DEVELOPMENT OF EFFLUENT
LIMITATION GUIDELINES AND STANDARDS OF PERFORMANCE
The effluent limitations guidelines and standards of per-
formance proposed herein were developed in a series of sys-
tematic tasks. The Mineral Mining and Processing Industry
was first studied to determine whether separate limitations
and standards are appropriate for different segments within
a point source category. Development of reasonable industry
categories and subcategories, and establishment of effluent
guidelines and treatment standards requires a sound
understanding and knowledge of the Mineral Mining and
Processing Industry, the processes involved, wastewater
generation and characteristics, and capabilities of existing
control and treatment methods.
This report describes the results obtained from application
of the above approach to the mining of clay, ceramic,
refractory, and miscellaneous minerals segment of the
mineral mining and processing industry. Thus, the survey
and testing covered a wide range of processes, products, and
types of wastes.
III-2
DRAFT
-------
DRAFT
The products covered in this report are listed below with
their Sic designations:
a. Bentonite (1452)
b. Fire Clay (1453)
c. Fuller's Earth (1454)
d. Kaolin and Ball Clay (1455)
e. Feldspar (1459)
f. Kyanite (1459)
g. Magnesite (1459)
h. Shale and other clay minerals, N.E.C. (1459)
i. Talc, Soapstone and Pyrophyllite (1496)
j. Natural abrasives (1499)
k. Diatomite mining (1499)
1. Graphite (1499)
m. Miscellaneous Non-metallic minerals,
N.E.C. (1499)
Any of the above minerals which are processed only (3295)
are also included.
_2jJ. Categorization and Waste Load Characterization
The effluent limitation guidelines and standards of perform-
ance proposed herein were developed in the following manner.
The point source category was first categorized for the
purpose of determining whether separate limitations and
standards are appropriate for different segments within a
point source category. Such subcategorization was based
upon raw material used, product produced, manufacturing
process employed, and other factors. The raw wastes
characteristics for each subcategory were then identified.
This included an analysis of (1) the source and volume of
water used in the process employed and the sources of waste
and waste waters in the plant; and (2) the constituents of
all wastewaters including harmful constituents and other
constituents which result in degradation of the receiving
water. The constituents of wastewaters which should be
subject to effluent limitations guidelines and standards of
performance were identified.
2.2 Treatment and Control Technologies
The full range of control and treatment technologies
existing within each subcategory was identified. This
III-3
DRAFT
-------
DRAFT
included an identification of each control and treatment
technology, including both in-plant and end-of-process tech-
nologies, which are existent or capable of being designed
for each subcategory. It also included an identification Of
the amount of constituents (including thermal) and the
characteristics of pollutants resulting from the application
of each of the treatment and control technologies. The
problems, limitations and reliability of each treatment and
control technology were also identified. In addition, the
non-water 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.
2.3 Data Base
Cost information contained in this report was obtained
directly from industry during plant visits, from engineering
firms and equipment suppliers, and from the literature. The
information obtained from the latter three sources has been
used to develop general capital, operating and overall costs
for each treatment and control method. Costs have been put
on a consistent industrial calculation basis of ten year
straight line depreciation plus allowance for interest at
ten percent per year (pollution abatement tax free money)
and inclusion of allowance for insurance and taxes for an
overall fixed cost amortization of fifteen percent per year.
This generalized cost data plus the specific information
obtained from plant visits was then used for cost effective-
ness estimates in Section VIII and wherever else costs are
mentioned in this report.
The data for identification and analyses were derived from a
number of sources. These sources included EPA research
information, published literature, qualified technical
consultation, on-site visits and interviews at numerous
mining and processing plants throughout the U.S., interviews
and meetings with various trade associations, and interviews
and meetings with various regional offices of the EPA. All
references used in developing the guidelines for effluent
limitations and standards of performance for new sources
reported herein are included in Section XIII of this report.
III-4
DRAFT
-------
DRAFT
2.ft Exemplary Plant Selection
The following selection criteria were developed and used for
the selection of exemplary plants.
a) Discharge effluent quantities
Plants with low effluent quantities or the ultimate of no
discharge of process wastewater pollutants were preferred.
This minimal discharge may be due to reuse of water, raw
material recovery and recycling, or to use of evaporation.
The significant parameter was minimal waste added to
effluent streams per weight of product manufactured. The
amounts of wastes considered here were those added to waters
taken into the plant and then discharged.
b) Effluent contaminant level
Preferred plants were those with lowest effluent contaminant
concentrations and lowest total quantity of waste discharge
per unit of product.
c) Water management practices
Use of good management practices such as water re-use, plan-
ning and in-plant water segregation, and the proximity of
cooling towers to operating units where airborne
contamination of water can occur were considered.
d) Land utilization
The efficiency of land use was considered.
e) Air pollution and solid waste cgntrol
Exemplary plants must possess overall effective air and
solid waste pollution control where relevant in addition to
water pollution control technology. Care was taken to
insure that all plants chosen have minimal discharges into
the environment and that exemplary sites are not those which
are exchanging one form of pollution for another of the same
or greater magnitude.
III-5
DRAFT
-------
DRAFT
f) Effluent treatment methods and their effectiveness
Plants selected shall have in use the best currently
available treatment methods, operating controls, and
operational reliability. Treatment methods considered
included basic process modifications which significantly
reduce effluent loads as well as conventional treatment
methods.
g) Plant facilities
All plants chosen as exemplary had all the facilities
normally associated with the production of the specific
product(s) in question. Typical facilities generally were
plants which have all their normal process steps carried out
on-site.
n) Plant management philosophy
Plants were preferred whose management insists upon
effective equipment maintenance and good housekeeping
practices. These qualities are best identified by a high
operational factor and plant cleanliness.
i) Geographic location
Factors which were considered include plants operating in
close proximity to sensitive vegetation or in densely
populated areas. Other factors such as land availability,
rainfall, and differences in state and local standards were
also considered.
j) Raw materials
Differences in raw materials purities were given strong con-
sideration in cases where the amounts of wastes are strongly
influenced by the purity of raw materials used. Several
plants using different grades of raw materials were
considered for those minerals for which raw material purity
is a determining factor in waste control.
III-6
DRAFT
-------
DRAFT
M Diversify of progesseg
On the basis that all of the above criteria are met,
consideration was given to installations having a
multiplicity of manufacturing processes. However, for
sampling purposes, the complex facilities chosen were those
for which the wastes could be clearly traced through the
various treatment steps.
1) Production
On the basis that other criteria are equal, consideration
was given to the degree of production rate scheduled on
water pollution sensitive equipment.
m) Product purj,tv
For cases in which purity requirements play a major role in
determining the amounts of wastes to be treated and the
degree of water recycling possible, different product grades
were considered for subcategorization.
III-7
DRAFT
-------
DRAFT
GENERAL DESCRIPTION OF INDUSTRY BY PRODUCT
Clays and other ceramic and refractory materials differ
primarily because of varying crystal structure, presence of
significant non-clay materials, variable ratios of alumina
and silica, and variable degrees of hydration and hardness.
This industry, together with ore mining and coal mining, _
differs significantly from the process industries for which
effluent limitation guidelines have previously been
developed. The industry is characterized by an extremely
variable raw waste load, depending almost entirely upon the
characteristics of then natural deposit. The prevalent
pollutant problem is suspended solids, which vary
significantly in. .quantity and treatability .
Clays are a group of important fine-grained nonmetallic
minerals which are mostly hydrous aluminum silicates
containing various amounts of other inorganic and some
organic materials. Some clays, notably the bentonites , have
small but important components of exchangeable ions which
impart desirable characteristics such as, for the
sodium-base bentonite, the ability to swell to many times
the original clay volume in water and thus to form a
thixotropic gel. Many clays, in particular the fuller's
earths, are highly absorptive and others also can be
activated by various treatments to become effective
absorbents .
Most clays are mined from open pits, using modern surface
mining equipment such as draglines, power shovels ,
scraper-loaders, and shale planers. A few clay pits are
operated using crude hand-mining methods. A small number of
clay mines (principally underclays in coal-mining areas) are
underground operations employing mechanized room and pillar
methods. Truck haulage from the pits to processing plants
is most common, but other methods involve use of rail
transport, conveyor belts, and pipelines in the case of
kaolin. Recovery is near 100 percent of the minable beds in
open-pit mines, and perhaps 75 percent in the underground
operations. The waste-to-clay ratio is highest for kaolin
(about 7:].) and lowest for miscellaneous clay (about
0.25:]).
III-8
DRAFT
-------
DRAFT
Processing of clnys ranges from very simple and inexpensive
crushing anil screening for some common clays to very
elaborate and expensive methods necessary to produce paper
coating clays and high-quality filler clnys for use in
rubber, paint, and other products. Waste material fxfom
processing consists mostly of quartz, mica, feldspar, and
iron minerals.
Clays are classified into six groups in Bureau of Mines
publications. These are kaolin, ball clay, fire clay,
bentonite, fuller's earth, and miscellaneous clay.
Halloysite is included under kaolin in Bureau of Mines
statistical reports. Specifications of clays are based on
tho method of preparation (crude, air separated, water
washed, delaminated, air dried, spray dried, calcined, slip,
pulp, slurry, or water suspension), in addition to specific
physical and chemical properties.
Pentonito (SIC 3452)
Dentonitcs are composed essentially of minerals of the
montmorillonite group. The swelling type has a high sodium
ion concentration which causes a material increase in volume
when the clay is wetted with water, whereas the nonswelling
types usually contain high calcium ion concentrations.
Standard qrades of swelling bentonite increase from )5 to 20
times their dry volume* on exposure to water. Specifications
are based on pertinent physical and chemical tests,
particularly those relating to particle size and swelling
index. Bentonite clays are processed using the following
processes: weathering, drying, grinding, sizincr, and
granulation. The supply-demand relationships for bentonite
and other clays for 1968 are shown in Figure 111-3,3.3.
3.2 Fire Clay (SIC. 3453)
The terms "fire clays" and "stoneware clays" are based on
refractoriness or on tho intended usage (fire clay
indicating potential use for refractories, and stoneware
clay indicating use for such items as crocks, jugs, and
jars). Fire clays are basically kaolinitic but usually
include other clay minerals and impurities. Included under
tho general term fire clay are the diaspore, burley, and
burloy-flint clays. The fired colors of fire clays range
from reds to buffs and grays. Specifications are based on
pertinent physical an* e*f»nir*:i tests of the clays, and of
products made from them.
The fire clays are processed by crushing, calcining and
final blending.
III-9
DRAFT
-------
I
M;
O
WORLD PRODUCTION
It 350,000
Other
North Americo
£/ 12,767
South America
& 12.000
U.S.S.R.
-*/S5,OOO
West Garmony
.5/25,000
Jopon
$/ 28,000
Fronc«
1/16,000
Other Asia
«/ 37,000
Africa
.1/IO,OOO
Italy
.4/17,000
CtharCountrle*
.S/64,000
1
United Statei
57,233
United Kingdorr
J/16,000
KEY
Units: Thousand sho
-H
1
— !
— 1
1 i
— s
— <
I to
Kaolin
4,201
Boll clay
630
Fire cloy
8,054
Bentonfte
2. 438
Fuller* earth
922
Olhtr c!sy*
40,939
Import), kcoliri
75
Tirorts, boil
day
IS
Imports.ottwr
4
i«
••H
•••^
^^^H
^^•M
, U.S.i«ppI» . U.S.d«nvmd
57,529 55.810
Ei ports
M ..520
_£/ Estimate
SIC Standard Industrial CloisKicatlon
Structural day pfoducn
rsie 3
23.656
Hydraulic cement
tsicsun
11.234
Expanded snate and
clay
I SIC 3193)
9,280
Figure 111-3.T.I Supply-Demand Relationships for Clays, 1968.
Iron and steef
isiesiitl
2.40O
,'Jonferrous metals
ISIC1}}.13411
1.125
Gl a &s
211-Stltt
477
Paper mills
1,800
Founcry sands
(SIC3131I
6SO
Pottery anii related
product!
tsicstt) '
494
Drilling mud
Is ic it an
520
Iron ore
I Si e 10 III
410
Other
3,714
-------
DRAFT
3.3 Fuller's Earth (SIC 1454)
The term "fuller's earth" is derived from the first major
use of the material, which was for cleaning wool by fullers.
Fuller's earths are essentially montmorillonite or
attapulgite for which the specifications are based on the
physical and chemical tests of the products. Major uses are
for decolorizing oils, edible fluids, and for cat litter.
The fuller's earth clays are processed by blunging,
extruding, drying, crushing, grinding and finally sizing
according to the requirements of its eventual use.
3^4 Kaolin and Ball Clay (SIC 1455)
Ball clays consist principally of kaolinite, but have a
higher silica-to-alumina ratio than is found in most kaolins
in addition to larger quantities of mineral impurities and,
often, much organic material. They are usually much finer
grained than kaolins and, in general, set the standards for
plasticity of clays. Specifications for ball clays are
based on methods of preparation (crude, shredded, air
floated) and pertinent physical and chemical tests, which
are much the same as those for kaolin.
The last Bureau of Mines category of clays, is the
miscellaneous clay category. Miscellaneous clay may contain
some kaolinite and montmorillonite, but usually illite
predominates, particularly in the shales. There are no
specific recognized grades based on preparation, and very
little based on usage, although such a clay may sometimes be
referred to as common, brick, sewer pipe, or tile clay.
Specifications are based on the physical and chemical tests
of the products.
Most of the environmental disturbance related to clay mining
and processing is concerned with miscellaneous clays, which
are used mostly for making heavy clay construction products,
lightweight aggregates, and cement. The environmental
considerations are significant, not because the waste
products from clay mining are particularly offensive, but
because of the large number of operations and the necessity
for locating them in or near heavily populated consumption
centers. The principal environmental factors involved are
dust, noise, and unsightly or incongruous appearance.
Ill-11
DRAFT
-------
DRAFT
Inadequate long-range area planning has often contributed to
the environmental disturbance in the past, but the growing
awareness of the need for orderly development of area
resources should result in improvements in the future.
Environmental disturbances in kaolin mining and processing
are of major concern in central Georgia, where most of the
high-quality filler grades are produced. Although the clay
mining for the most part is not in areas of high population
density, the mined areas are extensive, and large amounts of
materials are generated. On occasion, flash floods may dump
significant quantities of clay wastes into local streams,
and although the wastes are not reactive, temporary
overloading of the streams might be harmful to some types of
marine life. Steps are being taken to alleviate the
undesirable conditions by rapid rehabilitation of mined
areas and by using the waste materials as fill.
Ball clay mining contributes little mineral waste each year,
and since it is spread over several states, does not
contribute substantially to environmental disturbance by the
clay industry.
3,5 Feldspar
Feldspar is a general term used to designate a group of
closely related minerals, especially abundant in igneous
rocks and consisting essentially of aluminum silicates in
combination with varying proportions of potassium, sodium,
and calcium. The principal feldspar species are orthoclase
or microcline (both K2O«Al2O3«6SiO2), albite
(Na2O«AJ2O3«6siO2) , and anorthite (CaO«A.12O3»2SiO2) .
Specimens of feldspar closely approaching the ideal
compositions are seldom encountered in nature, however, and
nearly all potash feldspars contain significant proportions
of soda. Albite and anorthite are really the theoretical
end members of a continuous compositional series known as
the plagioclase feldspars, none of which, moreover, is
ordinarily without at least a minor amount of potash.
Originally, only the high-potash feldspars were regarded as
desirable for most industrial purposes. At present,
however, in many applications the potash and the soda
varieties, as well as mixtures of the two, are considered to
be about equally acceptable. Perthite is the name given to
111-12
DRAFT
-------
DRAFT
material consisting of orthoclase or microcline, the
crystals of which are intergrown to an indefinite and
variable degree with crystals of albite. Most of the
feldspar of commerce can be classified most correctly as
perthite. Anorthite and the plagioclase feldspars are of
limited commercial importance.
Until a few decades ago virtually all the feldspar employed
in industry was material occurring in pegmatite deposits as
massive crystals pure enough to require no treatment other
than hand cobbing to bring it to usable grade. More
recently, however, stimulated by the often unfavorable
location of the richer pegmatite deposits relative to
markets and by the prospect of eventual exhaustion of such
sources, technological advances have created a situation in
which more than 90 percent of the total current domestic
supply is extracted from such feldspar-bearing rocks as
alaskite and from beach sands. A large part of the material
obtained from beach sands is in the form of feldspar-silica
mixtures that can be used, with little or no additional
processing, as furnace feed ingredients in the manufacture
of glass. In fact, this use is so predominant that
feldspathic sands are considered in volume II of this
document under industrial sands.
Feldspar and feldspathic materials in general are mined by
various systems depending upon the nature of the deposits
being exploited. Because underground operations entail
higher costs, as long as overburden ratio will permit and
unless land-use conflicts are a decisive factor, most
feldspathic rocks will continue to be quarried by open-pit
procedures using drills and explosives. Feldspathic sand
deposits are mined by dragline excavators.
High-grade, selectively mined feldspar from
coarse-structured pegmatites can be crushed in jaw crushers
and rolls and then subjected to dry milling in flint-lined
pebble mills.
Feldspar ores of the alaskite type are mostly beneficiated
by froth flotation processes. The customary procedure
begins with primary and secondary comminution and fine
grinding in jaw crushers, cone crushers, and rod mills,
respectively. The sequence continues with acid-circuit
flotation in three stages, each stage preceded by desliming
111-13
DRAFT
-------
DRAFT
and conditioning. The first flotation step depends on an
amine collector to float off and remove mica, and the second
uses sulfonated oils to separate iron-bearing minerals. The
third step floats the iron- and mica-free feldspar with
another amine collector, leaving behind a residue that
consists chiefly of quartz.
The supply-demand relationships for feldspar in 1968 are
shown in Figure III-3.5.1.
3.6 Kyanite JSIC 1<*59>
Kyanite and the related minerals andalusite,
sillimanite, dumortierite, and topaz are natural
aluminum silicates which can be converted by heating to
mullite, a stable refractory raw material with some
interstitial glass also being formed. Dumortierite contains
boron, and topaz contains fluorine, both of which vaporize
during the conversion to mullite.
With exception of the production of a small amount of
by-product kyanite-sillimanite from Florida heavy mineral
operations, the bulk of domestic kyanite production is
derived from two mining operations in Virginia, operated by
the same company, and one in Georgia. The mining and
process methods used by these producers are basically the
same. Mines are open pits in which the hard rock must be
blasted loose. The ore is hauled to the nearby plants in
trucks where the ore is crushed and then reduced in
rodmills. Three-stage flotation is used to obtain a kyanite
concentrate. This product is further treated by magnetic
separation to remove most of the magnetic iron in a high
iron fraction which is wasted. Some of the concentrate is
marketed as raw kyanite, while the balance is further ground
and/or calcined to produce mullite.
Florida beach sand deposits are worked primarily for zircon
ant titanium minerals, but the tailings from the zircon
recovery units contain appreciable quantities of sillimanite
and kyanite, which can be recovered by flotation and
magnetic separations. Production and marketing of Florida
sillimanite-kyanite concentrates started in 1968.
Ill-14
DRAFT
-------
DRAFT
WORLD PRODUCTION
2,123
I
E«llmalt
UNIT: Thoutand long Ion*
SIC! Standard Induttrlol cloislflcalloA
Figure 111-3.5.1 Supply-Demand Relationships for Feldspar, 1968
111-15
DRAFT
-------
DRAFT
The kyanite producers are located in areas of low population
density, and since the waste minerals generated by mining
and processing of kyanite ore are relatively inert, and
settle rapidly, they present no appreciable environmental
problem. The land area involved in kyanite operations is
not extensive.
The production and uses of kyanite and related minerals are
shown in Figure III-3.6.1.
3^7 Maanesite (SIC 1459)
Magnesium is the eighth most plentiful element in the earth
and, in its many forms, makes up about 2.06 percent of the
earth's crust. Although it is found in 60 or more
materials, only four, dolomite, magnesite, brucite, and
olivine, are used commercially to produce its compounds.
Currently dolomite is the only domestic ore used as
principal raw material for producing magnesium metal. Sea
water and brines are also principal sources of magnesium,
which is the third most abundant element dissolved in sea
water, averaging 0.13 percent magnesium by weight.
Dolomite, the double carbonate of magnesium and calcium and
a sedimentary rock commonly interbedded with limestone,
extends over large areas of the United States. Most
dolomites are probably the result of replacement of calcium
by magnesium in preexisting limestone beds.
Magnesite, the natural form of magnesium carbonate, is found
in bedded deposits, as deposits in veins, pockets, and shear
zones in ferro-magnesium rocks, and as replacement bodies in
limestone and dolomite. Significant deposits occur in
Nevadar California, and Washington. Brucite, the natural
form of magnesium hydroxide, is found in crystalline
limestone and as a decomposition product of magnesium
silicates associated with serpentine, dolomite, magnesite,
and chromite.
Olivine, or chrystolite, is a magnesium iron silicate
usually found in association with other igneous rocks such
as basalt and gabbro. It is the principal constituent of a
rock known as dunite. Commercial deposits are in
Washington, North Carolina, and Georgia.
Ill-16
DRAFT
-------
DRAFT
WORLD PRODUCTION
jt/ 340
I
Government stockpile bolonce.... 5
KEY
«/ Estimate
QJ Kyonite
.b/ Sillimonltt
cj Andalusile
4j Synthetic mullite
SIC Standard Industrial Classification
Unit: Thousand short ton»
Figure 111-3.6.1 Supply-Demand Relationship for Kyanite and
Related Minerals, 1968
111-17
DRAFT
-------
DRAFT
Evaporites are deposits formed by precipitation of salts
from saline solutions. They are found both on the surface
and underground. The Carlsbad, New Mexico, and the Great
Salt Lake evaporite deposits are sources of magnesium
compounds. The only significant commercial source ot
magnesium compounds from well brines is in Michigan,
although brines are known to occur in many other areas.
Mining. Selective open-pit mining methods are being used to
mine magnesite at Gabbs, Nevada. This plant is the only
known U.S. facility that produces magnesia from naturally
occurring magnesite ore.
Processing. Dolomite, magnesite, and brucite ore is
delivered from the mines to gyratory or jaw crushers where
it is reduced to a minus 5-inch size and carried by belt
conveyors to storage piles. The crushed ore is processed
according to the manner in which it is to be used. In the
case of dolomite, an appreciable quantity of raw, crushed
ore is delivered directly to the iron and steel plants and
is used as dead-burned dolomite.
In the magnesite refractory plants, the minus 5-inch ore is
conveyed to cone crushers which reduce it to sizes averaging
5/8-inch to minus 3/8-inchr and it is screened and washed.
The screens are equipped with washing sprays. The minus
3/8-inch ore is then passed over rake classifiers to remove
slimes and is ground in ball mills to 98 percent minus
100 mesh; the ground discharge from the ball mills is
conveyed to flotation cells where a silicate flotation
removes the impurities. The cleaned concentrate is filtered
and dried, then conveyed to the reduction plant.
Refractory magnesia is produced from crude magnesite by
calcining the ore in rotary kilns at temperatures ranging
from 2,640° to 3,200°F. Two classes of refractory magnesia
are made: brick grade and maintenance grade. Periclase is
produced when a pure grade of MgO is calcined at
temperatures above 3,1000F. Brucite is beneficiated in a
heavy media process for use as refractory material.
When the source of magnesia is sea water or well brine, the
waters are treated with calcined dolomite or lime obtained
from oyster shell by calcining, to precipitate the magnesium
as magnesium hydroxide. The magnesium hydroxide slurry is
III-18
DRAFT
-------
DRAFT
filtered to remove water, after which it is conveyed to
rotary kilns fired to temperatures that may be as high as
1850°C (3,360°F). The calcined product contains
approximately 97 percent MgO.
The principal uses for magnesium compounds follow:
Compound and grade Use
Magnesium oxide:
Refractory grades
Caustic-calcined
U.S.P. and technical
grades
Precipitated magnesium
carbonate
Magnesium hydroxide
Magnesium chloride
Basic refractories.
Cement, rayon, fertilizer,
insulation, magnesium metal,
rubber, fluxes, refractories,
chemical processing and manu-
facturing, uranium processing,
paper processing.
Rayon, rubber (filler and
catalyst), refractories, medi-
cines, uranium processing,
fertilizer, electrical insula-
tion, neoprene compounds and
other chemicals, cement.
Insulation, rubber, pigments
and paint, glass, ink, ceramics,
chemicals, fertilizers.
Sugar refining, magnesium oxide,
Pharmaceuticals.
Magnesium metal, cement, ceramics,
textiles, paper, chemicals.
Basic refractories used in metallurgical furnaces are
produced from magnesium oxide and accounted for over
80 percent ot total domestic demand for magnesium in 1968.
Technological advances in steel production required higher
temperatures which were met by refractories manufactured
from high-purity magnesia capable of withstanding
temperatures above 1930°C (3,500°F).
Ill-19
DRAFT
-------
DRAFT
3.8 Shale and Other Clay Minerals tLiEiC
3.8.1 Shale
Shale is a soft laminated sedimentary rock in which the
constituent particles are predominantly of the clay grade.
Just as clay possesses varying properties and uses, the same
can be said of shale. Thus, the word shale does not connote
a single mineral, inasmuch as the properties of a given
shale are largely dependent on the properties of the
originating clay species.
Mining of shales depends on the nature of the specific
deposit and on the amount and nature of the overburden.
Some deposits are mined underground, however, the majority
of shale deposits are worked as open quarries.
Shales and common clays are used interchangeably in the
manufacture of formed and fired ceramic products and are
frequently mixed prior to processing for optimization of
product properties. This type of product consumes about
70 percent of shale production. Certain impure shales (and
clays) have the property of expanding to a cellular mass
when rapidly heated to 1000°-1300°C. On sudden cooling, the
melt forms a porous slag-like material which is screened to
produce a lightweight concrete aggregate (60-110 lb/ft.3) .
Probably 20-25 percent of the total market for shale goes
into aggregate production.
3«8.2 Aplite
Aplite is a granitic rock of variable composition with a
high proportion of soda or lime-soda feldspar. It is
therefore useful as a raw material for the manufacture of
container glass. Processing of the ore is primarily for the
purpose of obtaining sufficient particle size reduction and
for removing all but a very small fraction of iron- bear ing
minerals.
Aplite of sufficient quality is produced in the U.S. from
only two mines, both in Virginia (Nelson County and Hanover
County) . The aplite rock in Hanover County has been
decomposed so completely that it is mined without resort to
drilling and/or blasting.
111-20
DRAFT
-------
DRAFT
3.8.3 Nepheline Syenite
Nepheline syenite is a feldspathic, igneous rock which
contains little or no free silica, but does contain
nepheline (K2O3Na2O4A12O3«9SiO2) . The valuable properties
of nepheline are the same type as those of feldspar,
therefore, nepheline syenite, being a mixture of the two, is
a desirable ingredient of glass, whiteware and ceramic
glazes and enamels.
A high quality nepheline syenite is mined in Ontario,
Canada, and is being imported into the U.S. in
ever-increasing quantities for ceramics manufacture.
Deposits of the mineral exist in the U.S. in Arkansas, New
Jersey, and Montana, but mining occurs only in Arkansas,
just outside of Little Rock. There, the mineral is mined in
open pits as a secondary product to crushed rock. Since
this is the only mining of this material in the U.S., it
will not be considered further.
3.9 Talc, soapstone and Pvrophvllite (SIC 1496)
The mineral talc is a soft, hydrous magnesium silicate,
3MgO«4SiO2«H2O. The talc of highest purity is derived from
sedimentary magnesium carbonate rocks; less pure talc from
ultra basic igneous rocks; and pyrophyllite, a hydrous
aluminum silicate similar to talc in most properties and
applications, from acidic igneous rocks.
Steatite has been used to designate a grade of industrial
talc that is especially pure and is suitable for making
electronic insulators. Block steatite talc is a massive
form of talc that can be readily machined, has a uniform low
shrinkage in all directions, has a low absorption when fired
at high temperature, and gives proper electrical resistance
values after firing. Phosphate bonded talc which is
approximately equivalent to natural block can be
manufactured in any desired amount.
French chalk is a soft, massive variety of talc used for
marking cloth.
111-21
DRAFT
-------
DRAFT
Soapstones refer to the sub-steatite, massive varieties of
talc and mixtures of magnesium silicates which with few
exceptions have a slippery feeling and can be carved fcy
hand.
Pyrophyllite is a hydrous aluminum silicate similar to talc
in properties and in most applications, and its formula is
Al2.03«4Si02«H20.
Wonderstone is a term applied to a massive block pyro-
phyllite from the Republic of South Africa.
During 1968 talc was produced from 52 mines in Alabama,
California, Georgia, Maryland, Montana, Nevada, New York,
North Carolina, Texas, and Vermont. Soapstone was produced
from 13 mines in Arkansas, California, Maryland, Nevada,
Oregon, Virginia, and Washington. Pyrophyllite was produced
from 10 mines in California and North Carolina.
Sericity-schist, closely resembling pyrophyllite in physical
and chemical properties, was produced in Pennsylvania and
included with pyrophyllite statistics.
Slightly more than half of the industrial talc is mined
underground and the rest is quarried as is soapstone and
pyrophyllite. Small quantities of block talc also are
removed by surface method. Underground operations are
usually entirely within the ore body and thus require timber
supports that must be carefully placed in talc operations
because of the slippery nature of the ore.
Mechanization of underground mines has become common in
recent years, especially in North Carolina and California
where the ore body ranges in thickness from 10 to 15 feet
and dips 12 to 19 degrees from horizontal. In those mines
where the ore body suffers vein dips of greater than 20
degrees, complex switch backs are introduced to provide the
gentle slopes needed for easier truck haulage of the ore.
At one quarry in Virginia, soapstone for decorative facing
is mined in large blocks approximately 4 by 8 by 10 feet
which are cut into slices by gang saws with blades spaced
about 3 inches apart. In the mining of block talc of crayon
grade, a minimum of explosive is used to avoid shattering
the ore; extraction of the blocks being accomplished with
hand equipment to obtain sizes as large as possible.
111-22
DRAFT
-------
DRAFT
When mining ore of different grades within the same deposit,
selective mining and hand sorting must be used. Operations
of the mill and mine are coordinated, and when a certain
specification is to be produced at the mill, the desired
grade of ore is obtained at the mine. This type of mining
and/or hand sorting is commonly used for assuring the proper
quality of the output of crude talc-group minerals.
Roller mills, in closed circuit with air separators, are the
most satisfactory for fine grinding (100- to 325-mesh) of
soft talcs or pyrophyllites. For more abrasive varieties,
such as New York talc and North Carolina ceramic-grade
pyrophyllite, grinding to 100 to 325 mesh is effected in
quartzite- or silex-lined pebble mills, with quartzite
pebbles as a grinding medium. These mills are ordinarily in
closed circuit with air separators but some times are used
as batch grinders, especially if reduction to finer particle
sizes is required.
Talc and pyrophyllite are amenable to processing in an addi-
tional microgrinding apparatus. Microgrinding or
micronizing is also done in fluid-system with subsequent air
drying of the product.
The production and uses of talc, soapstone and pyrophyllite
are shown in Figure III-3.9.1.
J3i.10 Natural Abrasives
Abrasives consist of materials of extreme hardness that are
used to shape other materials by grinding or abrading
action. Such materials may be classified as either natural
or synthetic (manufactured). Of interest here are the
natural abrasive minerals which include cleamorid, corundum,
emery, pumice, tripoli and garnet. Of lesser importance,
other natural abrasives include feldspar, calcined clays,
chalk and silica in its many forms such as sandstones, sand,
flint and diatomite.
111-23
DRAFT
-------
a | H
£! H
WORLD PRODUCT/ON
4,738
1
1
Japan
1,853
U.S.S.R.
*J 408
India
194
China
*/ 165
Rumania
JE/ 143
South Korea
165
Norway
J/88
Austria
-§/ 86
Brazil
-2/ 64
}
United States
958
France
_l/232
Italy
-S/I25
Canada
78
Other
*J 169
g Imports
24
JL
JL
P Industry stocks
1 / 1 / R ft
zaKcnfl | / | / O O
3J 13!
mil JIIKI
Industry stocks
r~* . 12/31/68
^/ 161
U.S. supply U.S. demand
J/ 1, 13 "^ 886
Exports
66
KEY
J/ Estimate
SIC Standard Industrial Classification
Units: Thousand short tons
Ceromlc*
ISIC32S3.3263.3Z64.
3i69)
24 8
Paint
(SIC 28 51)
I 70
Roofing
(SIC295Z)
85
Insecticides
(SIC 2879)
69
Paper
(SIC ZGZI)
39
Refractories
(SIC 3 2 S3)
34
Rubber
(S/C3069)
24
Toilet preparations
(SIC 28 44)
35
Other
182
I
H
Figure 111-3.9.1 Supply-Demand Relationships for Talc, Soapsfone, and Pyrophyllire, 1968
-------
DRAFT
Corundum
Corundum is a mineral with the composition A12O3
crystallized in the hexagonal system which was formed by
igneous and metamorphic processes.
Abrasive grade corundum has not been mined in the United
States for more than 60 years. There is no significant
environmental problem posed by the processing of some 2,360
kkg of corundum per year (1968 data).
Emery
Emery consists of an intimate admixture of corundum with
magnetite or hematite, and spinel.
The major domestic use of emery involves its incorporation
into aggregates as a rough ground product for use as heavy
duty non-skid flooring and for skid resistant highways.
Additional quantities (25 percent of total consumption) are
used in general abrasive applications.
Recent statistics show the continuing down-turn in demand
for emery resulting from the increasing competition with
such artificial abrasives as A12O3 and Sic. Emery was not
considered further in this report because it was not deemed
economically significant.
Tripoli
Tripoli is the generic name applied to a number of fine
grained, light weight, friable, minutely porous, forms of
decomposed siliceous rock, presumably derived from siliceous
limestones or calcareous cherts. Tripoli is often confused,
in both the trade and technical literature, with tripolite,
a diatomaceous earth (diatomite), found in Tripoli, North
Africa.
The two major working deposits of tripoli are those in the
Seneca, Missouri area and in southern Illinois. The
Missouri ore resembles tripolite and was incorrectly named
tripoli the name has persisted and now has definite
physical and trade association with the ore from the
Missouri-Oklahoma field. The material from the southern
Illinois area is often refered to as "amorphous" or "soft"
111-25
DRAFT
-------
DRAFT
silica. In both cases the ore contains 97 to 99 percent
Si02 with minor additions of alumina, iron, lime, soda and
potash. The rottenstone obtained from Pennsylvania is of
higher density and has a composition approximately 60
percent silica, 18 percent alumina, 9 percent iron oxides, 8
percent alkalies and the remainder lime and magnesia.
Tripoli mining involves two different processes depending on
the nature of the ore and of the overburden. In the
Missouri-Oklahoma area, the small overburden of
approximately six feet in thickness coupled with tripoli
beds ranging from 2 to 14 feet in thickness, lends itself to
open pit mining. The tripoli is first hand sorted for
texture and color, then piled in open sheds to air dry (the
native ore is saturated with water) for three to six months.
The dried material is subsequenly crushed with hammer mills
and rolls.
In the southern Illinois field, due to the terrain and the
heavy overburden, underground mining using a modified room-
and-pillar method is practiced. The resulting ore is
commonly wet milled after crushing to 1/4 to 1/2 inch
sizing, the silica is fine-ground in tube mills using flint
linings and flint pebbles in a closed circuit system with
bowl classifiers. The resulting accurately sized product is
thickened, dried and packed for shipment.
Tripoli is primarily used as an abrasive or as a constituent
of abrasive materials for such uses as polishing and buffing
of such materials as copper, aluminum, brass and zinc. In
addition, the pulverized product is widely used as the
abrasive element in scouring soaps and powders, in polishes
for the metal-working trades and as a mild mechanical
cleaner in washing powders for fabrics. The pure white
product from southern Illinois, when finely ground, is
widely used as a filler in paint. The other colors of
tripoli are often used as fillers in the manufacture of
linoleum, phonograph records, pipe coatings and so forth.
Total U. S. production of tripoli (1971) was of the order of
68,000 kkg, some 70 percent of which was used as abrasive,
the remainder as filler.
111-26
DRAFT
-------
DRAFT
Garnet
Garnet is an orthosilicate having the general formula
3RO«R2O3«3SiO2 where the bivalent element may be calcium,
magnesium, ferrous iron or manganese; the trivalent element,
aluminum, ferric iron or chromium, rarely titanium; further,
the silicon is occasionally replaced by titanium.
The members of the garnet group of minerals are common
accessory minerals in a large variety of rocks, particularly
in gneisses and schists. They are also found in contact
metamorphic deposits, in crystalline limestones; pegmatites;
and in serpentines. Although garnet deposits are located in
almost every state of the United States and in many foreign
countries, practically the entire world production comes
from New York and Idaho. The Adirondack deposit consists of
an alamandite garnet having incipient lamellar parting
planes which cause it to break under pressure into thin
chisel-edge plates. Even when crushed to very fine size
this material still retains this sharp silvery grain shape—
—a feature of particular importance in the coated abrasive
field.
The New York mine is a surface site worked by open quarry
methods. The ore is quarried in benches about 35 ft. in
height, trucked to the mill and dumped on a pan conveyor
feeding a 24 x 36 inch jaw crusher. The secondary crusher
which is a standard 4 feet Symonds cone is in closed circuit
with a 1-1/2 inch screen. The minus 1-1/2 inch material is
screened on a 10 mesh screen. The oversize from the screen
goes to a heavy media separation plant while the undersize
is classified and concentrated on jigs. The very fine
material is treated by flotation. The combined
concentrates, which have a garnet content of about 98
percent, are then crushed, sized and heat treated. It has
been found that heat treatment, to about 700 to 800 degrees
C. will improve the hardness, toughness, fracture properties
and color of the treated garnets.
The only other significant production of garnets in the
United States is situated on Emerald Creek in Benewah
County, Idaho. This deposit is an alluvial deposit of
alamandite garnets caused by the erosion of soft mica
schists in which the garnets have a maximum grain size of
about 3/16 inch. The garnet bearing gravel is mined by drag
111-27
DRAFT
-------
DRAFT
line, concentrated on trommels and jigs then crushed and
screened into various sizes. This garnet is used mainly tor
sandblasting and as filtration media.
Approximately US percent of the garnet marketed is used in
the manufacture of abrasive coated papers, about 35 percent
in the glass and optical industries with the remainder for
sand blasting and miscellaneous uses.
3.11 Diatomite (SIC 14991
Diatomite is siliceous rock of sedimentary origin which may
vary in the degree of consolidation but which consists
mainly of the fossilized remains of the protective silica
shells formed by diatoms, single-celled non-flowering
microscopic plants. The size, shape and structure of the
individual fossils and their mass packing characteristics
result in microscopic porous material of low specific
gravity.
There are numerous sediments which contain diatom residues,
admixed with substantial amounts of other materials
including clays, carbonates or silica; these materials are
classified as diatomaceous silts, shales or mudstones; they
are not properly diatomite, a designation restricted to
material of such quality that it is suitable for commercial
uses. The terms diatomaceous earth and kieselgur are
synonymous with diatomite; the terms infusorial earth and
tripolite are considered obsolete.
Diatomaceous silica is the most appropriate designation of
the principal component of diatomite; that is, the substance
of the fossil silica shell is the major constituent of
beneficiated diatomite of processed diatomaceous products.
Commercially useful deposits of diatomite show SiO2 concen-
tration ranging from a low of 86 percent (Nevada) to a high
of 90.75 percent (Lompoc, CA) for the United States
producers; the SiO2 content of foreign sources is somewhat
lower. The remainder consists of alumina, iron oxide,
titanium oxide, and lesser quantities of phosphate,
magnesia, and the alkali metal oxides. In addition, there
is usually some residual organic matter as indicated by
ignition losses which are typically of the order of 4 to
5 percent.
111-28
DRAFT
-------
DRAFT
The formation of diatomite sediments was dependent upon the
existence of the proper environmental conditions over an
adequate period of time to permit a significant accumulation
of the skeletal remains. These conditions include a
plentiful supply of nutrients and dissolved silica for
colony growth and the existence of relatively quiescent
physical conditions such as exist in protected marine
estuaries or in large inland lakes. In addition, it is
necessary that these conditions existed in relatively recent
times in order that subsequent metamorphic processes would
not have altered the diatomite to the rather more indurated
materials such as porcelanite and the opaline cherts.
The upper tertiary period was the period of maximum diatom
growth and subsequent deposit formation. The great beds
near Lompoc, CA are upper Miocene and lower Pliocene (about
20 x 10* years old); formations of similar origin and age
occur along the California coast line from north of San
Francisco to south of San Diego. Most of the dry lake
deposits of California, Nevada, Oregon and Washington are of
freshwater origin formed in later tertiary of Pleistocene
(less than 12 x 106 years old.)
Currently, the only significant production of diatomite
within the U.S. is in the western states, with California
the leading producer, followed by Nevada, Oregon and
Washington. Commonly, beds of ordinary sedimentary rocks
such as shales, sandstones, or limestone overlie and
underlie the diatomite beds, thus the first step in mining
requires the removal of the overburden (which ranges from
zero to about 15 times the thickness of the diatomite bed)
by ordinary earth moving machinery. The ore is ordinarily
dug by power shovels without the necessity of previous
fragmentation by drilling or blasting although such
operations may be carried out.
Initial processing of the ore involves size reduction by a
primary crusher followed by further size reduction and
drying (some diatomite ores contain up to 60 percent water)
in a blower-hammer mill combination with a pneumatic feed
and discharge system. The suspended particles in the hot
gases pass through a series of cyclones and a baghouse where
they are separated into appropriate particle size groups.
111-29
DRAFT
-------
DRAFT
The uses of diatomite result from the size (from 10 to
greater than 500 microns in diameter), shape (generally
spiny structure of intricate geometry) and the pacKing
characteristics of the diatom shells. Since physical
contact between the individual fossil shells is chiefly at
the outer points of the irregular surfaces, the resulting
compact material is microscopically porous with an apparent
density of only 5 to 16 pounds per cubic foot for ground
diatomite. The processed material has dimensional stability
to temperatures of the order of 400 degrees C. The domestic
consumption of diatomite is shown in Figure III-3.11.1.
3., 12 Graphite |SIC 14991
Natural graphite is the mineral form of elemental carbon,
crystallized predominately in the hexagonal system, found in
silicate minerals of varying kind and percentage. The three
principal types of natural occurrence of graphite are
classified as lump, amorphous and crystalline flake; a
classification based on major differences in geologic origin
and occurrence.
Lump graphite occurs as fissure-filled veins wherein the
graphite is typically massive with particle size ranging
from extremely fine grains to coarse, platy intergrowths or
fibrous to acicular aggregates. The origin of vein-type
deposits is believed to be either hydrothermal or
pneumatolytic since there is no apparent relationship
between the veins and the host rock. A variety of minerals
generally in the form of isolated pockets or grains, occur
with graphite, including feldspar, quartz, mica, pyroxene,
zircon, rutile, apatite and iron sulfides.
Amorphous graphite, which is fine-grained, soft, dull black,
earthy looking and usually somewhat porous, is formed by
metamorphism of coalbeds by nearby intrusions. Although the
purity of amorphous graphite depends on the purity of
coalbeds from which it was derived, it is usually associated
with sandstones, shales, slates and limestones and contains
accessory minerals such as quartz, clays and iron sulfides.
111-30
DRAFT
-------
7- 30
U- 5. 5,/e,
o ~
X TALY
SJ 70
/2/3//05
-e*
MU/JiCif/fL
237
*
Figure 111-3.11.1 Supply-Demand Relationships for Diatomite, 1968
-------
DRAFT
Flake graphite, which is believed to have been formed by
metamorphism from sedimentary carbon inclusions within tne
host rocks, commonly occurs disseminated in.re9iOna^v
metamorphosed sedimentary rocks such as gneisses, scnists
and marbles.
Southwestern Graphite Co., near Burnet, Texas, the only
domestic producer, mines the flake graphite by open pit
methods utilizing an 18-foot bench pan. The ore is hard and
tough and thus requires much secondary blasting. The broken
ore is hauled by motor-trucks to the mill.
Because of the premium placed upon the mesh size of flake
graphite, the problem in milling is one of grinding to free
the graphite without reducing the flake size excessively;
this is difficult because during grinding, the graphite
flakes are cut by quartz and other sharp gangue materials,
thus rapidly reducing the flake size. However, if the flake
can be removed from most of the quartz and other sharp
minerals soon enough, subsequent grinding will usually
reduce the size of the remaining gangue, with little further
reduction in the size of the flake. Impact grinding or
essentially pure flake in a ball mill reduces flake size
rather slowly, the grinding characteristics of flake
graphite under these conditions being similar to those of
mica.
Graphite floats readily and does not require a collector;
hence, flotation has become the accepted method for
beneficiating disseminated ores. Although high recoveries
are common, concentrates with acceptable graphitic carbon
content are difficult to attain and indeed with some ores
impossible. The chief problem lies with the depression of
the gangue minerals since relatively pure grains of quartz,
mica, and other gangue minerals inadvertently become smeared
with fine graphite, making them floatable resulting in the
necessity for repeated cleaning of the concentrates to
attain high-grade products. Regrinding a rougher
concentrate reduces the number of cleanings needed. Much of
the natural flake either has a siliceous skeleton (which can
be observed when the carbon is burned) or is composed of a
layer of mica between outer layers of graphite making it
next to impossible to obtain a high-grade product by
flotation.
111-32
DRAFT
-------
DRAFT
The supply-demand relationships for 1968 are shown at
Figure III-3.12.1.
3.13 Miscellaneous Non-Metallic Minerals. N.E.C. ,[S£C
14991
3.13,1
The term jade is applied primarily to the two minerals
jadeite and nephrite, both minerals being exceedingly tough
with color varying from white to green. Jadeite, which is a
sodium aluminum silicate (NaAlSi^Ojj) contains varying
amounts of iron, calcium and magnesium is found only in
Asia.
Nephrite is a tough compact variety of the mineral tremolite
(Ca.2Mgj>Si8O22 (OH) 2) which is an end member of an isomorphous
series where in iron may replace the magnesium.
In the U.S. production of jade minerals is centered in
Wyoming, California and Alaska.
3.13.2 Novaculite
Novaculite is a generic name for massive and extensive
geologic formations of hard, compact, homogenous,
microcrystalline silica located in the vicinity of Hot
Springs, Arkansas. There are three strata of novaculite
lower, middle, and upper. The upper strata is not compacted
and is a highly friable ore which is quarries, crushed,
dried and air classified prior to packaging. Chief uses are
as filler in plastics, pigment in paints, and as a micro-
inch metal polishing agent.
3.13.3 Whetstone
Whetstones, and other sharpening stones, are probably
produced in small volume across the U.S. wherever deposits
of very hard silaceous rock occur. However, the largest
center of sharpening stone manufacture is in the Hot
Springs, Arkansas, area. This area has extensive out-
cropping deposits of very hard and quite pure silica, called
"Novaculite", which are mined and processed into whetstones.
Most of the mining and processing is done on a very small
scale by individuals or very small companies.
111-33
DRAFT
-------
WORLD PRODUCTION
_£/ 474,000
North Korea
83,000
U.S.S.R.
77,000
I
Unfed States
3,OOO
China
(Mainland)
34,000
Mexico
45,000
Malagasy
16,500
Ceyicn
12,000
West Germany
14,000
Norway
8,300
South Korea,
Republic of
143,100
Austria
33,000
Other
5,100
55,160
4?025
2,222
2,506
2,999
4GO
28
410
^ Imports
1 67,810 ~
Industry Q con-
suiier stock, __•
1/1/68
1/500
Govt. stockpile
release
(A) 302
(D) 118
JL
SK
Un
Go
(A)
(8)
(C)
ID)
Industry and
consumer stocks,
~~1 i2/3'/G8
.e/7, SCO
j U.S. supply U.S. demand
| 71,730 _e/60,0&0
I
J Exports
, 4,I7C
KEY
1 Estimate .
~j Stonicrd Industrial Classification
t: Short tor.t
vt. Stockpile Salar.ce 43 653
Malagasy crystalline fioKe 25,829
MolCQOsy crystalline fines 7 20G
Ceylon amorphous lump 5 9^6
Othpr/*rv^tnl'ir*i ^7^5
f
—4
Foundries (facings)
IS 1C 33Z.33SI
£/23,07Q
— *
""^ "V
— >
r— i
— •
t__
1
Steelmckn.}
(SIC33H)
e/6,700
RefroctoriesfOtherthan
cruci&los )
(•5/£T5?S^;
^/7,7SO
(crucibles)
/•5/(T 3297)
.e/4,250
Baileries
ISIC 3C9!)
j/ 1,500
I
Lecd pencils
] ISlC 19ZZ1
JV2.03C
J Broke tirthg
rJ/(T J,?5^;
1 _e/l,<;5C
iL'j&ricoMis end packings
IS1CZS3Z)
ey5,500
] Other
'7 .e/7,870
Figure 111-3.12.1 Supply-Demand Relationships for Natural Graphite, 1968
-------
DRAFT
The total production in 1972 of all special silica stone
products (grinding pebbles, grindstones, oilstones, tube-
mill liners, and whetstones) was only 2,940 kkg
(3,240 tons), with a value of $670,000. This production and
value is not economically significant and will not be
treated further in this report.
4.0 PRODUCTION OF CLAY. CERAMIC. REFRACTORY^ AND
MISCELLANEOUS MINERALS
The 1972 production and employment figures for the clay,
ceramic, refractory and miscellaneous minerals industries
were derived either from the Bureau of the Census (U.S.
Department of Commerce) publications or the Commodity Data
Summaries (1974) Appendix I to Mining and Minerals Policy,
Bureau of Mines, U.S. Department of the Interior. These
figures are tabulated in Table III-1.
111-35
DRAFT
-------
DRAFT
Table III-1
1972 U.S. Production and Employment Figures For Clay,
Ceramic, Refractory, and Miscellaneous Minerals
Sic code Product
Production
Employment
1452
1U53
1454
1455
1455
1459
1459
1459
1459
1459
1496
1496
1496
1499
1499
1499
1499
1499
Bentonite
Fire clay
Fuller's
Earth
Kaolin
Ball clay
Feldspar
Kyanite
Magnesite
Aplite
Crude common
Clay
Talc
Soapstone
Pyrophyllite
Abrasives
Garnet
Tripoli
Diatomite
Graphite
Jade
Novaculite
kkq (tons)
2,150,000
(2,767,000)
3,250,000
(3,581,000)
896,000
(988,000)
4,810,000
(5,318,000)
612,000
(675,000)
664,000
(732,000)
Est. 108,000
(Est. 120,000)
Withheld
190,000
(210,000)
41,840,000
(46,127,000)
v
> 1,004,000
/^
17,200
(19,000)
80,000
(88,000)
522,000
(576,000)
Withheld
107
(118)
Withheld
* includes ball clay
900
500
1,200
3,900*
450
165
Unknown
Unknown
2,600
950
Unknown
Unknown
500
54
Unknown
15
111-36
DRAFT
-------
DRAFT
SECTION IV
INDUSTRY CATEGORIZATION
1.0 INTRODUCTION
In the development of effluent limitations guidelines and
recommended standards of performance for new sources in a
particular industry, consideration should be given to
whether the industry can be treated as a whole in the
establishment of uniform and equitable guidelines for the
entire industry or whether there are sufficient differences
within the industry to justify its division into categories.
For this segment of the mineral mining and processing
industry, which includes eighteen mineral types, the
following factors were considered as possible justifications
for industry categorization and subcategorization:
1) manufacturing processes;
2) raw materials
3) pollutants in effluent wastewaters;
4) product purity;
5) water use volume;
6) plant size;
7) plant age; and
8) plant location.
2.0 INDUSTRY CATEGORIZATION
The first categorization step was to segment the mineral
mining and processing industry according to product use.
Thus, Volume I is "Mining of Minerals for the Construction
Industry," Volume II is "Mining of Minerals for the Chemical
and Fertilizer Industries," and this volume. Volume III, is
IV-1
DRAFT
-------
DRAFT
"Mining of Clay, Ceramic, Refractory and Miscellaneous
Minerals."
This segment of the industry was categorized on a commodity
basis. Each commodity sweeps up in itself some or all of
the above-mentioned criteria (processing, raw materials,
etc.). However, some differences do exist within a given
commodity, e.g., wet and dry process kaolin. Differences
such as these were used as a basis for subcategorization.
Table IV-1 lists the thirteen categories and twenty-two
subcategories discussed in this report.
IV-2
DRAFT
-------
DRAFT
Commodity
Bentonite
Fire clay
Fuller's earth
Kaolin and ball
clay
Feldspar
Kyanite
Magnesite
Shale G Common
Clay, NEC
Talc Minerals
Group
TABLE IV-1
Industry Categorization
SIC Code Category
1452
1453
1454
1455
1459
1459
1459
1459
1496
Natural Abrasives 1499
Diatomite 1499
Graphite 1499
Misc. Minerals, 1499
NEC
1
2
3
6
7
8
10
11
12
13
Subcategory
None
None
3.1 Attapulgite
3.2 Montmorillonite
4.1.1 Dry Kaolin Mining
and Processing
4.1.2 Kaolin Mining and
Wet Processing for High-
Grade Product
4.2 Ball Clay
5. 1 Feldspar Wet Process-
ing
5.2 Feldspar Dry Process-
ing
None
None
8.1 Shale
8.2 Aplite
9.1 Talc Minerals Group.
Dry Process
9.2 Talc Minerals Group,
Ore Mining & Washing
9.3 Talc Minerals Group,
Ore Mining, Heavy Media
and Flotation
10.1 Garnet
10.2 Tripoli
None
None
13.1 Jade
13.2 Novaculite
3,0 FACTORS CONSIDERED
3.1 Manufacturing Processes
This segment of the mineral mining and processing industry
can be divided into three very general classes - dry
crushing and grinding, wet crushing and grinding (shaping),
IV-3
DRAFT
-------
An
DRAFT
and crushing and beneficiation (including flotation, heavy
media, et al). Each of these processes is described in
detail in Section V of this report, including process now
diagrams pertinent to the specific facilities using tne
process.
Upon examination of the various processes and wastes
generated therefrom, it is evident that the process was
justification for subcategorization of the minerals mining
industry but not for major segmentation of the industry.
example of this is talc minerals group processing which is
carried out by all three general processes mentioned above.
3.2 Raw Materials
The raw materials used are principally ores, which vary
across this segment of the industry and also vary within a
given deposit. Raw materials are not a suitable basis for
categorization.
3.3 Pollutants in Effluent
The principal pollutant from this segment of the mineral
mining and processing industry is total suspended solids.
There are occasional limited instances of deleterious
materials, specifically, zinc from the processing of high
grade kaolin and fluoride from feldspar processing.
Although suspended solids are ubiquitous, the treatability
of the effluents varies widely, depending heavily, among
other things, upon the other constituents present in the ore
and overburden. Because of the across-the-board presence of
suspended solids, distinguished by widely varying degrees of
treatability, pollutants in the effluent were not judged to
be an adequate basis for categorization.
3A4 Product Purity
The mineral extraction processes covered in this report
yield products which vary in purity from what would be
considered a chemical technical grade to an essentially
analytical reagent quality. Product purity was not
considered to be a viable criterion for categorization of
the industry. Pure product manufacture usually generates
more waste than the production of lower grades of material,
and thus may be a basis for subcategorization.
IV-4
DRAFT
-------
DRAFT
3,5 Water Use Volume
In this segment of the mineral mining industry, water use is
determined by the needs of the individual facility and
varies greatly depending on both the material extracted and
the grade of the ore. For mineral extractive processes
studied herein, water use varies from zero to 250,000 liters
per metric ton of product.
Water use was not considered to be a workable criterion for
industry categorization.
3.*. 6 Plant Size
For this segment of the industry, information was obtained
from more than 90 different mineral mining sites, capacity
varied from as little as two metric tons per day to
6,800 metric tons per day. The variance of this factor was
so great that plant age was not felt to be useful in
categorizing this segment of the industry.
3.7 Plant Age
The newest plant studied was less than a year old and the
oldest was 90 years old. There is no correlation between
plant age and the ability to treat process wastewater to
acceptable levels of pollutants. Therefore, plant age was
not an acceptable criterion for categorization.
3.8 Plant Location
The locations of the more than 90 mineral mining and
processing sites studied are in twenty states spread from
coast to coast and north to south.
Some plants are located in arid regions of the country,
allowing the use of evaporation ponds and surface disposal
on the plant site. Other plants are located near raw
material mineral deposits which are highly localized in
certain areas of the country.
In these instances geographical location was felt to be a
legitimate criterion for industry subcategorization.
IV-5
DRAFT
-------
DRAFT
Thus, plant location was used for further segmentation
within a category, but not for categorization.
IV-6
DRAFT
-------
DRAFT
SECTION V
WATER USE AND WASTE CHARACTERIZATION
1.0 INTRODUCTION
This section discusses the specific water uses in the clay,
ceramic, refractory, and miscellaneous minerals segment of
the mineral mining and processing industry, and the amounts
of process waste materials contained in these waters. The
process wastes are characterized as raw waste loads
emanating from specific processes in the extraction of the
materials involved in this study and are given either in
terms of kilograms per metric ton of product produced or ore
processed (pounds per short ton). The specific water uses
and amounts are given in terms of liters per metric ton of
product produced or ore mined (gallons per short ton) for
each of the facilities contacted in this study. The
treatments used by the mining and processing facilities
studied are specifically described and the amount and type
of water borne waste effluent after treatment is
characterized.
The verification sampling data measured at specific
exemplary facilities for each subcategory is set forth in
Supplement B of this report. A description of the
analytical techniques used for this verification of plant
data is also provided in Supplement B.
2.0 SPECIFIC WATER USES
Water is used in the mineral mining and processing industry
for seven principal purposes falling under three major
characterization headings. The principal water uses are:
(1) Non-contact cooling water
(2) Process water - wash water
transport water
scrubber water
process and product consumed water
miscellaneous water
(3) Auxiliary processes water
V-1
DRAFT
-------
DRAFT
Non-contact cooling water is defined as that cooling water
which does not come into direct contact with any raw
material, intermediate product, by-product or product usea
in or resulting from the process.
Process water is defined as that water which, during the
manufacturing process comes into direct contact with any raw
material, intermediate product, by-product or product used
in or resulting from the process.
Auxiliary processes water is defined as that used for
processes necessary for the manufacture of a product but not
contacting the process materials. For example, water
treatment regeneration is an auxiliary process.
The quantity of water usage for facilities in the clay,
ceramic, refractory and miscellaneous minerals segment of
the mineral mining and processing industry generally ranges
from zero to 2,200,000 liters per day (0 to 580,000 gallons
per day). In general, the plants using very large
quantities of water use it for heavy media separation and
flotation processes and, in some cases, wet scrubbing and
non-contact cooling.
2,1 Non-Contact Cooling Water
The largest use of non-contact cooling water in this segment
of the mineral mining industry is for the cooling of
equipment, such as kilns, pumps and air compressors.
2.2 Contact Cooling Water
Insignificant quantities of contact cooling water is used in
this segment of the mineral mining industry. When used, it
usually either evaporates immediately or remains with the
product.
2.3 Wash Water
This water also comes under the heading of process water
because it comes into direct contact with either the raw
material, reactants or products. Examples of this type of
water usage are ore washing to remove fines and filter cake
washing. Waste effluents can arise from these washing
sources, due to the fact that the resultant solution or
V-2
DRAFT
-------
DRAFT
suspension may contain impurities or may be too dilute a
solution to reuse or recover.
2.1 Transport Water
Water is widely used in the mineral mining industry to
transport ore to and between various process steps. Water
is used to move crude ore from mine to plant, from crushers
to grinding mills and to transport tailings to final
retention ponds.
2^5 Scrubber Water
Particularly in the dry processing of many of the minerals
in this industry, wet scrubbers are used for air pollution
control. These scrubbers are primarily used on dryers,
grinding mills, screens, conveyors and packaging equipment.
2f6 Process and Product Consumed Water
Process water is primarily used in this industry during
blunging, pug milling, wet screening, log washing, heavy
media separation and flotation unit processes. The largest
volume of water is used in the latter two processes.
Product consumed water is often evaporated or shipped with
the product as a slurry or wet filter cake.
2^7 Miscellaneous Water
These water uses vary widely among the facilities with
general usage for floor washing and cleanup, safety showers
and eye wash stations and sanitary uses. The resultant
streams are either not contaminated or only slightly
contaminated with wastes. The general practice is to
discharge such streams without treatment or combine with
process water prior to treatment.
Another miscellaneous water use in this industry involves
the use of sprays to control dust at crushers, conveyor
transfer points, discharge chutes and stockpiles. This
water is usually low volume and is either evaporated or
absorbed in the ore.
V-3
DRAFT
-------
DRAFT
2.8 Auxiliary Processes Water
Auxiliary processes water include blowdowns from
towers, boilers and water treatment. The volume
used for these purposes in this industry is minimal.
However, when they are present, they usually are hignj.y
concentrated in waste materials.
Is! PgQCESS WASTE CHARACTEglEATION
The mineral products are discussed in SIC Code numerical
sequence in this section. For each mineral product the
following information is given:
— a short description of the processes at the
facilities studied and pertinent flow diagrams;
— raw waste load data per unit weight of product
or raw material processed;
~ water consumption data per unit weight of product
or raw material processed;
~ specific plant waste effluents found and the post-
process treatments used to produce them.
Bentonite
Process Description
Bentonite is mined in dry, open pit quarries. After the
overburden is stripped off, the bentonite ore is removed
from the pit using bulldozers, front end loaders, and/or pan
scrapers. The ore is hauled by truck to the processing
plant. There, the bentonite is crushed, if necessary,
dried, sent to a roll mill, stored, and shipped, either
packaged or in bulk.
Dust generated in drying, crushing, and other plant
operations is collected using cyclones and bags. In plant
3030 this dust is returned to storage bins for shipping. A
general process flowsheet is given in Figure V-3.1.1.
V-4
DRAFT
-------
g
CRUSHER
VFWT
OPEN PIT
QUARRY
!
1
1
i 1
«™
1
i
SCREENS
tt, rjr,, , MI, , mmm STORAGE
B* ROLL MILL —- -aa. B|NS
* A
I 1
" 1
* 1 i
i
PRODUCT
O
70
RGURETT-S.I.I
BENTONITE MINING AND PROCESSING
-------
DRAFT
3.1.2 Raw Haste Load
Waste is generated in the mining of bentonite in the form of
overburden, which must be removed to reach the bentonite
deposit.
Waste is generated in the processing of bentonite as dust
from drying, crushing, and other plant operations.
There is no water used in the mining or processing of
bentonite .
3.1,*i waste Water Treatinent
Since there is no water used in bentonite mining or
processing f no wastewater is generated.
Jil^S Effluent and Disposal
There is no discharge of any wastewater from bentonite
operations.
The solid overburden removed to uncover the bentonite
deposit is returned to mined-out pits for land disposal and
eventual land reclamation. Dust collected from processing
operations is either returned to storage bins as product or
it is land- dumped.
Fire clay is principally kaolinite but usually contains
other materials such as diaspore, ball clay, bauxitic clay,
and shale« Its main use is in refractory production and
only the mining is covered here* Due to the similarity in
all types of clay mining, this section will also serve for
common clay mining not in conjunction with manufacturing.
3.2.1 Process Description
Fire clay is obtained from open pits using bulldozers and
front-end loaders for removal of the clay. Blasting is
occasionally necessary for removal of the hard shale-like
flint clay. The clay is then transported by truck to the
-------
DRAFT
plant for processing. This processing includes crushing,
screening, and other specialized steps, for example,
calcination. There is at least one case (plant 3047) where
the clay is shipped without processing. However, most of
the fire clay mined is used near the mine site for producing
refractories. A general process diagram is given in
Figure V-3.2. 1.
3.2a2 Raw Waste Load
The solid waste generated in fire clay mining is overburden
which is used as fill to eventually reclaim mined-out areas.
Pit pumpout is the only other waste in this subcategory.
J&2i3 Water Use
There is no water used in fire clay mining. However, due to
rainfall and ground water seepage, there can be water which
accumulates in the pits and must be removed. Pit pumpout is
intermittent depending on frequency of rainfall and
geographic location. Flow rates are not generally
available. In many cases, however, the plants provide
protective earthen dams and ditches to prevent accumulation
of rainwater in the clay pits.
3.2.4 Waste Water Treatment
There is no processing wastewater. In some cases, settling
ponds are employed to reduce the amount of suspended solids
in the pit pumpout before discharge. Usually, pit pumpout
is discharged to a nearby body of water, to a watershed, or
is evaporated on- land.
Effluent and Disposal
Pit pumpout is discharged either after settling or with no
treatment. There is no discharge of process wastewaters.
3 . 3 Fuller's Earth
Fuller's Earth is a clay, usually high in magnesia, which
has decolorizing and absorptive properties. Production from
the region that includes Decatur County, Georgia, and
Gadsden County, Florida, is composed predominantly of the
distinct clay mineral attapulgite. Most of the Fuller's
V-7
DRAFT
-------
1s
oo
OPEN
PIT
CRUSH
1
1
1
1
1
SCREEN
1
1
*
CALCINE
.lfc REFRACTORY _ 111-tonnnniirT
88 OPERATIONS -^PHODUCT
••• ~ •••«•• I*""" «••«" " ^"™" ™^^^* PRODUCT
1
| PRODUCT
o
•n
FIGURE Y-3.2.1
FIRE CLAY MINING AND PROCESSING
-------
DRAFT
Earth occurring in the other areas of the U.S. contains
primarily montmorillonite. Thus, two subcategories are
pertinent in this section: attapulgite and montmorillonite.
Five plants, representing 83 percent of the total U.S.
production of Fuller^ Earth, provided the data for this
section.
Attapulgite
3«3A1... 1 Process Description
Attapulgite is mined from open pits, with removal of
overburden using scrapers and draglines. The clay is also
removed using scrapers and draglines and is trucked to the
plant for processing. Processing consists of crushing and
grinding, screening and air classification, pug milling
(optional) , and a heat treatment that may vary from simple
evaporation of excess water to thermal alteration of crystal
structure. A general process diagram is given in
Figure V-3.3.1.
SjjjJ^J paw Waste Load
Solid waste is generated in attapulgite mining as overburden
which is used as fill to reclaim worked-out areas.
Waste in the form of dusts and fines is generated from
drying and screening operations at plant 3060. This waste
is sent to worked-out pits which serve as settling ponds,
and the solids settle out.
At plant 3058 waste is generated from screening operations
as fines which are slurried and pumped to settling ponds.
No data is available on the amounts of these solid wastes
generated in attapulgite processing.
3.3.1.3 Water Use
No water is used in the mining, but rain and ground water do
collect in the pits, particularly during the rainy season.
This type of clay settles rapidly and pit pumpout is
generally clear except when overburden gets into the water.
V-9
DRAFT
-------
OPEN
PITS
I WATER-
LEGEND:
WER-
SCRUBBERS
KILN
CRUSHING
AND
SCREENING
VtNl
!
ROTARY
DRYERS
MILLS
PUG
MILL
|
POND
T
MILL
EFFLUENT
EFFLUENT
) ALTERNATE PROCESS ROUTES
FIGURE ¥-3.3.1
FULLER'S EARTH MINING AND PROCESSING
(ATTAPULGITE)
CLASSIFY
PRODUCT
PRODUCT
O
-------
DRAFT
There are no settling ponds used at the mines for pit
pumpout.
Untreated creek water serves as source and make-up for
plants 3058 and 3060. Water is used by plant 3058 for
cooling, pug milling, and waste fines slurrying. Plant 3060
also uses water for cooling and pug milling, and, in
addition, uses water in dust scrubbers for air pollution
control. There is no recycle of process water at either
plant, all being evaporated, sent to ponds, and/or
eventually discharged. Typical flows are:
liter/metric ton of product
(gal/ton)
3058 3060
Intakes
Make-up 460 (110) total unknown
includes average
intermittent needs
Use:
cooling 184 (44) unknown amount
waste disposal 230 (55) 345-515
and dust collection intermittent (82-122)
pug mill 46 (11) 42 (10)
Consumption:
cooling water
discharge none unknown
process discharge 230 (55) 440 (105)
evaporation 230 (55) 42 (10)
Total 460 (110) unknown
3±3.1.4 Waste Water Treatment
Pit pumpout at both attapulgite plants is discharged without
treatment to a nearby creek.
Bearing cooling water at plant 3060 is pumped directly back
to the creek, with no treatment, while water used in pugging
and kiln cooling is evaporated in the process. Scrubber
V-ll
DRAFT
-------
DRAFT
waters are directed to worked-out pits which serve as
settling ponds before discharge back to the creek.
At plaht 3058 cooling and pug mill water is evaporated in
the process. Water used to slurry waste fines for disposal
is pumped to settling ponds, from which clear effluent is
returned to the creek.
J^jbJLs.1 Effluent and Disposal
Effluents from both plants arise from waste disposal;
slurrying of waste fines at 3058 and scrubber water from
dtast collection at 3060. Both plants send these effluents
igh settling ponds for reduction of suspended solids and
discharge to a nearby creek.
There is no data available from plant 3058 on effluent
quality. A water analysis, based on one twenty-four hour
composite,, shows effluent quality of plant 3060:
parameter discharge
suspended solids 21 mg/liter
pH 7.4
Based on this analysis, the calculated average amount of suspended
solids discharged at plant 3060 is 0.01 kg per metric ton of
product (0.02 Ib/ton).
3.3.2 Montmorillonite
Montmorillonite wastes present more of a settling problem in
water than attapulgite wastes. The information presented
foelow is based on 3 of 4 plants in this subcategory. This
represents over 80 percent of the U.S. montmorillonite
production.
3_,_3? 2f 1 Process Description
Montmorillonite is mined from open pits. Overburden is
removed by scrapers and/or draglines, and the clay is
draglined and loaded onto trucks for transport to the plant.
Processing consists of crushing, drying, milling, screening,
and, for a portion of the clay, a final drying prior to
V-12
DRAFT
-------
DRAFT
packaging and shipping. A general process diagram is given
in Figure V-3.3.2.
3,3.2.2 Raw Waste Load
Solid waste generated in mining montmorillonite is
overburden which is used as fill to reclaim worked-out pits.
Waste is generated in processing as dust and fznes from
milling, screening, and drying operations. The dust and
fines which are gathered in bag collectors from drying
operations are hauled, along with milling and screening
fines, back to the pits as fill. Slurry from scrubbers is
sent to a settling pond with the muds being returned to
worked-out pits after recycling the water. There are no
data available on the amount of these solid wastes.
3.3.2.3 Water Use
There is no water used in the mining operations. However,
rain water and ground water collect in the pits forming a
murky colloidal suspension of the clay. This water is
pumped to worked-out pits where it settles to the extent
possible and is discharged intermittently to a nearby body
of water, except in the case of plant 3073 which uses this
water as scrubber water makeup. The estimated flow is up to
1140 liters per day (300 GPD) .
Water is used in processing only in dust scrubbers. Typical
flows are:
liter /metric ton product jgal/ton)
Plant 3059 3072 3073
Intake 1,930 (460) 500 (120) 143 (34)
Dust Scrubbers 1,930 (460) 500 (120) 143 (34)
Consumption:
Discharge none 150 (36) none
Evaporation plus
Landfill Of Solid 1,930 (460) 350 (84) 143 (34)
Wastes
Plants 3059 and 3073 recycle essentially 100 percent of the
scrubber water.
V-13
DRAFT
-------
PIT
CRUSHING
WATER•
LEGEND:
ALTERNATE AIR
POLLUTION TREATMENTS
DRYER AND COOLER
RECYCLE
POND
CLAY SLUDGE
TO MINE
CYCLONES
BAG
COLLECTORS
AND
SCREEN
™&S2
ROTARY
DRYER
«4fe
DUST AND FINES TO MINE
•PRODUCT
AND
COOLER
O
73
FIGURE IT-3.3.2
FULLER'S EARTH MINING AND PROCESSING
(MONTMORILLONITE)
-------
DRAFT
3.3.2.4 Waste Water Treatment
Plants 3059 and 3073 recycle essentially 100 percent of the
scrubber water, while plant 3072 recycles only about
70 percent. Scrubber water must be kept neutral because
sulfate values in the clay become concentrated, making the
water acidic and corrosive. Plants 3059 and 3073 use
ammonia to neutralize recycle scrubber water, forming
ammonium sulfate. This ammonium sulfate settles into the
muds collected in the settling pond, which are then returned
to worked-out pits. Plant 3072 uses lime (Ca(OH)2), which
forms calcium sulfate in the settling pond. To keep the
scrubber recycle system working, some water containing a
build-up of calcium sulfate is discharged to a nearby creek.
However, plant 3072 intends to recycle all scrubber water by
mid-1975.
Pit pumpout presents a greater problem for montmorillonite
producers than for attapulgite producers, due to the very
slow settling rate of the suspended clay. Accumulated rain
and ground water is pumped to abandoned pits for settling to
the extent possible and is then discharged. No data was
furnished on the volume or quality of the discharge. A pit
pumpout sample from plant 3059 (Versar data) had a TSS of
215 mg/liter. At plant 3073 the pit water is used as makeup
for the scrubber water.
3.3.2.5 Effluent and Disposal
There is no process discharge from plants 3059 and 3073.
Plant 3072 discharges a small amount of scrubber water after
settling and lime treatment. This effluent contains
0.2 percent suspended solids and has a pH of 8. This
effluent corresponds to an average TSS of 0.3 kg per metric
ton of product (0.6 lb/*on).
The settling pond muds at all three plants are landfilled in
worked-out pits.
V-15
DRAFT
-------
DRAFT
3.4 Kaolin and Ball Clav. J§IC 14551
3.4.1 Kaolin
Kaolin is produced in mines in 17 states with Georgia
accounting for the bulk (75%) of the U.S. production. Six
kaolin mines and plants distributed between eastern and
western U.S. were contacted representing 48 percent of the
total kaolin production in the U.S.
Plants were found having different water usages, so two
swbcategories are established for kaolin processing; wet for
high grade product, and dry, for general purpose use.
3j4._1. 1 Dry Process
3.4.1,1.1 Process Description
The clay is mined in open pits using shovels, caterpillars,
carry-alls and pan scrapers. Trucks haul the kaolin to the
plant for processing. At plants 3035, 3062, 3063 the clay
is crushed, screened, and used for processing to refractory
products. Processing at plant 3036 consists of grinding,
drying, classification and storage. A general dry process
diagram is given in Figure V-3.4.1.
3,4.1. 1.2 Raw Waste Load
There is no waste generated in the mining of the kaolin
other than overburden, and in the processing, solid waste is
generated from classification. No data is available on the
amount of this waste.
There is no water used in the mining or processing of kaolin
at these four plants. There is rainwater and ground water
which accumulates in the pits and must be pumped out. The
quantity of this pit pumpout is unknown.
V-16
DRAFT
-------
,TRUCK
fiPFN PIT
x
Mil 1 INfi
m
*
DRYING
ANH
CLASSIFICATION
t
RAINWATER
GROUND WATER
SETTLING
PONDS
SOLID
WASTE
•PRODUCT TO SHIPPING
»TO ON-SITE REFRACTORY
MANUFACTURING
EFFLUENT
RGURE T-3.4J
DRY KAOLIN MINING AND PROCESSING
FOR GENERAL PURPOSE USE
-------
DRAFT
3. U. 1.1. 4 Waste Water Treatment
There is no process wastewater generated at any of the four
plants, but the pit pumpout is normally sent through a
series of small settling ponds before discharge,
3.4,1.1.5 Effluent and Disposal
The solid waste generated is land-disposed on-site. There
is no process effluent discharged. The pit pumpout is, in
most instances, sent through a series of settling ponds to
reduce the suspended solids. The effluent composition is
unknown,
3.4^1^2 Wet Process
Process Description
sixty percent of the U.S. production of kaolin is by this
general process.
Mining of kaolin is an open pit operation using draglines or
pan scrapers. The clay is then trucked to the plant or, in
the case of plant 3025, some preliminary processing is
performed near the mine site including blunging or pug
milling, degritting, screening and slurrying to pump the
clay to the main processing plant. Subsequent operations
are hydroseparation and classification, chemical treatment
(principally bleaching with zinc hydrosulfite), filtration,
and drying (via tunnel dryer, rotary dryer or spray dryer).
For special properties, other steps can be taken such as
magnetic separation, delamination or attrition (plant 3024).
Also, plant 3025 ships part of the kaolin product as slurry
(70% solids) in tank cars. A general wet process diagram is
Qi.v
-------
WATER
ZINC
HYDROSULFITE
OPEN
PIT
T
BLUNGING
AND/OR
PUG MILLING
DEGRITTING
AND
CLASSIFICATION
PIT
PUMPOUT
BLEACHING
AND/OR
CHEMICAL
TREATMENT
FILTRATION
WATER80RNE
TAILINGS TO
SETTLING POND
OR BY-PRODUCT
RECOVERY
I |
LIME-
POND
EFFLUENT
PRODUCT
o
y_
KAOLIN
BULK
SLURRY
70%
SLURRY
PRODUCT
FIGURE Y-3.4.2
WET KAOLIN MINING AND PROCESSING
FOR HIGH GRADE PRODUCT
-------
DRAFT
carried through to wastewater from the bleaching operations
The raw waste loads at these two plants are:
kq/kka product_llb/tQnl
Waste Material 3024 3025
2inc 0.37 (0.74) 0.5 (1.0) est.
dissolved solids 8 (16) 10 (20) est.
suspended solids 35 (70) 100 (200) est.
The dissolved solids are principally sulfates and sulfites
and the suspended solids are ore fines and sand.
IsJLJUlsJ Water Use
Water is used in wet processing of kaolin for pug milling,
blunging, cooling, and slurrying. At plant 3024, water is
obtained from deep wells, all of which is chlorinated and
most of which is used as plant process water with no
recycle. Plant 3025 has a company-owned ground water system
as a source and also incoming slurry provides some water to
the process none of which is recycled. Typical water flows
arej
liters/kkg product (gal/ton)
3024 3025
water intake 4,250 (1,020) 4,290 (1030)
process wastewater 3,400 (810) 4,000 (960)
water evaporated, etc. 850 (210) 290 (70)
These plants do not recycle their process water but
discharge it after treatment. Recycle of this water would
interfere with the process operation.
laib-luLsJ Waste Water Treatment
Open pit mining of kaolin does not utilize any water.
However, when rainwater and ground water accumulate in the
pits it must be pumped out and discharged. Usually this
V-20
DRAFT
-------
DRAFT
pumpout is discharged without treatment, but, in at least
one case, pH adjustment is necessary prior to discharge.
The plants treat the ponds with lime to adjust pH and remove
excess zinc which has been introduced as a bleaching agent.
This treatment effects a 99.8% removal of zinc, 99.9%
removal of suspended solids, and SOX removal of dissolved
solids.
These plants are considering the use of sodium hydrosulfite
as bleach to eliminate the zinc waste.
3.4.1.2.5
Effluent and Disposal
Solid wastes generated in kaolin mining and wet processing
are land-disposed with overburden being returned to
mined-out pits, and dust, fines, and other solids to
settling ponds.
Waste waters are in all cases sent to ponds where the solids
settle out and the water is discharged after lime treatment.
Plants 3024 and 3025 discharge an effluent containing
0.25 mg/liter Zn, 6-25 ing/liter suspended solids and
480 mg/liter dissolved solids (mostly CaSO4). On the basis
of the average waste flow these parameters amount to:
waste flowr
1/kkg (gal/ton)
302ft
3,400
(810)
parameter quantity
kg/kkg (Ib/ton):
zinc 0.0009
(0.0018)
suspended solids 0.022
(0.044)
dissolved solids 1.6 (3.2)
3025
4,000
(960)
0.001
(0.002)
0.10
(0.20)
1.1 (2.2)
average
3,700
(890)
0.001
(0.002)
0.06
(0.12)
1.4 (2.8)
V-21
DRAFT
-------
DRAFT
Ball C^av
Ball clay is a plastic, white-firing clay used principally
for bonding in ceramic ware. Four ball clay producers
representing 40 percent of total U.S. ball clay production
provided data for this section. There are twelve plants in
this category.
Process Description
After overburden is removed, the clay is mined using
front-end loaders and/or draglines. The clay is then loaded
onto trucks for transfer to the processing plant.
Processing consists of shredding, milling, air separation
and bagging for shipping. Plants 5684 and 5685 have
additional processing steps including blunging, screening,
and tank storage for sale of the clay in slurry form, and
rotary drying directly from the stockpile for a dry
unprocessed ball clay. A general process diagram is given
in Figure V-3.4.3.
Waste Load
Ball clay mining generates a large amount of overburden
which is returned to worked-out pits for land reclamation.
The processing of ball clay generates dust and fines from
milling and air separation operations. These fines are
gathered in baghouses and returned to the process as
product. At the plants where slurrying and rotary drying
are done, there are additional process wastes generated.
Blunging and screening the clay for slurry product generates
lignite and sand solid wastes after dewatering. The drying
operation uses wet scrubbers which result in a slurry of
dust and water sent to a settling pond.
There are no data available on the amount of wastes
generated in producing the slurry or the dry product, but
the waste materials are limited to fines of low solubility
minerals.
V-22
DRAFT
-------
HOT
AIR
PITS
SHRED
QTHPK'PII P
O I vA*i\r IL-t
HAMMER
M!LL |
LEGEND:
o
73
ALTERNATE PROCESS ROUTES
I
NJ
Ul
CHEMICALS -
WATER-
BLUNGER
Jr.
SCREEN
i
SOLID WASTE
(LIGNITE, SAND)
I
ROTARY
DRYER
WATER
SCRUBBERS
POND
CYCLONES
BAG
HOUSE
EFFLUENT
I
AIR SEPARATOR
BAGGED
PRODUCT
BULK
PRODUCT
SLURRY
PRODUCT
FIGURE Y-3.4.3
BALL CLAY MINING AND PROCESSING
-------
DRAFT
3.4.2.3 Water Use
There is no water used in ball clay mining, however, when
rain and ground water collects in the pits, there is an
intermittent discharge. Pit pumpout is either discharged
without treatment, or pumped to a settling pond before
discharge to a nearby body of water. There is usually some
diking around the pit to prevent run-off from flowing in.
There are no flow rates or water quality data available on
pit pumpout,
In ball clay processing, two of the plants visited use a
completely dry process. The others produce a slurry product
using water for blunging, a product dried directly from the
stockpile with water used for wet scrubbers, and/or the dry
process product, well water serves as the source for the
plants which use water in their processing. Typical flows
ares
liters/metric ton of product
5684
jgaI/ton)
5689
Intake
Use:
Blunging
Scrubber
Consumption
total
unknown
unknown
88 (21)
total
unknown
1,130
(270)
42 (10)
1,080
(260)
1,130
(270)
4,300
(1,030)
none
4,300
(1,030)
4,300
(1,030)
Water used in blunging operations is consumed both as
product and evaporated from water material. Scrubber water
is impounded in settling ponds and eventually discharged.
Plants 5685 and 5689 use water scrubbers for both dust
collection from the rotary driers and for in-plant dust
collection. Plant 5684 has only the former.
l^dLulsJ* Waste Water Treatment
Pit pumpout is discharged either after settling in a pond or
sump or without any treatment.
V-24
DRAFT
-------
DRAFT
Scrubber water at these plants is sent to settling ponds.
In addition, plants 5684 and 5689 treat the scrubber water
with a flocculating agent which improves settling of
suspended solids into the pond. Plant 5689 has three ponds
of a total of 1.0 hectare (2.5 acres) area.
3.4.2.5 Effluent, and Disposal
There are no data available on the quality of the
intermittent pit pumpout from any of the ball clay producers
visited.
Effluent discharged from the settling pond at plant 5685 has
the following parameters: a pH of 6.4 and TSS of 400 mg/1.
Total suspended solids at plant 5689 averages less than
40 mg/liter.
No data are available on effluent from plant 5684.
The amounts of process wastes discharged by these plants are
calculated to be:
discharge. TSS.
liters/kfccr of product kg/kka of product
plant faal/ton) (Ib/ton)
5684 88 (21)
5685 1,080 (260) 0.43 (0.86)
5689 4,300 (1,030) 0.17 (0.34)
There are two significant types of operations in ball clay
manufacture insofar as water use is concerned: those having
wet scrubbers, which have a wastewater discharge, and those
without wet scrubbers, which have no process wastewater.
Insofar as plants having scrubbers is concerned, plant 5689
is exemplary in its treatment, discharging a low
concentration of TSS and a moderate total amount.
V-25
DRAFT
-------
DRAFT
3.5 Feldspar
Feldspar mining and/or processing has been sub- categorized
as follows:
(1} wet processing - dry quarries - flotation processing
(2) dry processing - dry quarries - dry crushing and classi-
fication
Feldspathic sands are included in the Industrials Sands
category in Volume I of this report.
Feldspar - Wet Processing
This subcategory of feldspar mining and processing is
characterized by dry operations at the mine and wet
processing in the plant. This is the most important
subcategory of feldspar, since about 73 percent of the total
tonnage of feldspar sold or used {in 1972) was produced by
this process.
Wet processing is carried out in five plants owned by three
companies. All five of these plants (Plant nos. 3026, 3054,
3065, 3067, and 3068) are represented in the data below. A
sixth plant is now coming into production and will replace
one of the above five plants in 1975.
J^JIjLLJ. Process Description
At all five plants, mining techniques are quite similar:
after overburden is removed, the ore is drilled and blasted,
followed by loading of ore onto trucks by means of power
shovels, draglines, or front end loaders for transport to
the plant. In some cases, additional break-up of ore is
accomplished at the mine by drop-balling. No water is used
in mining at any location*
The first step in processing the ore is crushing which is
generally accomplished at the plant, but may be accomplished
at the mine (Plant 3068) . Subsequent steps for all wet
processing plants vary in detail, but the basic flow sheet,
as given in Figure V-3.5.1, contains all the fundamentals of
these plants.
V-26
DRAFT
-------
O
KJ
WATER
J
CRUSHER WASHER
QUARRY — • AND — «* OR — »
MILLS SCRUBBER
FLOTATIOf*
WATER AGENTS
1 1
CLASSIFICATION,
CONDITIONING,
AMH
AIMU
FLOTATION
(3 REPETITIONS)
1
IRON
SOLID
WASTE
WASTE
SLURRIES
TO
POND
BALL
, MILL
T T~
"ENTERING MAGNETIC
~~ OWING SEPARA™
WASTE
WATER
N — •» PRODUCT
BY-PRODUCT
MICA FROM
»»F!PST F1 OAT
^^UT r ICJUUC I
SAND FROM
THIRD FLOAT
O
RGURE Y-3.5.1
FELDSPAR MINING AND PROCESSING
(WET)
-------
DRAFT
By-products from flotation include mica, which may be
further processed for sale (at Plants 3054, 3065, 3067, and
3068), and quartz or sand (at Plants 3026, 3054, and 3068).
At Plants 3065 and 3067, a portion of the total flow to the
third flotation step is diverted to dewatering, drying,
guiding, etc., and is sold as a feldspathic sand.
3.5.1.2 Raw Waste Loads
Mining operations at the open pits result in overburden of
varying depth. The overburden is applied to land
reclamation of nearby worked-out mining areas.
waste recovery and handling at the processing plants is a
major consideration, as large tonnages are involved. Waste
varies from a low of 26 percent of mined ore at Plant 3065
to a high of 53 percent at Plant 3067. The latter value is
considerably larger due to the fact that this plant does not
sell the sand from its feldspar flotation. Most of the
other plants are able to sell all or part of their by-
product sand. Typical flotation reagants used in this
production subcategory contain hydrofluoric acid, sulfuric
acid, sulfonic acid, frothers, amines and oils.
The raw waste data calculated from information supplied by
these plants are:
kq/kkg of ore
processed (Ib/toni
filant ore tailings and slimes fluoride
3026 270 (540) 0.22 (0.44)
3054 410 (820) 0.24 (0.48)
3065 260 (520) 0.20 (0.40)
3067 530 (1,060) est. 0.25 (0.50)
3068 350 (700) est. 0.25 (0.50)
These raw wastes are generally settled in ponds or sent to
thickeners. The bulk of the solids and adsorbed organics
would then be separated from the liquid containing dissolved
fluoride and some suspended solids.
V-28
DRAFT
-------
DRAFT
3.5.1.3
Water is not used in the quarrying of feldspar. There is
occasional drainage from the mine, but pumpout is not
generally practiced.
Wet processing of feldspar does result in the use of quite
significant amounts of water. At the plants visited, water
was obtained from a nearby lake, creek, or river and used
without any pre-treatment. Recycle of water is minimal,
varying from zero at several plants to a maximum of about
17 percent at Plant 3026. The primary reason for little or
no water recycle is the possible build-up of undesirable
soluble organics and fluoride ion in the flotation steps.
However, some water is recycled in some plants to the
initial washing and crushing steps, and some recycle of
water in the fluoride flotation step is practiced at plant
3026.
Total water use at these plants varies from 7,000 to
22,200 liters/kkg of ore processed (1,680 to 5,300 gal/ton).
Most of the process water used in these plants is discharged
as a wastewater. Some water is lost in tailings and drying.
This is of the order of 1 percent of the water use at
plant 3065.
The use of the process water in the flotation steps amounts
to at least one-half of the total water use. The water used
in the fluoride reagent flotation step ranges from 10 to
25 percent of the total flow depending on local practice and
sand-to-feldspar ratio. Only two of these five plants use
any significant recycling of water. These are:
plant 3026 - 17 percent of intake (on the average)
plant 3067 - 10 percent of intake
3.5.1.4 Waste Water Treatment
Treatment at three plants (3054, 3065, 3068) consists of
pumping combined plant effluents into thickeners, with
polymer added to aid in flocculation. Both polymer and lime
are added at one plant (3065). At the other two plants,
(3026, 3067) there are two settling ponds in series, with
one plant adding alum (3026).
V-29
DRAFT
-------
DRAFT
Measurements by Versar on the performance of the treatment
system at plant 3026, consisting of two ponds in series and
alum treatmentt showed the following reductions in
concentration (mg/liter):
TSS fluoride
wastewater into system 3,790 14
discharge from system 21 1.3
Disposal
The process water effluents after treatment at these five
plants have the following average quality characteristics:
giant £g ma/liter mq/liter
3026 6.5-6.8 21* 8
3054 6.8 45 15*
3065 10.8* 319 23*
3067 7.5-8.0 35* 34*
3068 7-8 40-150 32
The asterisked values are Versar measurements in lieu of
plant- furnished data not available. Plant 3065 adds lime to
the treatment, which accounts for the higher than average
pE,
The average amounts of the suspended solids and fluoride
pollutants present in these waste effluent streams
calculated from the above values are given below together
with the relative effluent flows.
V-30
DRAFT
-------
p].ant
3026
3054
3065
3067
3068
DRAFT
ore processed basis
flow- TSS,
liters/kkq kg/kkg
fqal/tonl (Ib/ton)
fluoride.
14,600
(3,500)
12,500
(3,000)
11,000
(2,640)
6,500
(1,560)
18,600
(4,460)
0.31
(0.62)
0.56
(1.12)
1.1
(2.2)
0.23
(0.46)
Clb/tonl
0.12
(0.24)
0.18
(0.36)
0.25
(0.50)
0.22
(0.44)
0.7-2.8 0.6
(1.4-5.6) (1.2)
The higher than average suspended solids content of the
effluents of 3065 and 3068 is caused by froth carrying of
mica through the thickeners to the discharges. Therefore,
the waste treatment systems in these two plants are not
performing in an exemplary fashion. Plant 3026 is exemplary
in regard to the levels of discharge of both suspended
solids and fluoride. The fluoride content of the discharge
is almost one-half of the raw waste load, whereas the other
plants discharge nearly all the fluoride raw waste. This
plant uses alum to coagulate suspended solids, which may be
the cause of the reduction in fluoride. Alum has been found
in municipal water treatment studies (references 4 and 12)
to reduce fluoride by binding into the sediment. The
effectiveness of the treatment at 3026 to reduce suspended
solids is comparable to that at plants 3054 and 3067. All
three of these plants have exemplary suspended solids
discharge levels for this subcategory.
The treatment at plant 3054 results in little or no reduc-
tion of fluoride, but good reduction of suspended solids.
Nothing known about this treatment system would lead to an
expectation of fluoride reduction.
V-31
DRAFT
-------
DRAFT
The treatment at plant 3067 apparently accomplishes no
reduction of fluoride, but its suspended solids discharge is
significantly lower than average in both amount and
concentration .
Based on these conclusions, plant 3026 is exemplary in
regard to both suspended solids and fluoride discharges. In
addition, plants 3054 and 3067 exhibit exemplary reduction
of suspended solids only.
Solid wastes are transported back to the mines as reclaiming
fill, although these wastes are sometimes allowed to
accumulate at the plant for long periods before removal.
3.5.2 Feldspar - Dry Processing
This subcategory of feldspar mining and processing is
characterised by completely dry operations at both the mine
and the plant. Only two such plants were found to exist in
the U.S. and both were visited. Together they represent
approximately 8.5 percent of total U.S. feldspar production.
However, there are two important elements of difference
between these two operations as follows:
All of plant 3032 production of feldspar is sold for use as
an abrasive in scouring powder. At plant 3064, the high
quality orthoclase (potassium aluminum silicate) is
primarily sold to manufacturers of electrical porcelains and
ceramics.
3^5A2,J Process Description
Underground mining is accomplished at Plant 3032 on an
intermittent, as-needed, basis using drilling and blasting
techniques. A very small amount of water is used for dust
control during drilling. At Plant 3064, the techniques are
similar, except mining is in an open pit and is carried on
for 2-3 shifts/day and 5-6 days/week depending on product
demand. Hand picking is accomplished prior to truck
transport of ore to the plant.
At the two plants ore processing operations are virtually
identical. They consist of crushing, ball milling, air
classification, and storage prior to shipping. Product
V-32
DRAFT
-------
DRAFT
grading is a function of air classification operation. A
schematic flow sheet is shown in Figure V-3.5.2.
3.5.2.2 Raw Waste Loads
At Plant 3032, there are no mine wastes generated, and only
a small quantity of high-silica solids emanate from the
plant. The quantity of waste is unknown, and the material
is used as land fill. At Plant 3064, rejects from hand
picking are used as mine fill. There is very little waste
at the plant.
3.5.2.3 Water Use
At the Plant 3032 mine, water is used to suppress dust while
drilling. It is spilled on the ground and is readily
absorbed; volume is only about 230 liters/day (about
60 GPD). No water is used in plant processing at the mine.
At Plant 3064, no water is used at the mine. Plant water is
used at a daily rate of <1,900 liters/day (500 GPD) to
suppress dust in the crushers.
No pre-treatment is applied to water used at either plant.
3.5,2.4 Wastewater Treatment
Any wastewater is spilled on the ground (Plant 3032) or is
evaporated off during crushing and milling operations (Plant
3064). There is no wastewater treatment at either plant.
3.5,2.5 Effluents and Disposal
There are no effluents from either mine or plant locations.
3^6 Kyanite
Kyanite is produced in the U.S. from 3 open pit mines, two
in Virginia and one in Georgia. In this study two of these
three mines were visited, one in Virginia, and one in
Georgia, representing approximately 75 percent of the U.S.
production of kyanite.
V-33
DRAFT
-------
QUARRY
PRf I^HFRQ
BALL
MILLS
AIR
CLASSIFICATION
•PRODUCT
O
I
co
RGURE T -3.5.2
FELDSPAR MINING AND PROCESSING
(DRY)
-------
DRAFT
3.6.1 Process Description
Kyanite is mined in dry open quarries, using blasting to
free the ore. Power shovels are used to load the ore onto
trucks which then haul the ore to the processing plant.
Processing consists of crushing and milling, classification
and desliming, flotation to remove impurities, drying, and
magnetic separation. Part of the kyanite is converted to
mullite via high temperature firing at 1510°-1650°C (2800-
3000°F) in a rotary kiln. A general process diagram is
given in Figure V-3.6.1.
3i_6r2_ Raw Waste Load
Wastes are generated in the processing of the kyanite, in
classification, flotation and magnetic separation
operations. These wastes consist of pyrite tailings, quartz
tailings, flotation reagents, muds, sand and iron sealpings.
These wastes are greater than 50 percent of the total mined
material.
waste material kg/kkg of kvanite (Ibs/ton)
plant 3015 tailings 2,500 (5,000) (est.)
plant 3028 tailings 5,700 (11,300) (est.)
3.6.3 Water Use
Water is used in kyanite processing in flotation,
classification, and slurry transport of ore solids. This
process water amounts to:
liters/kkg of kyanite (gal/ton)
plant 3015 29,200 (7,000)
plant 3028 87,600 (21,000)
The process water is recycled, and any losses due to
evaporation and pond seepage are replaced with make-up
water. Make-up water for plant 3028 is used at a rate of
4,200,000 liters/day (0.288 MGD) and plant 3015 obtains
V-35
DRAFT
-------
FLOTATION
WATER REA6FNTS
WATER RECYCLE WATP-R ,
j r
fMIADDV •». f*m IC*LJIM^
co
OY
.;
••M
III T
CLASSIFICATION,
FLOTATION
UNDERFLOW
TAILINGS
._ _.., POND
MAGNETIC , 1
SEPARATION
^ ROTARY ^ MULLITE
SCALPINGS
1
TO WASTE
RGUREY-3.6.1
KYANITE MINING AND PROCESSING
-------
DRAFT
make-up water from run-off draining into the settling pond
and also from an artesian well.
Waste Water Treatment
Process water used in the several beneficiation steps is
sent to settling ponds from which clear water is recycled to
the process. There is total recycle of the process water
that is not lost through evaporation and pond seepage.
Effluent and Disposal
There is no deliberate discharge of process water from plant
3015. The only time pond overflow has occurred at plant
3015 was after an unusually heavy rainfall. Plant 3028 has
occasional pond overflow, usually occurring in October and
November.
The solid waste generated in kyanite processing is
land-disposed after recovery from settling ponds. An
analysis of pond water at plant 3015 showed low values for
BOD (2 mg/liter) and oil and grease (t mg/liter). Total
suspended solids were 11 mg/liter and total metals 3.9
mg/liter, with iron being the principal metal. No analyses
were available on the occasional overflow at plant 3028.
3,7 Maanesite
There is only one known U.S. plant that produces magnesia
from naturally occurring magnesite ore. This facility,
plant 2063, mines and beneficiates magnesite ore and
produces dead burned magnesia, caustic burned magnesia and
flotation concentrate. The company's current holdings in
this category consist of three dry open pit mines, one heavy
media separation (HMS) plant and a flotation mill.
3,7.1 Process Description
All mining operations are accomplished by the open pit
method. The deposit is chemically variable, due to the
interlaid horizons of dolomite and magnesite, and megascopic
identification of the ore is difficult. The company has
devised a selective quality control system to obtain the
various grades of ore required by the processing plants.
V-37
DRAFT
-------
DRAFT
The pit is designed with walls inclined at 60° , with 20-foot
catch benches every 50 feet of vertical height. The crude
ore is loaded by front end loaders and shovels and then
trucked to the primary crusher. The quarry is located
favorably so that there is about 2 kilometers (1.25 miles)
distance to the primary crusher.
About 2260 kkg/day (2500 tons/day) of ore are crushed in the
mill for direct firing and beneficiation. The 5 percent
waste from this operation is primarily silicates. The
remainder of the crusher product (95% of the input) is
distributed to the kiln. Heavy Media Separation (HMS) and
flotation at 15, 50 and 30 percent respectively.
The flow of material through the plant, for direct firing,
follows two major circuits: (1) the dead burned magnesite
circuit, and (2) the light burned magnesite circuit.
In the dead burned maanesite circuit, the ore is crushed to
minus 3/4 inch in a cone crusher. All raw materials
including iron oxide, chrome, and other ingredients required
for a particular mix are stored ahead of grinding. The raw
materials are dry ground in two ball mills that are in
closed circuit with an air classifier. The minus 65 mesh
product from the classifier is transported by air slides to
the blending silos. From the silos the dry material is fed
to pug mills where water and binding materials are added.
From the pug mills the material is briquetted, dried, and
stored in feed tanks ahead of rotary kilns. The oil- or
natural-gas-fired kilns convert the magnesite into dense
magnesium clinker of various chemical constituents,
depending upon the characteristics desired in the product.
After leaving the kiln, the clinker is cooled by an air
quenched rotary or grate type coolers, crushed to desired
sizes, and stored in large storage silos for shipment.
In ii3h£ burned maanesite circuit, minus 3/4" magnesite is
fed to two Herreshoff furnaces. By controlling the amount
of liberated CO2 from the magnesite a caustic oxide is
produced from these furnaces. The magnesium oxide is cooled
and ground in a ball mill into a variety of grades and
sizes, and is either bagged or shipped in bulk.
Magnesite is beneficiated at plant 2063 by either HMS and/or
froth flotation methods.
V-38
DRAFT
-------
DRAFT
In the HMS plant, the feed is crushed to the proper size,
screened, washed and drained on a vibratory screen to
eliminate the fines as much as possible. The screened feed
is fed to the separating cone which contains a suspension of
finely ground ferro-silicon and/or magnetite in water,
maintained at a predetermined specific gravity. The light
fraction floats and is continuously removed by over-flowing
a weir. The heavy particles sink and are continuously
removed by an airlift.
The float weir overflow and sink airlift discharge go to a
drainage screen where 90 percent of the medium carried with
the float and sink drains through the screen and is returned
to the separatory cone.
The "float" product passes from the drainage section of the
screen to the washing section where the fines are completely
removed by water sprays. The solid wastes from the wet
screening operations contain -3/8 to +1-1/2" material which
is primarily used for the construction of settling pond
contour. The fines from the spray screen operations, along
with the "sink" from the separating cone, are sent into the
product thickener.
In the flotation plant, the feed is properly crushed,
milled, and classified and then sent into the cyclone
clarifier. Make-up water, along with the process recycled
water, is introduced into the cyclone classifier. The
oversize from the classifier is ground in a ball mill and
recycled back to the cyclone. The cyclone product is
distributed to the rougher flotation and the floated product
is then routed to cleaner cells which operate in series.
The flotation concentrate is then sent into the product
thickener. The underflow from this thickener is filtered,
dried, calcined, burned, crushed, screened and bagged for
shipment.
The tailings from the flotation operation and the filtrate
constitute the waste streams of these plants and are sent
into the tailings thickener for water recovery. The
overflows from either thickener are recycled back to
process. The underflow from the tailings thickener
containing about 40 percent solids is impounded in the
plant. A simplified flow diagram for this plant is given in
Figure V-3.7.1.
V-39
DRAFT
-------
o <
id I
ORE
MNH
CRUSHERS
••M
5% 15%
FINES TO
TO KILN
WASTE
RECYCLED
WATER
i
H HEAVY
SEPARATION
, , PLANT
<50% f
* SOLID
WASTE
FLOTATION
AGENT
C30% 1
CRUSHERS ROUGHER
-., ROD MILLS fc AMD
AND CLEANER
CLASSIFIERS CELLS
'
VENT
t
BAG
HOUSE
8 i
UKYiNG,
CONCENTRATE VACUUM _. C^$ WING, MAGNESIA
^ THICKENER "" FILTERS CRUSHING ~~^PRODUCT
CrDCTMIMrt
1 1 RECYCLE
*
OVERFLOW TAILINGS
THICKENER
FILTRATE
MAKE-UP WATER
UNDERFLOW
40% SOLIDS
TO SETTLING POND
D
FIGURE 3T-3.7.I
MAGNESITE MINING AND PROCESSING
-------
DRAFT
3^7.2 Raw Waste Loads
The raw waste from this plant consists of the underflow from
the tailings thickeners and it includes about 40 percent
suspended solids. The average values reported are given
below:
waste material kg/day fibs/day)
suspended solids 590,000 (1,300,000)
No data were supplied on daily production rates. These
figures are considered confidential by this company.
3.7A3 Plant Water Use
This plant's fresh water system is serviced by eight wells.
All wells except one are hot water wells, 50 to 70°C (121°
to 160°F).
The total mill intake water is 2,200,000 liters per day
(580,000 gal/day), 88 percent of which is cooled prior to
usage. The hydraulic load of this plant is given below:
water consumption liters/day (gal/day)
process water to refine the
product 163,000 (43,000)
road dust control 227,000 (60,000)
sanitary 11,360 ( 3,000)
tailing pond evaporation 492,000 (130,000)
tailing pond percolation 757,000 (200,000)
evaporation in water sprays.
Baker coolers 6 cooling towers 545,000 (144,000)
No process wastewaters are discharged out of the property at
this plant. There is no mine water pumpout at this
facility.
3.7.4 Waste Water Treatment
The waste stream at this plant is the underflow of the
tailings thickener which contains large quantities of solid
wastes. To aid the flow, make-up water is added to this
waste stream and then discharged into the tailings pond.
V-41
DRAFT
-------
DRAFT
The estimated area of this pond is 15 hectares (37 acres).
The estimated evaporation at this area is 54 inches per year
and the annual rainfall is 6 inches per year. The
wastewater is, therefore, dried about 40 percent by
evaporation and about 60 percent by percolation.
No stream discharge from the mill is visible in any of the
small washes in the vicinity of the tailings pond, and also,
no green vegetative patches, that would indicate the
presence of near surface run-offs, were visible. The
tailings pond is located at the upper end of an alluvial
fan. This material is both coarse and angular and has a
rapid percolation rate. This could account for the lack of
run-off and the total recharge of the basin.
Effluent
As all process waters at plant 2063 are either recycled or
lost by evaporation and percolation, there is no process
water effluent discharge out of this property.
3.8.1 Shale
Shale is a consolidated sedimentary rock composed chiefly of
clay minerals, occurring in varying degrees of hardness.
Shales and common clays are for the most part used by the
producer in fabricating or manufacturing structural clay
products (SIC 3200) so only shale mining is discussed here.
Less than 10 percent of total clay and shale output is sold
outright. Therefore, for practical purposes, nearly all
such mining is captive to ceramic or refractory
manufactures.
3.8.1.1 Process Description
Shale is mined in open pits using rippers, scrapers,
bulldozers, and front-end loaders for removal of the shale
from the pit. Blasting is needed to loosen very hard shale
deposits. The shale is then loaded on trucks or rail cars
for transport to the plant. There, primary crushing,
grinding, screening, and other operations are used in the
manufacture of many different structural clay products. A
general process diagram is given in Figure V-3.8.1.
V-42
DRAFT
-------
COARSE
SHALE
PIT
PRIMARY
CRUSHER
i
GRIND
SCREEN
PRODUCTS
I
£».
U>
1
PIT
PUMPOUT
FIGURE Y-3.8.1
SHALE MINING AND PROCESSING
-------
DRAFT
3.8.1.2 Raw Waste Load
Solid waste is generated in shale raining as overburden which
is used as fill to reclaim mined-out pits. Since ceramic
processing will not be discussed here, no processing waste
is accounted for.
3,8.1.3 Water Use
There is no water used in shale mining, however, due to
rainfall and ground water seepage, there can be water which
accumulates in the pits and must be removed. Pit pumpout is
intermittent depending on rainfall frequency and geographic
location. In many cases, plants will build small earthen
dams or ditches around the pit to prevent inflow of
rainwater. Also shale is, in most cases, so hard that run
off water will not pickup significant suspended solids.
Flow rates are not generally available for pit pumpout.
3.8.1.4 Waste Water Treatment
There is no wastewater treatment necessary for shale mining
and processing since there is no process water used. When
there is rainfall or ground water accumulation, this water
is generally pumped out and discharged to abandoned pits or
streams.
3.8.1.5 Effluent and Disposal
Pit pumpout is discharged without treatment. There is no
other effluent.
3.8.2 Aplite
Aplite is found in quantity in the U.S. only in Virginia and
is mined and processed by only two plants, both of which are
discussed below.
3.8,2.1 Process Description
The deposit mined by plant 3016 is relatively soft and the
ore can be removed with bulldozers, scrapers, and graders,
while that mined by plant 3020 requires blasting to loosen
from the quarry. The ore is then loaded on trucks and
hauled to the processing plant.
V-44
DRAFT
-------
DRAFT
Plant 3016 employs a wet process consisting of wet crushing
and grinding, screening, removal of mica and heavy minerals
via a series of wet classifiers, dewatering and drying,
magnetic separation and final storage prior to shipping.
Plant 3020 processing is dry, consisting of crushing and
dryingr more crushing, screening, magnetic separation and
storage for shipping. However, water is used for wet
scrubbing to control air pollution. A process flow diagram
is given in Figure V-3.8.2 depicting both processes.
3.8.2.2 Raw Waste Load
Mining waste is overburden and pit pumpout. The processing
wastes are dusts and fines from air classification, iron
bearing sands from magnetic separation, and tailings and
heavy minerals from wet classification operations. The
latter wastes obviously do not occur at the dry plant.
Water-borne kg/kkq
Waste kkg/vear of product
Materials fTPY) fibs/ton)
plant 3016 tailings and 136,000 1,000
(wet) heavy minerals (150,000) (2,000)
and fines
plant 3020 dust and fines 9,600 175
(dry) (10,600) (350)
Other, non-waterborne wastes come from the magnetic
separation step at plant 3020.
3^8.2.3 Water Use
Water is used at plant 3020 (dry process) only for wet
scrubbers which cut down on airborne dust and fines. This
water totals 1,230,000 liters/day (324,000 GPD) with no
recycle. There is occasional pit pumpout.
Water is used at plant 3016 for crushing, screening and
classifying at a rate.of 38,000,000 I/day (10,000,000 GPD)
which is essentially 100* recycled. Dust control requires
about 1,890,000 I/day (500,000 GPD) of water which is also
recycled. Any make-up water needed due to evaporation
V-45
DRAFT
-------
a
DRY PROCESS WATER B>
• ~ Wt I rKUG-tbo
SCRUBBERS
Jl
^ ^ "^| DUST,
•J
hJiMtr ppl iQuiKin -^^M£^L HPYiMrt -_^_4mr, CRUSHING ^^_ini
MINC CRUollING — «» DRYING - fl» SCREENING
t CLASSIFY
FINES
t J
1 VENT
1 t
SCREENING » CYCLONE to CLASSIFY •
DRYING
-«, AND
SCREENING
! ! ! *
1 |l~
* * * J
1
1 POND '
„
MAGNETIC
SEPARATION
i
__
1
1
1
1
1
1
i i
IRON SANDS
TO LANDFILL
OR BEACH SA
m API ITF
PRODUCT
^. APLITE
PRODUCT
a
S
hrj
1-3
ND .
POND
T
FIGURE TT-3.8.2
APLITE MINING AND PROCESSING
EFFLUENT
-------
DRAFT
losses comes from the river. The amount was not disclosed.
There is no pit pumpout at plant 3016 and any surface water
which accumulates drains to a nearby river.
The plant water use in this industry can be summarized:
liters/kkg of product (gal/ton)
process use; 3016 3020
scrubber or dust 3,600 (870) 5,900 (1,420)
control
crush, screen, 12,700 (3,040) 0
classify
net discharge (less approx. 0 5,900 (1,420)
pit pumpout)
pit pumpout 0 not given
make-up water not given 5,900 (1,420)
intake
3.8.2.4 Waste Water Treatment
The wastewater generated in these aplite operations is sent
to tailings ponds where solids are allowed to settle. The
scrubber water from plant 3020 is discharged after settling
while the occasional pit pumpout is discharged without
settling. The water from the wet process plant 3016 is
essentially 100% recycled to the process. Every few years,
when the pond level becomes excessive, plant 3016 discharges
from the pond to a river. When this occurs, the pond is
treated with alum to lower suspended solids levels in the
discharge. Likewise, when suspended solids levels are
excessive for recycle purposes, the pond is also treated
with alum. There is no other water loss from plant 3016
except for evaporation and pond seepage.
3.8.2.5 Effluent and Disposal
Plant 3020 discharges effluent arising from wet scrubber
operations to a creek after allowing settling of suspended
solids in a series of ponds. Aplite clays represent a
settling problem in that a portion of the clays settles out
rapidly but another portion stays in suspension for a long
time, imparting a milky appearance to the effluent.
Analytical data on the effluent is not presently available.
V-47
DRAFT
-------
DRAFT
The occasional pit pumpout due to rainfall is discharged
without treatment.
Plant 3016 recycles water from the settling ponds to the
process with only infrequent discharge to a nearby river
when pond levels become excessive (every 2 to 3 years).
This discharge is state regulated only on suspended solids
at 6<*9 mg/liter average, and 1000 mg/liter for any one day.
Actual settling pond water analyses have not been made.
The solid wastes generated in these processes are
land-disposed, either in ponds or as land-fill, with iron
bearing sands being sold as beach sand.
3.9 Talc. Steatite, Soapstone and Pvrophvllite
There are 33 known significant plants in the U.S. producing
talc, steatite, soapstone and pyrophyllite. Twenty-seven of
these plants use dry grinding operations, producing ground
products, two utilize log washing and wet screening
operations producing either crude talc or ground talc and
four are wet crude ore beneficiation plants, three using
froth flotation and one heavy media separation techniques.
3.9.1 Process Description of Dry grinding Operations
In a dry grinding mill, the ore is batched in ore bins and
held until a continuously cut sample is analyzed by the
laboratory. Each batch is then assigned to a separate ore
silo, and subsequently dried and crushed in a crushing
circuit. The ore, containing less than 12% moisture is
reclaimed from these storage silos and sent to fine dry
grinding circuits in the mill. In the pebble mill (Hardinge
circuit), which includes mechanical air separators in closed
circuit, the ore is grinded to minus 200 mesh rock powder.
Part of the grades produced by this circuit are used
principally by the ceramic industry; the remainder is used
as feed to other grinding or classifying circuits. In a few
plants, some of this powder is introduced into the fluid
energy mill and ground at high energy levels to manufacture
a series of minus 325 mesh products for the paint industry.
Following grinding operations, the finished grades are
pumped, in dry state, to product bulk storage silos. The
product is reclaimed from these silos, as needed, and either
V-48
DRAFT
-------
DRAFT
pumped to bulk hopper cars or to the bagging plant where it
is packed in bags for shipment. A generalized process
diagram for a dry grinding mill is given in Figure V-3.9.1.
There is no water used in dry grinding plants; therefore,
there is no generation of water-borne pollutants by these
plants. Bag house collectors are use throughout this
industry for dust control. In fluid energy mills using
steam in the process, steam is non- recuperative. The steam
generated in boilers is used in process and vented to
atmosphere after being passed through a baghouse dust
collector to remove dust product from the steam. The waste
streams emanating from the boiler operations are the sludge
generated from conventional hot or cold lime softening
process and/or zeolite softening operations, filter
backwash, and boiler blowdown wastes which are addressed
under general water guidelines in Section IX of this report.
Even though these plants do not use water in their process,
some of them do have mine water discharge from their
underground mine workings.
3^9.2 Process Description of Log Washing and Wet
screening
At log washing plant 2034 and wet screening plant 2035, the
water is used to wash fines from the crushed ore. In either
plant, the washed product is next screened, sorted and
classified. The product from the classifier is either
shipped as is or it is further processed in a dry grinding
mill to various grades of finished product.
At plant 2034 wash water is sent into a hydroclone system
for product recovery. The slimes from the hydroclone are
then discharged into a settling pond for evaporation and
drying. At plant 2035, the wash water, which carries the
fines, is sent directly into a settling pond.
The wet plants in this subcategory are operational on a
six-month per year basis. During freezing weather, these
plants are shut down, stockpiles of the wet plant products
are accumulated in summer and used as source of feed in the
dry grinding plant in winter. Simplified diagrams for
plants 2034 and 2035 are given in Figures V-3.9.2 and
V-3.9.3, respectively.
V-49
DRAFT
-------
TALC ORE-
JAW
AND
CONE
CRUSHERS
WET
BIN
FINE
CRUSHING
AND DRYING
CIRCUIT
DRY
/"\DC*
UKc.
SILOS
•*••
••••
PEBBLE
_» MILL
GRINDING
CIRCUIT
1
J *
cH
COARSE -> COMP1
MATERIAL /
1
f
FLUID
fc ENERGY
' ' GRINDING
CIRCUIT
•EAM
OR
MESSED
IIR
t
^^^tapimm IPTT
VENT
t
DRY
COLLECTOR
70
.PRODUCT
FIGURE T-3.9.1
TALC, STEATITE, SOAPSTONE AND PYROPHYLLITE MINING AND PROCESSING
(DRY)
-------
LOG
WASHER
VIBRATING I ^1 SCREW
SCREEN H CLASSIFIER
D
I
Ui
i
PRODUCT
FINES
HYDROCLONE
OVERSIZE TO
STOCKPILE
AND MILLING
SLIMES TO
SETTLING POND
FIGURE Y-3.9.2
TALC, STEATITE, SOAPSTONE AND PYROPHYLLITE MINING AND PROCESSING
(LOG WASHING PROCESS)
-------
-n
CRUDE ORE
I
oi
10
CRUSHER
WATER
WET
SCREENING
CLASSIFICATION
f
TAILINGS TO POND
SLIMES OVERSIZE
TO POND TO DUMP
STOCKPILES
AND
MILLS
PRODUCT
O
73
FIGURE T- 3.9.3
TALC, STEATITE, SOAPSTONE AND PYROPHYLLITE MINING AND PROCESSING
(WET SCREENING PROCESS)
-------
DRAFT
3.9.2.1 Raw Waste Loads
The raw waste from plant 2034 consists of the slimes from
the hydroclone operation, that of plant 2035 is the tailings
emanating from the wet screening operation and the slimes
from the classifiers. No data was supplied by either
company on the quantity of the wastes. Since no water is
discharged out of these properties, records on the wastes
are not kept.
3.9.2.2 Plant Water
Both plants are supplied by water wells on their property.
Essentially all water used is process water. Plant 2034 has
a water intake of 182,000 liters per day (48,000 gal/day)
and plant 2035 has a water intake of 363,000 liters per day
(96,000 gal/day). No data were supplied on daily production
rates. These figures were considered confidential by the
companies.
3.9.2.3 Waste Water Treatment
The waste streams emanating from the washing operations are
sent into settling ponds. The ponds are dried by
evaporation and seepage. In plant 2035, when the ponds are
filled with solids, they are harvested for reprocessing into
saleable products.
3.9.2.4 Effluent
There is no discharge out of these properties.
3.9.3 Mine Water Discharge
Underground mine workings intercept numerous ground water
sources. The water from each underground mine is directed
through ditches and culverts to sumps at each mine level.
The sumps serve as sedimentation vessels and suctions for
centrifugal pumps which discharge this water to upper level
sumps or to the surface. In some mines, a small portion of
the pump discharge is diverted for use as drill wash water
and pump seal water; the remainder is discharged into a
receiving waterway. The disposition and quantities of mine
discharges are given below:
V-53
DRAFT
-------
DRAFT
Solids
Miss.* is<
2036
2037
2038
2039
2040
2041
2042
2043
negli-
gible
negli-
gible
negli-
gible
200
200
200
200
Liquid
liters/day
faal/davl
545,000
(144,000)
Data not
available
Data not
available
946,000
(250,000)
1,100,000
(300,000)
76,000
(20rOOO)
76,000
(20,000)
76,000
(20,000)
Waste Load
Relative to
Product Load
liters/kkg
j gal/ton)
1000
(240)
Data not
available
Data not
available
5,200
(1,250)
8,900
(2,140)
(125)
(125)
(125)
500
500
500
3.9.3.1 Mine Water Treatment
In mines 2040,2041,2042 and 2043, the water from each mine
is directed through ditches and culverts to sumps at each
mine level. The sumps serve as sedimentation vessels and
suctions for centrifugal pumps which discharge this water to
upper level settling basins. The overflows from these
basins are discharged into a receiving stream. The
remaining mines employ no surface settling basins. The
water from the underground sump is directly discharged into
a receiving ditch, waterway or mine without further
settling.
V-54
DRAFT
-------
DRAFT
3.9.3.2 Effluent Compositj^pn
No information was available on mines 2037 and 2038. The
significant constituents, however, in the remaining mine
effluents are reported to be as follows:
Waste Material
Mine Number 2036 2039 2040-2043
TSS, mg/1 9 3 <20
Iron, mg/1 0.08 0.05
pH min-max 7.5-7.8 7.0-7.3 7.2-8.5
3.9.4 Process Description of Flotation and Heavy Media
Separation Elants
All four plants in this subcategory use either flotation or
heavy media separation techniques for upgrading the product.
In two of the plants, 2031 and 2032, the ore is crushed,
screened, classified and milled and then taken by a bucket
elevator to a storage bin in the flotation section. The
flotation feed is discharged through a feeder into the
conditioner. The well and recycled water flows into the
conditioner. The conditioner feeds special processing
equipment, which then sends the slurry to a pulp
distributor. In plant 2031, the distributor splits the
conditioner discharge over three concentrating tables. The
concentrates from these tables are the gangue material,
which is sent to the tailings pond. The talc middlings from
the tables are then pumped to the flotation machines.
However, in plant 2032, the distributor discharges directly
into rougher flotation machines. A reagent is added
directly into the cells and the floated product next goes to
cleaning cells. The final float concentrate feeds a rake
thickener which raises the solids content of the flotation
product from 10 to 35 percent. The product from thickener
is next filtered on a rotary vacuum filter and water from
the filter flows back into the thickener. The filter cake
is then dried and the finished product is sent into storage
bins. The flotation tailings, along with thickener
overflow, are sent to the tailings pond. A simplified flow
diagram is given in Figure V-3.9.4.
V-55
DRAFT
-------
WATER
TALC ORE
CRUSHING,
DRYING,
GRINDING
I 1
f 1
CONDITIONER
t
1
1
1
1
1
1
I
FLOTATION
__ REAGENTS
1 A
PULP
DISTRIBUTOR
AND
CONCENTRATING
TABLES
!
Jfl»
1
1
DISTRIBUTOR
AND
FLOTATION
CELLS
THICKENER
AND
FILTER
DRYER
•PRODUCT
I I
\^f
$
f
ui
TAILINGS BASIN
LEGEND:
CLARIFICATION
BASINS
ALTERNATE PROCESSES
EFFLUENT
FIGURE Y-3.9.4
TALC MINING AND PROCESSING
(FLOTATION PROCESS)
-------
DRAFT
Plant 2033 processes ores which contain mostly clay and it
employs somewhat different processing steps. In this plant,
the ore is scrubbed with the addition of liquid caustic to
raise the pH, so as to suspend the red clay. The scrubbed
ore is next milled and sent through thickening, flotation
and tabling. The product from the concentrating tables is
acid treated to dissolve iron oxides and other possible
impurities. Acid treated material is next passed through
the product thickener. The underflow from this thickener
contains the finished product. The thickener underflow is
filtered, dried, grinded and bagged. The waste streams
consist of the flotation tailings, the overflow from the
primary thickener and the filtrate. A generalized flow
diagram is given in Figure V-3.9.5.
Plant 2044 uses heavy media separation (HMS) technique for
the beneficiation of a portion of their product. At this
plant, the ore is crushed in a jaw crusher and sorted. The
-2" material is dried before further crushing and screening
operations whereas the +2" fraction is crushed, screened and
sized as recovered from the primary crushing stage. The -3
to +20 mesh material resulting from the final screening
operation is sent to HMS plant for the rejection of high
silica grains. The -20 mesh fraction is next separated into
two sizes by air classification.
Plant 2044 uses a wet scrubber on their t1 drier for dust
control. On drier #2 (product drier) a baghouse collecting
system is used and the dust recovered is marketed. A
simplified process flow diagram for this plant is given in
Figure V-3.9.6.
3.9.4.1 Raw Waste Loads
In plants 2031 and 2032, the raw waste consists of the mill
tailings emanating from the flotation step. In plant 2033,
in addition to the mill tailings, the waste contains the
primary thickener overflow and the filtrate from the product
filtering operation. In plant 2044 the raw waste stream is
the composite of the HMS tailings and the process waste
stream from the scrubber. The average values given are
listed below:
V-57
DRAFT
-------
O
70
CRUDE ORE— *»
LIQUID -_,
CAUSTIC
1
cn
CO
WATER
AND SULFUROUS
REAGENTS TAILINGS ACID
I i
SCRJCbHR, gL ._. _-.-..-.., — ., r*nt.tr*r-Ki-rF*A-ritLif* ACID TREAT.
BALL MILL, — » CONDITIONER X ^™N -*» C^NJ2fING -*• THICKENER,
THICKENER otu-b iMBLt^ FILTERS
I 20%
RECYCLE 1 .,
LIME a* SUMP
DRYER,
— • GRINDER,
BAGGER
.
TO SETTLING POND
FIGURE Y-3.9.5
TALC MINING AND PROCESSING
(IMPURE ORE)
•PRODUCT
-------
ORE
AIR
\-/
£
^d en
1-3 U3
&.
:R »»
PRI\
CRIK
i
4ARY
3HER
1
DRYER
1
,
WET
SCRUBBER
!
SETTLING
POND
CRUSHING
AND
SCREENING
.
r
PEBBLE
MILLS
AIR
CLASSIFIER
WATER
I
HEAVY
MEDIA
PLANT
|
SCREENING
AND
SCREW
CLASSIFIERS
_, PYROPHYLLIT
1 PRODUCT
CRUSHING
SCREENING
WET SAND
BY- PRODUCT
AMDALUSiTE
— ' BY- PRODUCT
_ PYROPKIUJTE
, *** BY-PRODUCT
EFFLUENT
WASTE
TO SETTLING POND
O
FIGURE Y-3.9.6
PYROPHYLLITE MINING AND PROCESSING
(HEAVY MEDIA SEPARATION)
-------
DRAFT
waste Material kq/kka of flotation product, jib/ton)
at Plant No. 203J 2&I2 203J 204J
Suspended solids 1800 1200-1750 800 26
(3600) (2400-3500) (1600) (52)
3,9.4.2 Pjlant Water Use
The flotation mill at plant 2031 consumes, on the average,
25,400 liters of water per metric ton (6,070 gallons/ton) of
product. This includes 200 liters of non-contact cooling
water per metric ton (48 gallons/ton) of products which is
used in cooling the bearings of their crushers.
Plant 2032 consumes 17,200 liters of water per metric ton
(4150 gallon/ton) of product; 40 percent of which may be
recycled back to process, after clarification. Recycled
water is used in conditioners and as coolant in compressor
circuits and for several other miscellaneous needs.
Plant 2033 consumes 16,800 liters of water per metric ton of
(4000 gal/ton) product; 20 percent of which is recycled back
to process from the primary thickener operation. Plant 2044
consumes on the average 5,400 liters of process water per
metric ton (1,305 gal/ton) of total product. The hydraulic
load of these plants is summarized below:
Consumption Liters/dav fgal/dav)
at Plant No. 2031 2032 .2,033 2044
Process 730,000 2,200,000 757,000 1,135,000
consumed (192,000) (583,000) (200,000) (300,000)
Non-contact 37,000 - — 54,000 ---
cooling (9,600) (14,400)
3.9.4.3 Plant Waste Treatment
At plant 2031, the mill tailings are pumped into one of the
three available settling ponds. The overflow from these
settling ponds enters by gravity into a common clarification
pond. There is no point discharge from this clarification
pond. The tailings remain in the settling ponds and are
dried by natural evaporation and seepage.
V-60
DRAFT
-------
DRAFT
At plant 2032, the mill tailings are pumped uphill through
3000 feet of pipe to a pond of 34,000,000 liters (9,000,000
gallons) in capacity for gravity settling. The overflow
from this pond is treated in a series of four settling
lagoons. Approximately 40 percent of the last lagoon
overflow may be sent back to the mill and the remainder is
discharged to a brook near the property.
In plant 2033, the filtrate, with a pH of 3.5-4.0, the
flotation tailings with a pH of 10-10.5 and the primary
thickener overflow are combined, and the resulting stream,
having a pH of 4.5-5.5, is sent to a small sump in the plant
for treating. The effluent pH is adjusted by lime addition
to a 6.5-7.5 level prior to discharge into the settling
pond. The lime is added by metered pumping and the pH is
controlled manually. The effluent from the treating sump is
routed into a "U" shaped primary settling pond. The flow
follows the "U" and is discharged into a secondary or back-
up pond. The total active pond area is about 0.8 hectare (2
acres). The clarification pond occupies about 0.3 hectare
(0.75 acres). The back-up pond (clarification pond)
discharges to an open ditch running into a nearby creek.
The non-contact cooling water in plants 2031 and 2033 is
discharged without treatment. Plant 2044 uses a 1.6 hectare
(4 acres) settling pond to treat the wastewater; the
overflow from this pond is discharged into the river. It
has been estimated that the present settling pond will be
filled within two years1 time. This company has leased a
new piece of property for the creation of a future pond.
3.9.4.4 Effluent Composition
As all process water at plant 2031 is impounded and lost by
evaporation, there is no process water effluent out of this
property.
At plants 2032, 2033, and 2044, the effluent consists of the
overflow from their clarification or settling pond. The
significant constituents in these streams are reported to be
as follows:
V-61
DRAFT
-------
DRAFT
Waste Material nftut
Plant Number 2032 2033 204J
pH 7.2-8.5 5.6 7.0
TSS, mg/1 <20 80 100
The average amounts of TSS discharged in these effluents
were calculated from the above data to be:
kcr/kkg of product (Ib/ton)
2032 <0.34 (<0.68)
2033 1.34 (2.68)
2044 0.50 (1.00)
Exemplary performance of wastewater treatment was attained
by plants 2032 and 2044, Also plant 2031 is a special case
in that it has no discharge by virtue of evaporation and
seepage of all wastewater.
3.10 Natural Abrasives
Garnet and tripoli are the major natural abrasives mined in
the U.S. Other minor products, e.g. emery and special
silica-stone products, are of such low volume production
(2,500-3,000 kkg/yr) as to be economically insignificant and
will not be considered further.
3.10.1 Natural Abrasives, Garnet
Garnet is mined in the U.S. almost solely for use as an
abrasive material. Two garnet abrasive producers,
representing more than 80 percent of the total U.S.
production, provided the data for this section. There are 4
plants in the u, S. producing garnet, one of which produces
it only as a by-product.
3.10.1T1 Process Description
The two garnet operations studied are in widely differing
geographic locations, and so the garnet deposits differ, one
being a mountain schists (3071)r and the other an alluvial
deposit (3037).
V-62
DRAFT
-------
DRAFT
Plant 3071 mines by open pit methods with standard drilling
and blasting equipment. The ore is trucked to a primary
crushing plant and from there conveyed to the mill where
additional crushing and screening occurs. The screening
produces the coarse feed to the heavy-media section and a
fine feed for flotation.
The heavy-media section produces a coarse tailing which is
dewatered and stocked, a garnet concentrate, and a middling
which is reground and sent to flotation. The garnet
concentrate is then dewatered, filtered, and dried.
Plant 3037 mines shallow open pits, stripping off
overburden, then using a dragline to feed the garnet-bearing
earth to a trumble (heavy rotary screen). Large stones are
recovered and used for road building or to refill the pits.
The smaller stones are trucked to a jigging operation, also
in the field, where the heavier garnet is separated from all
impurities except some of the high density kyanite. The raw
garnet is then trucked to the mill. There the raw garnet is
dried, screened, milled, screened and packaged.
Figure V-3.10.1 gives the general flow diagram for these
operations.
3.10.1,2 Raw Waste Load
Solid waste is generated in garnet mining as overburden
which is used for reclaiming worked-out pits. Large stones
recovered from in-the-field screening operations at plant
3037 are also used to refill pits or for road building.
In the processing of the garnet ore, solid waste in the form
of coarse tailings is generated from the heavy-media"plant
at plant 3071. These tailings are stocked and sold as road
gravel. The flotation underflow at plant 3071 consisting of
waste fines, flotation reagents and water is first treated
to stabilize the pH and then is sent to a series of tailings
ponds. In these ponds, the solids settle and are removed
intermittently by a dragline and used as landfill.
The categories of raw wastes generated at these plants are
therefore:
V-63
DRAFT
-------
QUARRY
WATER-
f.RE
£J
RECYCLE $
TRUMBLE
I
ARC
LARGE
STONES
FOR
FILL
WATER-
JIG
*
f
SETTLING
POND
EFFLUENT
WATER —gas
COARSE
^
CRUSHING
HEAVY
MEDIA
PLANT
Ax- RECYCLE
DEWATERING
SCREEN
FINESxj*.
T
WATER
COARSE TAILINGS
SOLD AS ROAD GRAVEL
-£s
FLOTATION
DRYING
RECYCLE
THICKENER
SETTLING
PONDS
EFFLUENT
FIGURE IT-3.10.1
GARNET MlNiNG AND PROCESSING
MILLING
AND
SCREENING
._
PRODUCT
73
-------
DRAFT
3037 3071
large stones and yes yes
coarse tailings
flotation fines and no yes
reagents
fine tailings yes no
3.10.1.3 Water Use
Untreated surface water is pumped to the pits at plant 3037
for initial washing and screening operations and for
make-up. This pit water is recycled and none is discharged
except as ground water. Surface water is also used for the
jigging operation, but is discharged after passage through a
settling pond. No data is available regarding the quantity
of water used in these operations.
At plant 3071, water is collected from natural run-off and
mine drainage into surface reservoirs, and it is used in
both the heavy media plant and in flotation. This process
water amounts to approximately 380-760 liter/min
(100-200 GPM) and is about 50 percent recycled.
Effluent flow varies seasonally from a springtime maximum of
570 liter/min (150 GPM) to a minimum in summer and fall.
The summarized average water flow data given below is based
on 50 percent recycle at plant 3071:
liters/kkg product (gallon/ton)
3037 3071
washing and screening amount not known none
heavy media separation
and flotation none 24,600 (5,900)
jigging amount not known none
discharge of wastes jigging water only 12,300 (3,000)
V-65
DRAFT
-------
DRAFT
3.10.1.4 Waste Water Treatment
Plant 3037 recycles untreated pit water used in screening
operations, and sends water from jigging operations to a
settling pond before discharging it back into the creek.
Waste water from flotation underflow at plant 3071 is first
treated with caustic to stabilize the pH which was acidified
from flotation reagents. Then the underflow is sent to a
series of tailings ponds. The solids settle out into the
ponds and the final effluent is discharged. Water from the
dewatering screen is recycled to the heavy media plant.
3.10.1.5 Effluent and Disposal
Effluent arising from flotation underflow at plant 3071 is
discharged. The pH is maintained at 7. The suspended
solids content were estimated to average 25 mg/liter in
concentration.
Effluent from jigging operations at plant 3037 is discharged
after passage through a settling pond. No data is available
on the quality of the discharge.
3.10.2 Natural Abrasives. Tripoli
Tripoli encompasses a group of fine-grained, porous, silica
materials which have similar properties and uses. These
include tripoli, amorphous silica and rottenstone. All four
producers of tripoli provided the data for this section.
3.10.2.1 Process Description
Amorphous silica (tripoli) is normally mined from
underground mines using conventional room-and-pillar
techniques. There is at least one open-pit mine (5688).
Trucks drive into the mines where they are loaded using
front-end loaders. The ore is then transported to the plant
for processing. Processing consists of crushing, screening,
drying, milling, classifying, storage, and packing for
shipping. A general process diagram is given in
Figure V-3.10.2. At one plant only, a minor portion of the
production„ value approximately $250,000, is made by a
unique process using wet-milling and scrubbing and produces
V-66
DRAFT
-------
BAG
HOUSES
CYCLONES
MINE
CRUSH
SCREEN
DRY
MILL
I
AIR
CLASSIFY
PRODUCT
FIGURE Y-3.10.2
TRIPOLI MINING AND PROCESSING
BY THE STANDARD PROCESS
-------
DRAFT
a special grade product. This segment is economically
insignificant and will not be considered further.
3t 10.2.2 Raw Waste Load
Both plants report no significant waste in processing. Any
dust generated in screening, drying, or milling operations
is gathered in cyclones and dust collectors and returned to
the process as product.
Mining generates a small amount of dirt which is piled
outside the mine and gravel which is used to build roads in
the mining areas. The product itself is of a very pure
grade so no other mining wastes are generated.
3.10.2.3 Water Use
There is no water used in mining, nor is there any ground
water or rain water accumulation in the mines.
The standard process is a completely dry process.
3. 10.2.4 W§s£e Water Treatment
Plants using the standard process generate no wastewater.
3ftjOA2i? 5 Effluent and Disposal
There is no effluent from plants using the standard process.
Mining
There are nine diatomite mining and processing facilities in
the UaS. The data from three are included in this section.
These three plants produce roughly one-half of the U.S. pro-
duction of this material.
jjJLl-^-l Process Description
After the overburden is removed from the diatomite strata by
power-driven shovels, scrapers and bulldozers, the crude
diatomite is dug from the ground and loaded onto trucks.
Plants 5504 and 5505 haul the crude diatomite directly to
the mills for processing. At plant 5500 the trucks carry
the crude diatomite to vertical storage shafts placed in the
V-68
DRAFT
-------
DRAFT
formation at locations above a tunnel system. These shafts
have gates through which the crude diatomite is fed to an
electrical rail system for transportation to the primary
crushers.
At plant 5500, after primary crushing, blending, and
distribution, the material moves to different powder mill
units. For "natural" or uncalcined powders, crude diatomite
is crushed and then milled and dried simultaneously in a
current of heated air. The dried powder is sent through
separators to remove waste material and is further divided
into coarse and fine fractions. These powders are then
ready for packaging. For calcined powders, high temperature
rotary kilns are continuously employed. After classifying,
these powders are collected and packaged. To produce
flux-calcined powders, particles are sintered together into
microscopic clusters, then classified, collected and bagged.
At plants 5504 and 5505, the ore is crushed, dried,
separated and classified, collected, and stored in bins for
shipping. Some of the diatomite is calcined at plant 5505
for a particular product. Diagrams for these processes are
given in Figure V-3.11.1.
One plant surface-quarries an oil-impregnated diatomite,
which is crushed, screened, and calcined to drive off the
oil. The diatomite is then cooled, ground, and packaged.
In the future, the material will be heated and the oil
vaporized and recovered as a petroleum product.
3.11.2 Raw Wasl
Wastes from these operations consist of the oversize waste
fraction from the classifiers and of fines collected in dust
control equipment. The amount is estimated to be 20 percent
of the mined material at plant 5500, 16-19 percent at plant
5504 and 5-6 percent solids as a slurry from scrubber
operations at plant 5505.
V-69
DRAFT
-------
O
70
"^-
F
WATEf
<
"nj
O
LEGEND:
•M^MMM^HB nr~?\irftftl PPf"lfT"OO n r"tW
— -•— - \ ALTERNATE PROCESS
WATER nnwn
RECYCLE j POND
i , , VENT
! * i
t i T
R SS* ^PRHRRFR^ RAf5 Mnil^P ..... MB
i T DUST 8
1 1
J
_,._._, - ,..„_. , . ,_.,.. I
1 8 I i
t ! i *-*•
t i
ROD MILL * """ ""] """"*
i WATEf
I 1 J
1 J
f f f
CYCLONE | PUG MILL
TRAPS
REAGENT
...... .,_....,_ ^n
~«i CLASSIFY --^PRODUCT -1
f^/ii r'iMir
L.ALUINC.
™ ^PRODUCT
?
ROUTES
ANC
WASTE TO LAND DISPOSAL
FIGURE Y-3.II.I
DIATOMITE MINING AND PROCESSING
-------
DRAFT
was.te material
Plant 5500, oversise,
dust fines
Plant 5504, sand, rock,
heavy diatoms
Plant 5505, dust
fines (slurry)
3.11.3 Water Use
kg/metric ton of ore (Ib/ton)
200 (400)
175 (350)
45 (90)
Water is used by plant 5500 in the principal process for
dust collection and for preparing the waste oversize
material for land disposal. In addition, a small amount of
bearing cooling water is used. Water is used in the process
at plant 5505 only in scrubbers used to cut down on dust
fines in processing, which is recycled from settling ponds
to the process. The only loss occurs through evaporation
with make-up water added to the system. Water is used in
the process at plant 5504 to slurry wastes to a closed pond.
This water evaporates and/or percolates into the ground. As
yet there is no recycle from the settling pond.
liters per metric ton of ore processed
fqallon/tonl
5500 5505 5504
Intake:
make-up water
2,800
(670)
Use:
dust collection 2,670
and waste disposal (640)
bearing cooling 125-160 (30-38)
Consumption:
evaporati on 2,800
(pond and process) (670)
880
(210)
8,700
(2,090)
880
(210)
3,800
(910)
3,800
(910)
3,800
(910)
V-71
DRAFT
-------
DRAFT
The much lower consumption of water at 5505 is due to the
use of recycling from the settling pond to the scrubbers.
3.11.4 waste Water Treatment
All wastewater generated in diatomite preparation at
plant 5500 is evaporated on the land. Plants 5504 and 5505
send wastewater to settling ponds with water being recycled
to the process at plant 5505 and evaporation/percolation of
the water at plant 5504.
3.11,5 Effluent and Disposal
The only wastewater at plant 5500 is land-evaporated
on-site. There is no process water, cooling, or mine
pumpout discharge.
At plants 5504 and 5505, the wastewater from scrubbers and
waste fines slurrying is sent to settling ponds. At plant
5505, the water is decanted and recycled to the process,
while plant 5504 currently impounds the water in a closed
pond and the water evaporates and/or percolates into the
ground. But in late 1974 a pump is being installed to
enable plant 5504 to decant and recycle the water from the
pond to the process. Thus, all of these diatomite
operations have no discharge of any wastewater.
The oversize fraction and dust fines waste is land-dumped
on-site at plant 5500. The solids content of this
land-disposed waste is silica (diatomite) in the amount of
about 300 g/liter (2.5 Ib/gal).
The waste slurries from plants 5504 and 5505 consisting of
scrubber fines and dust are land-disposed with the solids
settling into ponds. The solids content of these slurries
is 24 g/liter (0.2 Ibs/gal) for plant 5505 and 146 g/liter
(1.2 Ibs/gal) for plant 5504.
3.12 Graphite
There is one producer of natural graphite in the United
States and data from this operation is presented in the
following sections.
V-72
DRAFT
-------
DRAFT
3.12«1 Process Description
The graphite ore is produced from an open pit using
conventional mining methods of benching, breakage and
removal. The ore is properly sized for flotation by passing
through a 3-stage dry crushing and sizing system and then to
a wet grinding circuit consisting of a rod mill in closed
circuit with a classifier. Lime is added in the rod mill to
adjust pH for optimum flotation. The classifier discharge
is pumped to the flotation circuit where water additions are
made and various reagents added at different points in the
process flow. The graphite concentrate is floated,
thickened, filtered and dried. The underflow or waste
tailings from the cells are discharged as a slurry to a
settling pond. The process flow diagram for the plant is
shown in Figure V-3.12.1.
3.12.2 Raw Waste Loads
There are three sources of waste associated with the plant
operation. They are the tailings from the flotation
circuit, low pH seepage water from the tailings pond, and an
intermittent seepage from the mine.
waste material fea/metric ton of product (Ibs/ton)
flotation tailings 36,000 (72,000)
(The flotation reagents used in this process are alcohols
and pine oils.)
liters/metric ton of product (gal/ton)
low pH seepage water 19,000 (4,500) (1)
mine seepage water intermittent and unknown
(1) Estimated volume under normal operating and weather condi-
tions.
V-73
DRAFT
-------
MAKE-UP
LIME WATER REAGENTS WATER
GRAPHITE ORE-
<
CRUSHING
AND
SCREENING
GRINDING
AND
CLASSIFICATION
PLANT EFFLUENT
FIGURE Y-3.12.1
GRAPHITE MINING AND PROCESSING
PRODUCT
PRODUCT
-------
DRAFT
3.12.3 Water Use
The source of the intake water is almost totally from a
lake. The exceptions are that the drinking water is taken
from a well and a minimal volume for emergency or back-up
for the process comes from an impoundment of an intermittent
flowing creek. Some recycling of water takes place through
the reuse of thickener overflow, filtrate from the filter
operation and non-contact cooling water from compressors and
vacuum pumps.
water consumption liters/metric ton of product
(gal/ton)
total intake 159,000 (38,000)
process waste discharge 107,000 (26,000)
consumed (process, non-
contact cooling, sani- 52,000 (12,000)
tation)
3;12TU Wastewater Treatment
The waste streams associated with the operation are
flotation tailings and seepage water. The tailings slurry
at about 20 percent solids and at a near neutral pH
(adjustment made for optimum flotation) is discharged to a
partially lined 8 hectare (20 acre) settling pond. The
solids settle rapidly and the overflow is discharged. The
seepage water from the tailings pond, mine and extraneous
surface waters are collected through the use of an extensive
network of ditches, dams and sumps. The collected
wastewaters are pumped to a treatment facility where lime is
added to neutralize the acidity and precipitate the iron.
The neutralized water is pumped to the tailings pond where
the iron floe is deposited. The acid condition of the pond
seepage results from the extended contact of water with the
tailings which dissolve some part of the contained iron
pyrites.
V-75
DRAFT
-------
DRAFT
3.12.5 Effluent
There is one effluent stream from this operation which is
the overflow from the tailings pond. It is discharged into
a stream that flows into the lake that serves as the intake
water source for the plant. The effluent composition falls
within the limits established by the Texas State Water
Quality Board for the following parameters: flow; pH; total
suspended solids; volatile solids; BOD; COD; manganese and
iron. The measurements from the June 1974 report to the
state compared to the state limitations, both converted to a
basis of amount per unit production are:
June 1974
Average Maximum
Flow, liters/kkg 106,000 156,000
(gal/ton) (25,500) (37,500)
Constituents, kg/kkg (Ib/ton):
total residue 80 (160) ( )
total suspended solids 0.3 (0.6) 0.8 (1.6)
volatile solids 0.1 (0.2) (
manganese 0.01 (0.02) (
iron 0.01 (0.02) (—
BOD 1.0 (2.0) (
COD 2.1 (4.2) (—
State Standards
Average Maximum
Flow, liters/kkg 156,000 250,000
(gal/ton) (37,500) (60,000)
Constituents, kg/kkg (Ib/ton):
total residue 215 (430) ( )
total suspended solids 1.6 (3.2) 7.5 (15)
volatile solids 0.8 (1.6) ( )
manganese 0.03 (0.06) 0.25 (0.5)
iron 0.16 (0.32) 1.3 (2.6)
B°D 1.6 (3.2) 6.3 (12.6)
COD 2.3 (4.6) 7.5 (15.0)
Note: The above State limitation on TSS as a monthly average
of 1.6 kg/kkg is equivalent to only 10 mg/liter. This plant
has no problem meeting this requirement because of a unique
situation where the large volume of tailings entering the
V-76
DRAFT
-------
DRAFT
pond assists the settling of suspended solids more than that
normally expected from a well designed pond.
3,13.1 Jade
The jade industry in the U.S. is very small. One plant
representing 55 percent of total U.S. jade production
provided the data for this section.
3_i Ijy 1,1 Process Description
The jade is mined in an open pit quarry, with rock being
obtained by pneumatic drilling and wedging of large angular
blocks. No explosives are used on the jade itself, only on
the surrounding host rock. The rock is then trucked to the
plant for processing. There the rock is sawed, sanded,
polished and packaged for shipping. Of the material
processed only a small amount (3 percent) is processed to
gems and 47 percent is processed to floor and table tiles,
grave markers, and artifacts. A general process diagram is
given in Figure V-3.13.1.
,3,13s T«3 Raw Waste Load
Approximately 50 percent of the rock taken each year from
the quarry is unusable or unavoidably wasted in processing,
amounting to 29.5 kkg/year (32.5 TPY) . There is no pit
pumpout associated with this operation.
3. 13.1.3 Water Use
Well water is used in the process for the wire saw, sanding,
and polishing operations. This water use amounts to
190 I/day (50 GPD) of which none is recycled.
3« 13. 1.4 Waste Water Treatment
Waste waters generated from the wire saw, sanding, and
polishing operations, are sent to settling tanks where the
tailings settle out and the water is discharged onto the
plant lawn where it evaporates and/or seeps into the ground.
There is no other water treatment employed.
V-77
DRAFT
-------
O
1
CD
QUARRY
V,
w
GF
fATER SiC
i 1
WIRE
SAW
WATER
AND
POLISHING
OIL WATER SiC AGENTS
^~ RECYCLE
DIAMOND
SAW
|
V
SETTLING
TANK
J
SETTLING
TANK
ATER TAILINGS TAILINGS
TO TO TO
iOUND LANDFILL LANDFILL
* * F
+ t
n
••••••
^\RE
AG
PC
• PRODUCT
RECYCLE POLISHING
AGENTS TO EXTENT
POSSIBLE
FIGURE Y-3.I3.I
JADE MINING AND PROCESSING
-------
DRAFT
3.13.1.5 Effluent and Disposal
Solid wastes in the form of tailings which collect in
settling tanks are eventually land-disposed as fill.
There is no discharge of process wastewater to navigable
waterways.
3.13,2 Novaculite
Novaculite, a generic name for large geologic formations of
pure. Macrocrystalline silica, is mined only in Arkansas by
one plant. The data in this section was provided by that
plant.
3.13.2.1 Process Description
Open quarries are mined by drilling and blasting, with a
front-end loader loading trucks for transport to covered
storage at the plant. Since the quarry is worked for only
about 2 weeks per year, mining is contracted out.
Plant processing consists essentially of crushing, drying,
air classification and bagging. Normally silica will not
require drying but novaculite is hydrophilic and will absorb
water up to 9 parts per 100 ore. Part of the air classifier
product is diverted to a batch mixer, where organics are
reacted with the silica for specialty products. A general
process diagram is given in Figure V-3.13.2.
3.13.2.2 Raw Waste Load
wastes generated in the mining of novaculite remain in the
quarry as reclaiming fill, and processing generates only
scrubber fines which are settled in a holding tank and
eventually used for land-fill. There is no data available
on the amount of this material. However, a new plant dust
scrubber will be installed with recycle of both water and
fines.
3.13.2.3 Water
No water is used in novaculite mining and the quarry is so
constructed that no pit water accumulates.
V-79
DRAFT
-------
o <
70 1
>• QO
-n o
—i
QUARRY
VENT
t
rPliqHFR
DRYER
»-*. " A!R
ft CLASSIFY
1
PEBBLE
MILL
DRY SPECIALTY
MIX PRODUCTS
1 Mfe nnftnt ir*T
FIGURE Y-3.13.2
NOVACULITE MINING AND PROCESSING
-------
DRAFT
Total water usage at the plant for bearing cooling and the
dust scrubber totals approximately 18,900 I/day (5,000 GPD)
of city water. Of this total amount 7,300-14,500 I/day
(1,900-3,800 GPD) is used for bearing cooling and an
equivalent amount is used as make-up water to the dust
scrubber.
3.13.2. t* Waste Water Treatment
Water from the scrubber is sent to a settling tank and clear
water is recycled to the scrubber. Cooling water is
discharged onto the plant lawn with no treatment.
3.13.2.5 Effluent and Disposal
Dust from the scrubber is currently land-disposed. However,
with the installment of a new dust scrubber both the water
and muds will be recycled to the process.
Scrubber water is recycled to the process after settling out
of solids in a tank. Cooling water is discharged onto the
lawn at the plant and it either seeps into the ground or
evaporates.
1*0 DETERMINING THE RATIONALE FOR EFFLUENT LIMITATIONS
GUIDELINES'FOR MAXIMUM PAILY VALUES
The bulk of the data used in the technical development of
effluent limitations guidelines for the mineral mining and
processing industry have been representative of long-term
performance values. For all practical purposes, these
discharge data may be regarded as equivalent to monthly
average data.
It is recognized, however, that day-to-day discharges are
subject to a wide variety of factors which result in a
distribution of daily effluent values around a monthly mean.
Some of the reasons for wider daily variations in the
pollutant discharges are built-in process inhomogeneities
such as batch-wise process steps, process startups and
shutdowns, minor process upsets, the normal imprecision of
process controls, day-to- day weather (rainfall, ambient
temperature, humidity) variations, and the range of
differences among operating personnel.
V-81
DRAFT
-------
DRAFT
Daily variability data for the most common pollutant
parameter in these industries, suspended solids, is listed
in Table V-4,1 as the ratios of the concentrations of daily
effluent discharges to monthly average discharges for the
21 plants from which such detailed data were available. The
vast majority of facilities in this industry have not
sampled frequently enough to establish such a wide data
base, so the inference is drawn that the relative
variability found in these plants is representative of all
the other mineral mining and processing facilities insofar
as suspended solids concentration in the effluent is
concerned.
The data of Table V-4.1 have been arranged in the order of
increasing daily/monthly ratio. The last column is the
cumulative probability that a given plant's discharge would
have a daily/monthly ratio less than or equal to the value
shown. For example, 13 of the 21 plants (61.9 percent) of
the plants had a ratio of maximum daily/monthly average
suspended solids discharge less than or equal to 2.5.
These data are graphically shown in Figure V-4.1, where the
log of the daily/monthly ratio is plotted against the
cumulative probability. The straight line implies that the
log of the ratio is normally distributed. This assumption
seems justifiable in view of the good fit to the data
points.
V-82
DRAFT
-------
D
I
oo
10
15 20 30 4O 50 60 70 80 90
CUMULATIVE PROBABILITY, PERCENT
95 97.5
89
FIGURE ¥-4.1
DAILY/MONTHLY RATIO OF SEVERAL PLANTS
-------
DRAFT
TABLE V-4. 1
Ratio of Maximum Daily/Monthly Average r Effluent _.,Data_f or
2.1 Plants (arranged in ascending order)
Ratio ,of Maximum Daily/ Cumulative Probq
Plant No. Monthly Average
1 1.2 4.8
2 1.3 9.5
3 1.4 14.3
4 1.6 19.1
5. 1.8 28.6
6 1.8 28.6
7 1.9 33.3
8 2.1 38.1
9 2.2 52.4
10 2.2 52.4
11 2.2 52.4
12 2.3 57.1
13 2.5 61.9
™ 2.6 66.7
15 2.7 71.4
16 3.0 76.2
17 3.7 81.0
18 4.6 85.7
1^ 4.8 90.5
20 5.1 95.?
21 7.0 100.0
Using this distribution curve based on the TSS effluent con-
centration performance of a very United sample of mineral
processing olantr;, several reasonable multiplication factors
for monthly average to daily maximum could be selected. A
daily maximum value based on a factor of 2.5 would contain-
505 of normally varying daily values for plants exactly
meeting the specified Monthly guideline. In practice many
plants would average v/ell under the monthly guidelines, so
considerably nore than 501 would meet daily valuer, based on
a factor of 2.5. Similarly, a factor of 5, which
corresponds to -a two-standard-deviation limit would contain
at least 955 of normally varying daily samples .from plants
falling within a given monthly average limitation. Rased on
conservative practice, this latter value is recommended.
Other pollutant parameters found in these industries, such
as rliiorxde and zinc, occur infre.guentlv and therefore are
handled on a case-by-case basis.
DRAFT
-------
DRAFT
5.0 RATIONALE AjJD SUPPORTING DATA FOR GENERAL MINE WATER
DISCHARGE LIMITATIONS
Of the mines studied in detail in the clay, ceramic,
refractory, and miscellaneous materials segment of the
mineral mining and processing industry, approximately
i»0 percent were found not to have any mine pumpout water
discharge. Of the discharges found, the preponderances were
either intermittent or highly variable in flow. Mine
pumpout was also found to be unrelated to production rate
except that in certain instances pumpout was necessary to
start or maintain production.
The origin of the mine water is rainfall or leakage from
aquifers. Surface runoff into mines constitutes poor
practice and can be readily overcome by diversion ditches
and dikes. Because of the natural origin of this water,
volumes are extremely variable from plant-to-plant and from
season-to-season.
The mine water discharge quality data from 19 mines in these
industries are summarized in Table V-5.1. Ten of these
discharges are untreated. The treatment for the others
consists generally of pond settling with pH adjustment where
necessary.
The mine water discharge from the Fuller's Earth
(montmorillonite) mine stands out from the others in its
high concentration of suspended solids. This is to be
expected in that montmorillonite is a material that readily
disperses in water into a stable colloidal suspension. In
these industries bentonite is another montmorillonitic
mineral mined that has the same characteristic. However, no
bentonite mines were found having mine water. Since the
pumpout water for the mining of montmorillonitic clay
materials will contain non-settlable suspended solids, and a
sufficient data base does not exist on effluent
concentrations, meaningful mine pumpout effluent limitation
guidelines cannot be developed at this time for these
categories: Montmorillonite and Bentonite.
V-85
DRAFT
-------
DRAFT
TABLE V-5.1
MINE WATER PUMPOUT
CLAY, CERAMIC, REFRACTORY, AND MISC. MINERALS INDUSTRIES
Monthly Average
Mineral
Talc
Fire Clay and Shale
Plant-
Kaolin
Ball Clay
Fuller's Earth
(attapulgite)
Fuller's Earth
(montmorillonite)
Aplite
Garnet
Graphite
* No Data Available
LEGEND:
1. Ponds
2. Lime Treatment
3. Sump Hole
4. Make-up water
3058;3060
Treatment
2040;2041;)
2042; 2043 )
2036 *
2039
3078
3075
3076
3077
3082
3083
3084
3079
3085
3086
3074
3080
3081
3035/3036; )
3062;3063 )
3024;3025
5684;5686
5685;5687
1
1
1
1/2
None
None
None
None
1
l;2
1;2
None
None
None
None
None
1
None or 1;2
1
None or 3
None
3059
3072;3073
3020
3071
4000
None
None
None
1;4
1-2
V-86
DRAFT
pjj
7.2-8.5
7.5-7.8
7.0-7.3
6
6.5
8.3
8.3
8.5
7.3
6.5
6
8.0
8.0
6.2
6.4
6.0
TSS (mg/liter)
<20
9
3
*
30
30
18
22
3
26
20
5
6.1
10
10
10
*
*
6.9
*
*
*
215
Pumpout is part of process
water
-------
DRAFT
For the mine pumpout from the other subcategories, the
discharges were found to be within the pH range of 6-9.
Clearly, those with acidic mine water had treated to at
lease pH 6 prior to discharge. Those with no treatment had
no pH problem. Of the non-montmorillonitic mines,
78 percent were found to discharge an average TSS
concentration of 20 mg/liter or less. Of those mines having
at least a settling pond treatment for mine water,
89 percent had this quality of discharge.
V-87
DRAFT
-------
DRAFT
SECTION VI
SELECTION OF POLLUTANT PARAMETERS
INTRODUCTION
The wastewater constituents of pollution significance for
this segment of the mineral mining and processing industry
are based upon those parameters which have been identified
in the untreated wastes from each subcategory of this study.
The wastewater constituents are further divided into those
that have been selected as pollutants of significance with
the rationale for their selection, and those that are not
deemed significant with the rationale for their rejection.
The basis for selection of the significant pollutant para-
meters was:
(1) toxicity to humans, animals, fish and aquatic organisms;
(2) substances causing dissolved oxygen depletion in
streams;
(3) soluble constituents that result in undesirable tastes
and odors in water supplies;
(4) substances that result in eutrophication and stimulate
undesirable algae growth;
(5) substances that produce unsightly conditions in
receiving water; and
(6) substances that result in sludge deposits in streams.
2.0 SIGNIFICANCE AND RATIONALE FOR SELECTION OF POLLUTION
PARAMETERS
2.1 Biochemical Oxygen Demand (BOD)
Biochemical oxygen demand (BOD) is a measure of the oxygen
consuming capabilities of organic matter. The BOD does not
in itself cause direct harm to a water system, but it does
exert an indirect effect by depressing the oxygen content of
the water. Sewage and other organic effluents during their
processes of decomposition exert a BOD, which can have a
catastrophic effect on the ecosystem by depleting the oxygen
supply. Conditions are reached frequently where all of the
VI-1
DRAFT
-------
DRAFT
oxygen is used and the continuing decay process causes the
production of noxious gases such as hydrogen sulfide and
methane. Water with a high BOD indicates the presence of
decomposing organic matter and subsequent high bacterial
counts that degrade its quality and potential uses.
Dissolved oxygen (DO) is a water quality constituent that,
in appropriate concentrations, is essential not only to keep
organisms living but also to sustain species reproduction,
vigor, and the development of populations. Organisms
undergo stress at reduced D.O. concentrations that make them
less competitive and able to sustain their species within
the aquatic environment. For example, reduced DO
concentrations have been shown to interfere with fish
population through delayed hatching of eggs, reduced size
and vigor of embryos, production of deformities in young,
interference with food digestion, acceleration of blood
clotting, decreased tolerance to certain toxicants, reduced
food efficiency and growth rate, and reduced maximum
sustained swimming speed. Fish food organisms are likewise
affected adversely in conditions with suppressed DO. Since
all aerobic aquatic organisms need a certain amount of
oxygen, the consequences of total lack of dissolved oxygen
due to a high BOD can kill all inhabitants of the affected
area.
If a high BOD is present, the quality of the water is
usually visually degraded by the presence of decomposing
materials and algae blooms due to the uptake of degraded
materials that form the foodstuffs of the algal populations.
BOD was not a major contribution to pollution in this
industry.
2.2 Fluorides
As the most reactive non-metal, fluorine is never found free
in nature but as a constituent of fluorite or fluorspar,
calcium fluoride, in sedimentary rocks and also of cryolite,
sodium aluminum fluoride, in igneous rocks. Owing to their
origin only in certain types of rocks and only in a few
regions, fluorides in high concentrations are not a common
constituent of natural surface waters, but they may occur in
detrimental concentrations in ground waters.
VI-2
DRAFT
-------
DRAFT
Fluorides are used as insecticides, for disinfecting brewery
apparatus, as a flux in the manufacture of steel, for
preserving wood and mucilages, for the manufacture of glass
and enamels, in chemical industries, for water treatment,
and for other uses.
Fluorides in sufficient quantity are toxic to humans, with
doses of 250 to 450 mg giving severe symptoms or causing
death.
There are numerous articles describing the effects of
fluoride- bearing waters on dental enamel of children; these
studies lead to the generalization that water containing
less than 0.9 to 1.0 mg/liter of fluoride will seldom cause
mottled enamel in children, and for adults, concentrations
less than 3 or H mg/liter are not likely to cause endemic
cumulative fluorosis and skeletal effects. Abundant
literature is also available describing the advantages of
maintaining 0.8 to 1.5 mg/liter of fluoride ion in drinking
water to aid in the reduction of dental decay, especially
among children.
Chronic fluoride poisoning of livestock has been observed in
areas where water contained 10 to 15 mg/liter fluoride.
Concentrations of 30-50 mg/liter of fluoride in the total
ration of dairy cows is considered the upper safe limit.
Fluoride from waters apparently does not accumulate in soft
tissue to a significant degree and it is transferred to a
very small extent into the milk and to a somewhat greater
degree into eggs. Data for fresh water indicate that
fluorides are toxic to fish at concentrations higher than
1.5 mg/liter. Fluoride is found in one industry in this
segment, feldspar mining by the wet process.
2*3 Iron
Iron is considered to be a highly objectional constituent in
public water supplies, the permissible criterion has been
set at 0.3 mg/liter. Iron is found in significant
quantities in graphite mining and other categories.
VI-3
DRAFT
-------
DRAFT
Manganese
Manganese in various dissolved forms may be present in
significant amounts in the wastewater from the mining of
graphite. A permissible criterion of 0.05 mg/liter has been
proposed for public waters.
2..S 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.
Oil spills can damage the surface of boats and can destroy
the aesthetic characteristics of beaches and shorelines.
li_6 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
VT-4
DRAFT
-------
DRAFT
values indicate alkalinity. The relationship between pH and
acidity and 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.
2.7 Total Suspended Solids
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
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.
VT-5
DRAFT
-------
DRAFT
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
phot©synthetic 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. Total
suspended solids are the single most important pollutant
parameter found in this segment of the mineral mining and
processing industry.
VI-6
DRAFT
-------
DRAFT
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 some zinc might be found in natural waters.
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/liter 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/liter 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/liter 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
VI-7
DRAFT
-------
DRAFT
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,
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 mg/liter of
zinc.
Zinc sulfate has also been found to be lethal to many
plants, and it could impair agricultural uses.
Zinc is found in the effluent from one process in this
industry, high-grade kaolin.
3.0 SIGNIFICANCE AND RATIONALE FOR REJECTION OF POLLUTION
PARAMETERS
A number of pollution parameters besides those selected were
considered, but had to be rejected for one or several of the
following reasons:
1) insufficient data on degradation of water quality;
2) not usually present in quantities sufficient to cause
water quality degradation;
3) treatment does not "practicably" reduce the parameter;
and
4) simultaneous reduction is achieved with another
parameter which is limited.
3.1 Toxic Materials
Although arsenic, antimony, barium, boron, cadmium,
chromium, copper, cyanide ion, mercury, nickel, lead,
selenium, and tin are harmful pollutants, they were not
found to be present in quantities sufficient to cause water
quality degradation.
VI-8
DRAFT
-------
DRAFT
3.2 Aluminum + 3
Aluminum may be present in significant amounts in the
wastewater from this segment of the industry. Soluble
aluminum in public water supplies is not considered a health
problem and therefore was not included in the Public Health
Service Drinking Water Standards.
3,3 Calcium +2
Although calcium does exist in quantities in the wastewaters
of a number of these mines, there is no treatment to practi-
cably reduce it.
3.H Carbonate ^£
There is insufficient data for dissolved carbonate to
consider it a harmful pollutant.
3.5 Chloride -
Although chloride is present in sufficient quantities in
process wastewaters, there is no treatment to practicably
reduce it.
3_,^6 Magnesium +2
There is insufficient data for dissolved magnesium to
consider it a harmful pollutant.
3.7 Nitrate - and Nitrite -
There is insufficient data for dissolved nitrates and
nitrites to consider them harmful pollutants, and there is
no treatment to practicably reduce them.
3.8 Phosphates
Phosphates, reported as total phosphorus (P), contributes to
eutrophication in receiving bodies of water. However, they
were not found in quantities sufficient to cause water
quality degradation.
VI-9
DRAFT
-------
DRAFT
3.9 Potassium +
Although potassium does exist in quantity in the wastewaters
of some of these plants, there is no treatment to
practicably reduce it.
3.1.0 Silicates
Silicate may be present in the wastewaters from the mineral
mining and processing industry, but it is simultaneously
reduced with another parameter which is limited.
3.11 Sodium +
Although sodium does exist in quantity in the wastewaters of
a number of these processes, there is no treatment to
practicably reduce it.
3.12 Solids, Dissolved
The total dissolved solids is a gross measure of the amount
of soluble pollutants in the wastewater. It is an important
parameter in drinking water supplies and water used for
irrigation. A total dissolved solids content of less than
500 mg/liter is considered desirable. From the standpoint
of quantity discharged, TDS could have been considered a
harmful characteristic. However, energy requirements,
especially for evaporation, and solid waste disposal costs
are usually so high as to preclude limiting dissolved solids
at this time.
3.13 Sulfate ^*
Although sulfate does exist in quantity in the wastewaters
of some of these processes, there is no treatment to
practicably reduce it.
3.14 Temperature
Temperature is a sensitive indicator of unusual thermal
loads where waste heat is involved in the process. Excess
thermal load, even in non-contact cooling water, has not
been and is not expected to be a significant problem in this
segment of the mineral mining and processing industry.
VI-10
DRAFT
-------
DRAFT
SECTION VII
CONTROL AND TREATMENT TECHNOLOGY
1.0 INTRODUCTION
Water-borne wastes from the mining of clay, ceramic,
refractory and miscellaneous minerals consist primarily of
suspended solids. These are usually composed of chemically
inert and very insoluble sand, clay or rock particles.
Treatment technology is well developed for removing such
particles from wastewater and is readily applicable whenever
space requirements or economics do not preclude utilization.
In a few instances dissolved substances such as fluorides,
metal salts, acids, alkalies, chemical additives from ore
processing and organic materials may also be involved.
Where they are present, dissolved material concentrations
are usually low. Treatment technology for the dissolved
solids is also well-known, but may often be limited by the
large volumes of wastewater involved and the cost of such
large scale operations.
The control and treatment of the usually simple water-borne
wastes found in the mineral mining and processing industry
are complicated by several factors:
(1) the large volumes of wastewater involved for many of the
mining operations,
(2) variable wastewater amount and composition from day to
day, as influenced by rainfall and other surface and
underground water contributions,
(3) differences in wastewater compositions arising from ore
or raw material variability.
VII-1
DRAFT
-------
DRAFT
(4) geographical location: e.g., wastewater can be handled
differently in dry isolated locations than in
industrialized wet climates.
Each of these points are discussed in the following
sections.
2.0 PROBLEM AREAS IN THE CLAY, CERAMIC. REFRACTORY AND
MISCELLANEOUS MINERALS INDUSTRIES
Three significant wastewater problem areas have been found
in these industries:
(1) High suspended solids levels in discharged wastewaters
caused in some cases by formation of colloidal clay sus-
pensions which are difficult to settle. This problem is
encountered in several segments of the industry;
(2) In at least one subcategory of this industry problems
are encountered with water-borne fluoride wastes;
(3) In the bleaching of some clay products, zinc
hydrosulfite is sometimes employed. The use of this
material invariably leads to a wastewater discharge
containing zinc salts.
Below are given brief discussions of each of these problem
areas.
The principal pollutant encountered in this segment of the
minerals mining industry has been found to be suspended
solids which arise from two sources:
(1) underground or surface mine pumpouts;
(2) processing washwaters and scrubber waters.
Mine water pumpout was found to be intermittent in nature
and to be characterized by TSS loadings of from a few to
several thousand parts per million of suspended solids prior
VII-2
DRAFT
-------
DRAFT
to settling. Installation of settling areas for such waters
generally has the effect reducing TSS loadings to less than
20 mg/liter for most materials. It should be pointed out
that pit pumpout waters from montmorillonite clay mining
facilities appear to be an exception to the above statement.
This type of clay forms colloidal suspensions in wastewater
and are very difficult to settle. These colloidal
suspensions can be flocculated by addition of soluble
calcium salts at concentrations of about 100 milli-
equivalents of calcium salt per 100 grams of suspended mont-
morillonite (1,2). For other clays which settle more
readily, flocculation occurs generally at lower
concentrations of added calcium salt. This approach
apparently has yet to be tried in the industry. Other
approaches mentioned in the literature, such as treatment of
clays with alkyl ammonium salts (3,4) are not likely to be
applicable to this situation because their use would cause
worse environmental problems than those already present.
Process water discharge is encountered in several of the
product subcategories. For readily settleable materials,
settling lagoons were found to be effective in reducing
suspended solids loadings to less than 20 mg/liter in most
instances. For a few of the clay materials, such as
montmorillonite and fire clays, pond effluent concentrations
after simple settling tend to be at least an order of
magnitude higher in TSS. For one specific case with a
montmorillonite facility, scrubber wastewaters were found
with a TSS loading of 25,000 mg/liter before settling.
After settling with a retention time of less than five days
in a small lagoon, TSS loadings of about 2,000 mg/liter were
still present. Table VII-1 shows the settling
characteristics of some of the materials treated in this
volume. This is an area needing application of available
flocculation and clarification technology.
VII-3
DRAFT
-------
Table VIM.
Settling Characteristics of Some Suspended Materials
Product Stream
Fire Clay mine
seepage,
runoff, &
cooling
Montmorillonite scrubber
pit
•ytj — pumpout
> T
Tl -fs.
•"i Kaolin plant
raw
effluent
Ball Clay scrubber
scrubbers
Feldspar plant
raw
effluent
Talc mine
pumpout
Plant
3087
3072
3073
3024
5685
5689
3026
2041,
2042,
2043,
2044
Input to Pond
(mg/liter)
unknown
25,000
unknown
10,300
includes sand
unknown
unknown
3,800
200
Retention Time,
Condition
0 . 25 hour
soda ash added
4.1 days,
lime added
variable
unknown,
lime added
1-2 months,
simple settling
1 month,
flocculant,
3 ponds
unknown,
alum added,
2 ponds
unknown
Outflow
(mg/l iter)
45
2,000
215
6
400
40
21
<20
70
-------
DRAFT
The processing of feldspar ores involves a flotation step in
which hydrofluoric acid is one of the added reagents. This
gives rise to an acidic fluoride bearing wastewater stream
which, prior to treatment, can contain up to 50 mg/liter
fluoride ion. At present, treatment of such wastewaters has
been only partially effectively practiced. Current fluoride
effluent concentrations at feldspar producing facilities
range from 8 to about 40 ing/liter. This is another area
where improved treatment technology is needed.
In the bleaching of kaolin, solutions of zinc hydrosulfite
are generally employed. This gives rise to wastewaters
containing up to 25 mg/liter zinc ion prior to treatment.
Technology already in use in the pigments and inorganic
chemicals industries is available to reduce effluent levels
to a few ppm. This will be discussed later in this section.
3.0 CONTROL PRACTICES
Control practices such as selection of raw materials, good
housekeeping, minimizing leaks and spills, in-process
changes, and segregation of process wastewater streams are
not as important in the minerals mining industry as they are
in more process-oriented manufacturing operations. Raw
materials are fixed by the composition of the ore available;
good housekeeping and small leaks and spills have little
influence on the waste loads; and it is rare that any
non-contact water, such as cooling water, is involved in
minerals and mining processes.
There are a number of areas, however, where control is very
important. These include:
(1) wastewater containment
(2) separation and control of mine water, process water,
and rain water
(3) monitoring of waste streams.
VII-5
DRAFT
-------
DRAFT
3. j Containment:
The majority of wastewater treatment and control facilities
in the minerals and mining industry use one or more settling
ponds. Often the word "pond" is an euphemism for swamp,
gully, or other low spot which will collect water. In times
of heavy rainfall these "ponds" are often washed out and the
settled solids may be swept along as well. In many other
cases, the identity of the pond may be maintained during
rainfall but its function as a settling pond is
significantly impaired by the large amount of water flowing
through it. In addition to rainfall and flooding
conditions, waste containment in ponds can be troubled with
seepage through the ground around and beneath the pond,
escape through pot holes, faults and fissures below the
water surface and physical failure of pond dams and dikes.
In most instances satisfactory pond performance can be
achieved by proper design. In instances where it is not
possible to achieve satisfactory pond performance,
alternative treatment methods can be utilized: thickeners,
clarifiers, tube and lamella separators, filters,
hydrocyclones, and centrifuges.
3.2 Separation and Control of Wastewater
In these industries wastewater may be separated into
different categories:
VIl-6
DRAFT
-------
DRAFT
(1) Mine drainage water. For many mines this is the only
water effluent. Usually it is low in suspended solids,
but may contain dissolved minerals.
(2) Process water. This is water involved in transporting,
classifying, washing, benef iciating,, and separating ores
and other mined materials. When present in minerals
mining operations this water usually contains heavy
loads of suspended solids and possibly some dissolved
materials.
(3) Rain water runoff. Since minerals mining operations
often involve large surface areas, the rain water that
falls on the mine or mine property surface constitutes a
major portion of the overall wastewater load leaving the
property. This runoff entrains minerals, silt, sand,
clay, organic matter and other suspended solids.
The relative amounts and compositions of the above
wastewater streams differ from one mining category to
another and the separation, control and treatment techniques
differ for each.
Process water and mine drainage are normally controlled and
contained by pumping or gravity flow through pipes,
channels, ditches and ponds. Rain water runoff, on the
other hand, is often uncontrolled and may either contaminate
process and mine drainage water or flow off the land
independently as non-point discharges. Rain water runoff
also increases suspended solid material in rivers, streams,
creeks or other surface water used for process water supply
or, in some cases, as point discharge sources from mining
property.
3.3 Monitoring
Since most wastewater discharges from these industries
contain suspended solids as the principal pollutant, complex
water analyses are not usually required. On the other hand,
many of these industries today do little or no monitoring on
wastewater discharges. In order to obtain meaningful
knowledge and control of their wastewater quality, many
VTI-7
DRAFT
-------
DRAFT
mines and minerals processing plants need to institute
routine monitoring measurements of the few pertinent waste
parameters.
4.0 SUSPENDED SOLIDS REMOVAL
The treatment technologies available for removing suspended
solids from minerals and mining wastewater are numerous and
varied, but a relatively small number are used widely. The
following shows the approximate breakdown of usage for the
various techniques:
percent of treatment facilities
removal technique using technology
settling ponds (unlined) 95-97
settling ponds (lined) <1
chemical flocculation (usually 2-5
with ponds)
thickeners and clarifiers 1-2
hydrocyclones <1
tube and lamella settlers <1
screens <1
filters <1
centrifuges <1
4.1 Settling Ponds
As shown above, the predominant treatment technique for
removal of suspended solids involves one or more settling
ponds. Settling ponds are versatile in that they perform
several waste-oriented functions including:
(1) Solids removal. Solids settle to the bottom and the
clear water overflow is much reduced in suspended solids
content.
VII-8
DRAFT
-------
DRAFT
(2) Equalization and water storage capacity. The clear
supernatant water layer serves as a reservoir for reuse
or for controlled discharge.
(3) Solid waste storage. The settled solids are provided
with long term storage.
This versatility, ease of construction and relatively low
cost, explains the wide application of settling ponds as
compared to other technologies.
The performance of these ponds depends primarily on the
settling characteristics of the solids suspended, the flow
rate through the pond and the pond size. Settling ponds can
be used over a wide range of suspended solids levels. Often
a series of ponds is used, with the first collecting the
heavy load of easily settleable material and the following
ones providing final polishing to reach a desired final
suspended level. As the ponds fill with settled solids they
can be dredged to remove these solids or the ones may be
left filled and new ponds provided. The choice often
depends on whether land for additional new ponds is
available. When suspended solids levels are low and ponds
large, settled solids build up so slowly that neither
dredging nor pond abandonment is necessary, at least not for
a period of many years.
Settling ponds used in the minerals industry run the gamut
from small pits, natural depressions and swamp areas to
engineered thousand acre structures with massive retaining
dams and legislated construction design. The performance of
these ponds varies from excellent to poor, depending on
character of the suspended particles, and pond size and
configuration.
In general the suspended solids levels from the final pond
can be reduced to 10 to 30 mg/liter, but for some
wastewaters the discharge may still contain up to
100 mg/liter. Waste waters containing significant amounts
of hydrophilic colloids, such as montmorillonite, are
especially difficult to clarify.
VI I-9
DRAFT
-------
DRAFT
H.2 clarifiers and Thickeners
An alternative method of removing suspended solids is the
use of clarifiers or thickeners which are essentially tanks
with internal baffles, compartments, sweeps and other
directing and segregating mechanisms to provide efficient
concentration and removal of suspended solids in one
effluent stream and clarified liquid in the other.
Clarifiers differ from thickeners primarily in their basic
purpose. Clarifiers are used when the main purpose is to
produce a clear overflow with the solids content of the
sludge underflow being of secondary importance. Thickeners,
on the other hand, have the basic purpose of producing a
high solids underflow with the character of the clarified
overflow being of secondary importance. Thickeners are also
usually smaller in size and more massively constructed for a
given throughput.
Clarifiers and thickeners have a number of distinct
advantages over ponds:
(1) Less land space is required. Area-for-area these
devices are much more efficient in settling capacity
than ponds .
(2) Influences of rainfall are much less than for ponds. If
desired the clarifiers and thickeners can even be
covered.
(3) Since the external construction of clarifiers and
thickeners consists of concrete or steel tanks ground
seepage and rain water runoff influences do not exist.
On the other hand, clarifiers and thickeners suffer some
distinct disadvantages as compared with ponds:
(1) They have more mechanical parts and maintenance.
(2) They have only limited storage capacity for either
clarified water or settled solids.
VII-10
DRAFT
-------
DRAFT
(3) The internal sweeps and agitators in thickeners and
clarifiers require more power and energy for operation
than ponds.
Clarifiers and thickeners are usually used when sufficient
land for ponds is not available or is very expensive.
U.3 Hvdrocyclones
While hydrocyclones are widely used in the separation, clas-
sification and recovery operations involved in minerals
processing, they are used only infrequently for wastewater
treatment. Even the smallest diameter units available
(stream velocity and centrifugal separation forces both
increase as the diameter decreases) are ineffective when
particle size is less than 25-50 microns. Larger particle
sizes are relatively easy to settle by means of small ponds,
thickeners or clarifiers or other gravity principle settling
devices. It is the smaller suspended particles that are the
most difficult to remove and it is these that can not be
removed by hydrocyclones but may be handled by ponds or
other settling technology. Also hydrocyclones are of
doubtful effectiveness when flocculating agents are used to
increase settling rates.
Hydrocyclones are used as scalping units to recover small
sand or other mineral particles in the 25 to 200 micron
range, particularly if the recovered material can be sold as
product. In this regard hydrocyclones may be considered as
converting part of the waste load to useful product as well
as providing the first step of wastewater treatment.
4.4 Tube and Lamella Settlers
Tube and lamella settlers require less land area than
clarifiers and thickeners. These compact units, which
increase gravity settling efficiency by means of closely
packed inclined tubes and plates, can be used for either
scalping or wastewater polishing operations depending on
throughput and design.
VII-11
DRAFT
-------
DRAFT
U.5 Centrifuges
Centrifuges are not widely used for minerals mining
wastewater treatment. Present industrial-type centrifuges
are relatively expensive and not particularly suited for
this purpose. Future use of centrifuges will depend on
regulations, land space availability and the development of
specialized units suitable for minerals mining operations.
4^6 Flocculation
Flocculating agents increase the efficiency of settling
facilities and they are of two general types: ionic and
polymeric. The ionic types such as alum, ferrous sulfate
and ferric chloride function by destroying the repelling
double layer ionic charges around the suspended particles
and thereby allowing the particles to attract each other and
agglomereite. Polymeric types function by forming physical
bridges from one particle to another and thereby
agglomerating the particles.
Flocculating agents are most commonly used after the larger,
more readily settled, particles (and loads) have been
removed by a settling pond, hydrocyclone or other such
scalping treatment. Agglomeration, or flocculation, can
then be achieved with less reagent and less settling load on
the polishing pond or clarifier.
Flocculation agents can be used with minor modifications and
additions to existing treatment systems, but the costs for
the flocculating chemicals are often significant. Ionic
ty?pes are used in 10 to 100 mg/liter concentrations in the
wastewater while the higher priced polymeric types are
effective in the 2 to 20 mg/liter concentrations.
U.7 Screens
Screens are widely used in minerals and mining processing
operations for separations, classifications and
beneficiations. They are similar to hydrocyclones in that
they are restricted to removing the larger (<50-100 micron)
particle size suspended solids of the wastewater, which can
VII-12
DRAFT
-------
DRAFT
then often be sold as useful product. Screens are not
practical for removing the smaller suspended particles.
4.8 Filtration
Filtration is accomplished by passing the wastewater stream
through solids-retaining screens, cloths, or particulates
such as sand, gravel, coal or diatomaceous earth using
gravity, pressure or vacuum as the driving force.
Filtration is versatile in that it can be used to remove a
wide range of suspended particle sizes.
The large volumes of many wastewater streams found in
minerals mining operations require large filters. The cost
of these units and their relative complexity, compared to
settling ponds, has restricted their use to a few industry
segments committed to complex wastewater treatment.
5.0 DISSOLVED MATERIAL TREATMENTS
Unlike the ubiquitous suspended solids which need to be
removed from most minerals and mining wastewaters, dissolved
materials are a problem only in scattered instances in the
industries covered herein.
Treatments for dissolved materials are based on either
modifying or removing the undesired materials. Modification
techniques include chemical treatments such as
neutralization and oxidation-reduction reactions. Acids,
alkaline materials, sulfides and other toxic or hazardous
materials are examples of dissolved materials modified in
this way. Most removal of dissolved solids is accomplished
by chemical precipitation. Techniques such as ion exchange,
carbon adsorption, reverse osmosis and evaporation are
rarely used in the minerals mining industry.
Chemical treatments for abatement of water-borne wastes are
common. Included in this overall category are
neutralization, pH control, oxidation-reduction reactions,
coagulations, and precipitations.
VII-13
DRAFT
-------
DRAFT
5.1 Neutraliz ation
Some of the water-borne wastes of this study, often
including mine drainage water, are either acidic or
alkaline. Before disposal to surface water or other medium
excess acidity or alkalinity needs to be controlled to the
range of pH 6 to 9. The most common method is to treat
acidic streams with alkaline materials such as limestone,
lime, soda ash, or sodium hydroxide. Alkaline streams are
treated with acids such as sulfuric. Whenever possible,
advantage is taken of the availability of acidic waste
streams to neutralize basic waste streams and vice versa.
Neutralization often produces suspended solids which must be
removed prior to wastewater disposal.
5.2 22 Control
The control of pH may be equivalent to neutralization if the
control point is at or close to pH 7. Sometimes chemical
addition to waste streams is designed to maintain a pH level
on either the acidic or basic side for purposes of
controlling solubility.
Examples of pH control being used for precipitating
undesired pollutants are:
(1) Fe+3 + 30H- = Fe(OH)3
(2) Mn+z + 20H- = Mn(OH)2 = MnO2 + 2H+ + 4e~
(3) Zn+z + 20H- = Zn(OH)2
(4) Pb+z + 2 (OH)- = Pb(OH)2
(5) Cu + 20H- = Cu(OH)2.
Reaction (1) is used for removal of iron contaminants.
Reaction (2) is used for removing manganese from manganese-
containing water-borne wastes. Reactions (3), (4) , and (5)
are used on wastewater containing copper, lead, and zinc
salts.
VII-14
DRAFT
-------
DRAFT
5.3 Oxidation-Reduction Reactions
The modification or destruction of many hazardous wastes is
accomplished by chemical oxidation or reduction reactions.
Hexavalent chromium is reduced to the less hazardous triva-
lent form with sulfur dioxide or bisulfites. Sulfides, with
large COD values, can be oxidized with air to relatively
innocuous sulfates. These examples and many others are
basic to the modification of inorganic chemical water-borne
wastes to make them less troublesome. In general waste
materials requiring oxidation-reduction treatments are not
encountered in these industries.
5.U Precipitations
The reaction of two soluble chemicals to produce insoluble
or precipitated products is the basis for removing many
undesired water-borne wastes. The use of this technique
varies from lime treatments to precipitate sulfates,
fluorides, hydroxides and carbonates to sodium sulfide
precipitations of copper, lead and other toxic heavy metals.
Precipitation reactions are particularly responsible for
heavy suspended solids loads. These suspended solids are
removed by settling ponds, clarifiers and thickeners,
filters, and centrifuges.
The following are examples of precipitation reactions used
for wastewater treatment:
(1) SO.4= + Ca(OH)2 = CaSO4 * 2OH~
(2) 2F~ + Ca(OH)2 = CaF2 + 2OH~
(3) Zn++ + Na2C03 = ZnCO3 + Na+
6.0 SUMMARY OF TREATMENT TECHNOLOGY APPLICATIONS.
LIMITATIONS AND RELIABILITY
Table VII-2 summarizes comments on the various treatment
technologies as they are utilized for the minerals and
mining industry.
VII-15
DRAFT
-------
DRAFT
TeMe> VII-1. Summery of Technology, Applications, limitations and Reliability
Wo*.
Water
Suspended
Midi
i
[
Dissolved
Solidi
Treatment
(l)Pond
fettling
(2) Clorifier
Thickeners
(3)Hydro-
eyclones
(4) Tub. and
lamella
Settler.
(5) Screen)
(6) Rotary
Vacuum
filters
(7) Solid Bowl
Centrifuge
(8) leaf and
Pressure
Filter.
(9) Cartridge
and Candle
Rlten
(10) Sand and
Mixed
Media
Filter.
(1) Neutrali-
zation ond
pH Control
(2) Precipita-
tion
Application
U*ed for all
concentration!
Used for all
concentrations
Removal of larger
. particle sixes
Removal of smaller
particle sizes
Removal of larger
particle sixes
Mainly for sludges
and other high
impended lalids
streams
Mainly For sludges
and other high
suspended solids
streams
Used over wide
concentration
range
Mainly for polish-
ing Rltrottons of
impended tolidi
Mainly for poli*.
ing filtrationsof
impended lollds
General
Broadly uwd to
remove solubles
Percent
Solids
oO-99
60-99
50-99
90-99
50-99
90-99
60-99
90-99
50-99
50-99
99
50-99
&.p.Kt*d
Concen-
(n^l)
5-200
J-1000
-
-
-
5-1000
-
10-100
2-10
2-50
NA
0-20
Minimum
Concen-
tration
Achievable
(mg/l)
5-30
S-30
-
-
-
5-30
-
5-30
2-10
2-10
NA
0-10
Availa-
bility
of
Equip-
ment
none
Mooed
readily
aVQllabl.
rrcdv
• available
readilv
available
raody
available
readily
available
readily
available
readily
available
readily
ovollobl.
raodily
available
readily
available
readily
available
Lead
Time
(months)
1-12
3-24
3-12
3-12
3-12
3-12
3->2
3-0
1-3
3-6
3-12
3-6
Space
or
Land
Needed
large
1-500 acres
•moll
0.05-1 .0
acres
<1 acre
approx.
10' x tO'
approx.
10' x 101
approx.
10' x 10'
approx.
W x W
opprox.
10' x 101
opprox.
10' x 10'
opprox.
10' x 10
approx.
10' x 10*
tmall
20' x20- or
leu
imoll
JO'xW
Mainten-
ance
Required
small
nominal
small
small
nominal
nominal
nominal
small
small
small
minor
minor
Sensitivity
to
Shock
Loads
small
sensitive
sensitive
sensitive
small
sensitive
sensitive
sensitive
sensitive
sensitive
nominal
sensitive
effect,
of
Shutdown
ond
Startup
small
nominal
small
nominal
small
nominal
small
small
small
small
small
small
Energy
Require-
ments
snail
nominal
small
small
small
nominal
nominal
small
small
small
small
small
VII-16
DRAFT
-------
DRAFT
Estimates of the efficiency with which the treatments remove
suspended or dissolved solids from wastewater, given in the
Table need to be interpreted in the following context.
These values will obviously not be valid for all cir-
cumstances, concentrations or materials, but they should
provide a general guideline for treatment performance
capabilities. Several comments may be made concerning the
values:
(1) At high concentrations and optimum conditions, all
treatments can achieve 99 percent or better removal of
the desired material;
(2) At low concentrations, the removal efficiency drops off.
(3) Minimum concentration ranges achievable will not hold in
every case. For example, pond settling of some
suspended solids might not achieve less than the
100 mg/liter level. This is not typical, however, since
many such pond settling treatments can achieve 10 to
20 mg/liter without difficulty. Failure to achieve the
minimum concentration levels listed usually means that
either the wrong treatment methods have been selected or
that an additional treatment step is necessary (such as
a second pond or a polish filtration).
7.0 PRETREATMENT TECHNOLOGY
Mineral mining operations are usually conducted in
relatively isolated regions where there is no access to
publicly-owned activated sludge or trickling filter
wastewater treatment plants. In areas where publicly-owned
facilities could be used, pretreatment would often be
required to reduce the heavy suspended solids load.
In the relatively few instances where dissolved materials
are serious, pH control and some reduction of hazardous
constituents such as fluorides and heavy metals would be
required. Lime treatment will usually be sufficient for
reductions of both categories.
VII-17
DRAFT
-------
DRAFT
8j_0 NONWATER QUALITY ENVIRONMENTAL ASPECTS, INCLUDING ENERGY
REQUIREMENTS
The effects of these treatment and control technologies on
air pollution, noise pollution, and radiation are usually
small and not of any significance.
Large amounts of solid waste in the form of both solids and
sludges are formed as a result of all suspended solids
operations as well as chemical treatments for neutraliza-
tion, and precipitations.
Easy-to-handle, relatively dry solids are usually left in
settling ponds or dredged out periodically and dumped onto
the land. Since mineral mining properties are usually
large, space for such dumping is often available.
Sludges and difficultly settled solids are most often left
in the settling pond, but may in some instances be
landfilled.
In summary, the solid wastes and sludges from the mineral
mining industry wastewater treatments are very large in
quantity, but the industry, having sufficient space and
earth-moving capabilities, manages it with greater ease than
could most other industries.
VII-18
DRAFT
-------
DRAFT
SECTION VIII
COST, ENERGY. WASTE REDUCTION BENEFITS AND NON-WATER ASPECTS
OF TREATMENT AND CONTROL TECHNOLOGIES
1.0 SUMMARY
The clay, ceramic, refractory and miscellaneous minerals
segment of the mineral mining and processing industry is
characterized by individuality of facilities. Unlike
manufacturing operations, where raw materials for the
process may be selected and controlled as to purity and
uniformity, mining and minerals processing operations are
themselves largely controlled by the purity and uniformity
of the ores or raw materials involved. Operations have to
be located, at or near the mineral deposits. This lack of
control over raw material quality and location, coupled with
the fact that both mines and ore beneficiation processes may
have wastewater effluents, leads to several basic treatment
costing differences from those for manufacturing operations:
(1) In order to achieve reasonable homogeneity,
industries have to be segregated into subcategories
such as wet mines, dry mines, dry processes and one
or more wet processes.
(2) Solid waste loads vary widely depending on ore
composition.
(3) Types of water-borne waste vary with ore and
process. Processes are modified according to ore
composition.
VIII-1
DRAFT
-------
DRAFT
(4) Treatment costs often vary widely depending on
character of pollutants involved. The most
widespread example is particle size and composition
variation of suspended solids. Deposits with large
particle sized wastes have high settling rates
while small or colloidal suspended particles are
slow and difficult to settle, requiring large
ponds, thickeners, flocculating treatments, other
devices for removing suspended solids in many
cases.
In general, plant size and age have little influence on the
type of waste effluent. The amounts and costs for their
treatment and disposal are readily scaled from plant size
and are not greatly affected by plant age.
Geographical location is important. Mines and processing
plants located in dry western areas rarely require major
wastewater treatment or have subsequent disposal problems.
Terrain and land availability are also significant factors
affecting treatment technology and costs. Lack of
sufficient flat space for settling ponds often forces
utilization of mechanical thickeners, clarifiers, or
settlers. On the other hand, advantage is often taken of
valleys, hills, swamps, gullies and other natural
configurations to provide low cost pond and solid waste
disposal facilities.
In view of the large number of mines and beneficiation
facilities and the significant variables listed above, costs
have been developed for representative mines and processing
plants rather than specific exemplary plants that may have
advantageous geographical, terrain or ore composition.
A summary of cost and energy information for the present
level of wastewater treatment technology for this segment is
given in Table VIII-1. Present capital investment for
wastewater treatment in the clay, ceramic, refractory and
miscellaneous minerals segment is estimated at $7,500,000.
VIII-2
DRAFT
-------
DRAFT
Table VIII-1
CAPITAL INVESTMENTS AND ENERGY CONSUMPTION OF PRESENT WASTEWATER
TREATMENT FACILITIES
Subcategory
Bentonite
Fire Clay
Attapulgite )
Montmorillonite)
Kaolin (dry process)
Kaolin (wet process)
Ball Clay
Feldspar (dry process)
Feldspar (flotation)
Kyanite
Magnesite
Shale
Aplite
Talc minerals (dry)
Talc minerals (wet
washing)
Talc minerals (heavy
media flotation)
Abrasives, Garnet
Abrasives, Tripoli
Diatomite
Graphite
Jade
Novaculite
Capital Spent
Dollars
$ 330,000
2,670,000
335,000
1,000,000
375,000
300,000
695,000
335,000
450,000
370,000
500,000
<100,000
1,000
negligible
Present Energy
Use -
Kcal xlO6
No Waste Water
No Waste Water
180
No Waste Water
,6,875
825
No Waste Water
4,950
830
small
No Waste Water
2,230
No Waste Water
1,670
2,500
1,250
No Waste Water
small
small
negligible
negligible
Total Annual
Costs -$/kkg
Produced
0.22
0.29
0.26
1.65
2.83
0.19
0.69
1.09
1.09
5.88
(except one scrubber)
0.27
$20-25
negligible
negligible
Percent of
Selling price
0.9
1.0
1.5
10.2
4.0
0.1
price uftknow
3.2
3.2
5.2
0.4
<5
<0.1
<0.1
TOTAL
7,500,000
21,300
Vlll-3
DRAFT
-------
DRAFT
2.0 COST REFERENCES AND RATIONALE
Cost information contained in this report was assembled
directly from industry, from waste treatment and disposal
contractors, engineering firms, equipment suppliers,
government sources, and published literature. Whenever
possible, costs are taken from actual installations,
engineering estimates for projected facilities as supplied
by contributing companies, or from waste treatment and
disposal contractors quoted prices. In the absence of such
information, cost estimates have been developed insofar as
possible from plant-supplied costs for similar waste
treatments and disposal for other plants or industries.
2.1 Interest Costs and Eguity Financing Charges
Capital investment estimates for this study have been based
on 10 percent cost of capital, representing a composite
number for interest paid or return on investment required.
2.2 Time Basis for Costs
All cost estimates are based on August 1972 prices and when
necessary have been adjusted to this basis using the
chemical engineering plant cost index.
2.3 Useful Service Life
The useful service life of treatment and disposal equipment
varies depending on the nature of the equipment and process
involved, its usage pattern, maintenance care and numerous
other factors. Individual companies may apply service lives
based on their actual experience for internal amortization.
Internal Revenue Service provides guidelines for tax
purposes which are intended to approximate average
experience.
Based on discussions with industry and condensed IRS guide-
line information, the following useful service life values
have been used:
VIII-4
DRAFT
-------
DRAFT
(1) General process equipment 10 years
(2) Ponds, lined and unlined 20 years
(3) Trucks, bulldozers, loaders
and other such materials
handling and transporting
equipment. 5 years
Depreciation
The economic value of treatment and disposal equipment and
facilities decreases over its service life. At the end of
the useful life, it is usually assumed that the salvage or
recovery value becomes zero. For IRS tax purposes or
internal depreciation provisions, straight line, or
accelerated write-off schedules may be used. Straight line
depreciation was used solely in this report.
2.5 Capital Costs
Capital costs are defined as all front-end out-of-pocket
expenditures for providing treatment/disposal facilities.
These costs include costs for research and development
necessary to establish the process, land costs when
applicable, equipment, construction and installation,
buildings, services, engineering, special start-up costs and
contractor profits and contingencies.
2.6 Annual Capital Costs
Most if not all of the capital costs are accrued during the
year or two prior to actual use of the facility. This
present worth sum can be converted to equivalent uniform
annual disbursements by utilizing the Capital Recovery
Factor Method:
VIII-5
DRAFT
-------
DRAFT
Uniform Annual Disbursement = P i (1+ilnth power
(1+i) nth power - 1
Where P = present value (capital expenditure), i =
interest rate, V100, n = useful life in years
The capital recovery factor equation above may be
rewritten as:
Uniform Annual Disbursement = P(CR - i% - n)
Where (CR - iSt - n) is the Capital Recovery Factor for
iX interest taken over "n" years useful life.
2,7 Land Costs
Land-destined solid wastes require removal of land from
other economic use. The amount of land so tied up will
depend on the treatment/disposal method employed and the
amount of wastes involved. Although land is non-depreciable
according to IRS regulations, there are numerous instances
where the market value of the land for land-destined wastes
has been significantly reduced permanently, or actually
becomes unsuitable for future use due to the nature of the
stored waste. The general criteria applied to costing land
are as follows:
(1) If land requirements for on-site treatment/disposal are
not significant, no cost allowance is applied.
(2) Where on-site land requirements are significant and the
storage or disposal of wastes does not affect the
ultimate market value of the land, cost estimates
include only interest on invested money.
(3) For significant on-site land requirements where the
ultimate market value and/or availability of the land
has been seriously reduced, cost estimates include both
capital depreciation and interest on invested money.
(4) Off-site treatment/disposal land requirements and costs
are not considered directly. It is assumed that land
costs are included in the overall contractor's fees
along with its other expenses and profit.
VIII-6
DRAFT
-------
DRAFT
(5) In view of the extreme variability of land costs,
adjustments have been made for individual industry
situations. In general, isolated, plentiful land has
been costed at $2,470/hectare (1,000/acre).
2.8 Operating Expenses
Annual costs of operating the treatment/disposal facilities
include labor, supervision, materials, maintenance, taxes,
insurance and power and energy. Operating costs combined
with annualized capital costs give the total costs for
treatment and disposal operations. No interest cost was
included for operating (working) capital. Since working
capital might be assumed to be one sixth to one third of
annual operating costs (excluding depreciation), about
1-2 percent of total operating costs might be involved.
This is considered to be well within the accuracy of the
estimates.
2.9 Rationale for "Representativg Plants"
All plant costs are estimated for "representative plants"
rather than for any actual plant. "Representative plants"
are defined to have a size and age agreed upon by a
substantial fraction of the manufacturers in the subcategory
producing the given mineral, or, in the absence of such a
consensus, the arithmetic average of production size and age
for all plants.
Location is selected to represent the industry as closely as
possibly. For instance, if all plants are in northeastern
U.S., typical location is noted as "northeastern states".
If locations are widely scattered around the U.S., typical
location would be not specified geographically. If two
plants exist, one on the west coast and one on the east
cost, typical location would be "1 east coast - 1 west
coast".
It should be noted that the unit costs to treat and dispose
of hazardous wastes at any given plant may be considerably
higher or lower than the representative plant because of
individual circumstances.
VIII-7
DRAFT
-------
DRAFT
2.10 Definition of Levels of Treatment and Control
Costs are developed for various types and levels of
technology:
Minimum (or basic level), that level of technology which is
equalled or exceeded by most or all of the involved plants.
Usually money for this treatment level has already been
spent (in the case of capital investment) or is being spent
(in the case of operating and overall costs).
B^CfDfE Levels - Successively greater degrees of treatment
with respect to critical pollutant parameters. Two or more
alternative treatments are developed when applicable.
2.11 Rationale for Pollutant Considerations
(1) All non-contact cooling water is exempted from treatment
(and treatment costs) provided that no harmful
pollutants are introduced.
(2) Water treatment, cooling tower and boiler blowdown
discharges are not treated provided they contain no
harmful pollutants.
(3) Removal of dissolved solids, other than harmful
pollutants, is not included.
(4) Mine drainage treatments and costs are considered
separately from process water treatment and costs. Mine
drainage costs are estimated for all mineral categories
for which such costs are a significant factor.
(5) All solid waste disposal costs are included as part of
the cost development.
2»12' Cost Variances
The effects of age, location, and size on costs for
treatment and control have been considered and are detailed
in subsequent sections for each specific subcategory.
VIII-8
DRAFT
-------
DRAFT
3.0 INDIVIDUAL MINERAL. WASTE WATER TREATMENT AND DISPOSAL
COSTS
3a1 Bentonite
There is no wastewater from mining and processing of
bentonite. Therefore, there is no treatment cost involved.
Also there is no mine water drainage.
3.2 Fire Clay
The only wastewater from mining and processing of fire clay
is mine water discharge. Treatment costs for settling
suspended solids in mine water are estimated at
$0.01-0.05/kkg of produced fire clay. Since there is no
process water discharge in the production of fire clay,
there are no costs for process wastewater treatment.
3.3 Fuller's Earth
Fullerfs earth was divided into two subcategories -
attapulgite and montmorillonite. Suspended solids in
attapulgite mine drainage and process water generally settle
rapidly. Suspended solids in montmorillonite mine drainage
and process water are more difficult to settle.
Estimates of treatment costs for mine water, including use
of flocculating agents to settle montmorillonite wastes,
range from $0.17 to $0.28/metric ton of montmorillonite
produced, see Table VIII-3a.
Process and air scrubber wastewater treatment costs are
summarized in Tables VIII-2 and VIII-3.
3.3.1 Cost Variance
In the montmorillonite subcategory, there are three plants
ranging in age from 3 to 18 years. Age is not a significant
factor in cost variance.
There are two plants representing the attapulgite
subcategory ranging in age from 55 to 90 years. Age is not
a significant factor in cost variance.
VIII-9
DRAFT
-------
DRAFT
TABLE VIII-2.
COST-BENEFIT ANALYSIS FOR A REPRESENTATIVE PLANT
(ALL COSTS ARE CUMULATIVE)
SUBCATEGORY Attapulgite (Process Water Only)
PLANT SIZE 200,000 METRIC TONS PER YEAR OF Attapulgite
PLANT AGE 60 YEARS PLANT LOCATION Georgia-North Florida Region
INVESTED CAPITAL COSTS!
TOTAL
ANNUAL CAPITAL RECOVERY
OPERATING AND MAINTENANCE
COSTS:
ANNUAL 0 8 M (EXCLUDING
POWER AND ENERGY)
ANNUAL ENERGY AND POWER
TOTAL ANNUAL COSTS
COST/ METRIC TON Attapularte
WASTE LOAD PARAMETERS
(kg /metric ton of )
TSS
PH
RAW
WASTE
LOAD
LEVEL
A
(MIN)
71,000
8,400
37,400
200
46,000
0.21
0.01-0.02
6-9
B
77,000
9,300
39,800
200
49,300
0.22
0.01
6-9
C
95,000
11,100
39,100
300
50,500
0.23
0
—
0
E
LEVEL DESCRIPTION:
A — pond settling
B — A plus flocculating agents
C — B plus recycle to process
VIII-10
DRAFT
-------
UK AM
TABLE VIII-3.
COST- BENEFIT ANALYSIS FOR A REPRESENTATIVE PLANT
(ALL COSTS ARE CUMULATIVE)
SUBCATEGORY Montmorillonite (Process Water Only)
PLANT SIZE 182,000 METRIC TONS PER YEAR OF Montmorillonite
PLANT AGE 10 YEARS PLANT LOCATION Georgia _____
INVESTED CAPITAL COSTS!
TOTAL
ANNUAL CAPITAL RECOVERY
OPERATING AND MAINTENANCE
COSTS:
ANNUAL 0 8 M (EXCLUDING
POWER AND ENERGY)
ANNUAL ENERGY AND POWER
TOTAL ANNUAL COSTS
COST/METRIC TON Mnntnmonllonift
WASTE LOAD PARAMETERS
(kg /metric ton of monrmorilldr
TSS
pH
RAW
WASTE
LOAD
Ire)
LEVEL
A
(MIN)
60,000
7,000
30,900
200
38,100
0.21
0.3
6-9
6
65,000
7,900
32,900
200
417000
0.22
0.05
6-9
C
80,000
9,400
32,300
300
43,000
0.24
0
-
D
E
LEVEL DESCRIPTION:
A — pond settling of scrubber water
B — A plus flocculating agents
C — B plus recycle to process
VIII-11
DRAFT
-------
DRAFT
TABLE VIII-3A.
COST-BENEFIT ANALYSIS FOR A REPRESENTATIVE PLANT
(ALL COSTS ARE CUMULATIVE)
SUBCATEGORY Montmorillonite (Mine Wafer Only)
PLANT SIZE 182,000 METRIC TONS PER YEAR OF Monrmorillonire
PLANT AGE 10 YEARS PLANT LOCATION Georgia
INVESTED CAPITAL COSTS:
TOTAL
ANNUAL CAPITAL RECOVERY
OPERATING AND MAINTENANCE
COSTS:
ANNUAL 0 a M (EXCLUDING
POWER AND ENERGY)
ANNUAL ENERGY AND POWER
TOTAL ANNUAL COSTS
COST/METRIC TON Montmorillonite
WASTE LOAD PARAMETERS
(kg /metric ton of )
TSS, mg/liter
*estimates
RAW
WASTE
LOAD
LEVEL
A
(MIN)
0
0
0
0
0
0
200—
5,000*
B
60,000
15,800
12,300
3,000
32,300
0.17
200—
2,000*
c
62,000
16,300
32,300
3,000
51,800
0.28
<50*
D
E
LEVEL DESCRIPTION:
A — no treatment
B — pond settling
C — B plus flocculating agents
VIII-12
DRAFT
-------
DRAFT
Location
All the plants in the montmorillonite subcategory are
located in Georgia and, thus, location is not a significant
factor in cost variance.
The attapulgite plants are located in Georgia and Florida,
in close proximity and therefore, location is not a
significant factor in cost variance.
Size
The plants in the montmorillonite subcategory range from
13,600 to 207,000 kg/y (15,000-228,000 TPY). The
representative plant is 182,000 kkg/y (200,000 TPY).
The attapulgite plants are 213,000 kkg/y (235,000 TPY) and
227,000 kkg/y (250,000 TPY). The representative plant is
220,000 kkg/y (230,000 TPY).
In both these subcategories the cost variance with size is
estimated to be a 0.9 exponential function for capital and
its related annual costs, and directly proportional for
operating costs other than taxes, insurance and capital
recovery.
3.3.2 Cost Basis for Table VIII-2.
Capital Costs
Pond cost, dollars/hectare (dollars/acre): 24,700 (10,000)
Mine pumpout settling pond area, hectares (acres):0.1 (0.25)
Process Settling pond area, hectares (acres):2 (5)
Pumps and pipes: $10,000
Operating and Maintenance Costs
Energy unit cost: $0.01/kwh
Labor rate assumed: $10,000/yr
3.3.3 Cost Basis for Table VIII-3.
Capital Costs
Pond cost, dollars/hectare (dollars/acre);2»,700 (10ffOOO)
Mine pumpout settling pond hectares iacres);0.1 (0
Process settling pond area, hectares (acres);2 (5)
Pumps and pipes; $10«000
VIII-13
DRAFT
-------
DRAFT
Operating and Maintenance Costs
Treatment chemicals
Flocculating agent; $1.50/kcr (0.70/lb)
Energy unit cost; $0.01/kwh
Labor rate assumed; $10,000/vr
3.4 Kaolin and Ball Clay
Kaolin and ball clay mining and processing operations differ
widely as to their wastewater effluents. All treatments
involve settling ponds for their basic technology. Dry
mines need no treatment or treatment expenditures. Wet
mines (from rain water and ground seepage) use settling
ponds to reduce suspended solids. These settling ponds are
small and cost an estimated $O.Q1-$0.06/metric ton of clay
product.
Processing plants may be either wet or dry. Dry plants have
no treatment or treatment costs. Wet processing plants have
process wastewater from two primary sources: scrubber water
from air pollution facilities, and process water that may
contain zinc compound from a product bleaching operation.
Scrubber and process water need to be treated to reduce
suspended solids and zinc compounds. Costs for reduction
are summarized in Tables VIII-U and VIII-5 for wet process
kaolin and ball clay, respectively.
3.4.1 Cost Variance
The kaolin wet process subcategory consists of two plants
having ages of 29 and 37 years. Age is not a cost variance
factor.
The ball clay subcategory has a range of plant ages from 15
to 56 years. Age has not been found to be a significant
factor on costs.
Location
The wet process kaolin operations are only located in
Georgia, hence not a variance.
VIII-14
DRAFT
-------
DRAFT
TABLE VI11-4.
COST-BENEFIT ANALYSIS FOR A REPRESENTATIVE PLANT
(ALL COSTS ARE CUMULATIVE)
SUBCATEGORY Wet Process Kaolin
PLANT SIZE 450,000
METRIC TONS PER YEAR OF Kaol
in
PLANT AGE 30 YEARS
PLANT LOCATION Georgia-South
INVESTED CAPITAL COSTS!
TOTAL
ANNUAL CAPITAL RECOVERY
OPERATING AND MAINTENANCE
COSTS:
ANNUAL 0 8 M (EXCLUDING
POWER AND ENERGY)
ANNUAL ENERGY AND POWER
TOTAL ANNUAL COSTS
COST/METRIC TON of Kaolin
WASTE LOAD PARAMETERS
(kg/metric ton of Kaolin )
TSS
Dissolved zinc
pH
RAW
WASTE
LOAD
35-100
0.4
LEVEL
A
(MIN)
447,000
49,200
85,000
5,000
139,200
0.31
0.02-0.2
0.001
6-9
B
463,000
51,800
112,000
5,000
168,800
0.38
<0.1
0.001
6-9
C
487,000
55,600
90,000
5,000
152,200
0.34
0
0
—
D
E
LEVEL DESCRIPTION:
A — pond settling with lime treatment
B — A plus flocculating agents
C — pond settling and recycle to process (This should be satisfactory for cases where
only cooling water and scrubber water are present. Process water will build up
dissolved solids, requiring a purge.)
VIII-15
DRAFT
-------
DRAFT
TABLE VI11-5.
COST-BENEFIT ANALYSIS FOR A REPRESENTATIVE PLANT
(ALL COSTS ARE CUMULATIVE)
SUBCATEGORY Ball Clay
PLANT SIZE 75,000
METRIC TONS PER YEAR OF Ball Clay
PLANT AGE 30 YEARS PLANT LOCATION Kentucky-Tennessee Region
INVESTED CAPITAL COSTS:
TOTAL
ANNUAL CAPITAL RECOVERY
OPERATING AND MAINTENANCE
COSTS:
ANNUAL 0 a M (EXCLUDING
POWER AND ENERGY)
ANNUAL ENERGY AND POWER
TOTAL ANNUAL COSTS
COST/ METRIC TON of Ball Clay
WASTE LOAD PARAMETERS
(kg/metric ton of ball clay )
TS-S
pH
RAW
WASTE
LOAD
LEVEL
A
(MIN)
89,000
9,800
14,000
800
24,600
0.33
0.4-2.0
6-9
B
92,000
10,300
19,000
800
30,100
0.40
0.2
6-9
C
97,000
11,100
15,000
1,100
27,200
0.36
0
_
D
E
LEVEL DESCRIPTION:
A — pond settling
B — A plus flocculating agent
C — closed cycle operation (satisfactory only for scrubbers and cooling water)
VIII-16
DRAFT
-------
DRAFT
Ball clay operations are located in the Kentucky-Tennessee
rural areas and hence location is not a significant cost
variance factor.
Size
The two wet process kaolin plants are 300,000 and
600,000 kkg/yr (330*000 and 650,000 TPY) size. The
representative plant is 450,000 kkg/yr (500,000 TPY).
Capital costs over this size range are estimated to be a 0.9
exponential function of size, and operating costs other than
taxes, insurance, and capital recovery are estimated to be
proportional to size.
The ball clay facilities range from 3,000 to 113,000 kkg/yr
(3,300 to 125,000 TPY). The representative plant is
68,000 kkg/yr (75,000 TPY). Capital cost and operating cost
variance factors for size are the same as for wet process
kaolin above.
3.4.2 Cost Basis for Table VIII-4
Capital Costs
Pond cost, dollars/hectare (dollars/acre):12,350 (5,000)
Settling pond area, hectares (acres):20 (50)
Pumps and pipes: $25,000
Chemical metering equipment: $10,000
Operating and Maintenance Costs
Pond dredging: $20,000/yr ~
Treatment chemicals
Lime: $22/kkg ($20/ton)
Flocculating agent: $2.2/kg ($1/lb)
Energy unit cost: $0.01/kwh
Maintenance: $10,000-11,000/yr
3.4.3 Cost Basis for Table VIII-5
Capital Costs
Land cost, dojLJ.ars/hectare (dollars/acre); 12,350 (5.0001
Settling pond area, hectares (acres); 20 (50)
Pumps and pipes; $25,000
Chemical metering equipment; $10,000
Operating and Maintenance Costs
Pond dredging: $20,000/vr
VIII-17
DRAFT
-------
DRAFT
Treatment chemicals
Lime; $22/kka f$20/tonl
Flocculating agent; $2.2/kg f$1/lb>
Maintenance; $10.000-11.000/vr
3^5 Feldspar
Feldspar may be produced as the sole product, as the main
product with by-product sand and mica, or as a co-product of
processes for producing mica. Co-product production
processes will be discussed under mica. Dry processes (in
western U.S.) where feldspar is the sole product have no
water effluent and no wastewater treatment costs.
Therefore, the only subcategory involving major treatment
and cost is wet beneficiation of feldspar ore.
After initial scalpings with screens, hydrocyclones or other
such devices to remove the large particle sizes, the smaller
particle sizes are removed by (1) settling ponds or
(2) mechanical thickeners, clarifiers and filters. Often
the method selected depends on the amount and type of land
available for treatment facilities, where sufficient flat
land is available ponds are usually preferred.
Unfortunately, most of the industry is located in hill
country and flat land is not available. Therefore,
thickeners and filters are often used. Wastewater from the
feldspar beneficiation involves as primary pollutants
suspended solids and fluorides. There is also a solid waste
disposal problem for ore components such as mud, clays and
some types of sand, some of which have to be landdumped or
landfilled. Fluoride pollutants come from the hydrofluoric
acid flotation reagent.
Treatment and cost options are developed in Table VIII-6 for
both suspended solids and fluoride reductions. Successive
treatments for reducing suspended solids and fluorides are
shown.
Reduction of fluoride ion level to less than 10 mg/liter can
be accomplished through segregation and separate treatment
of fluoride-containing streams. This approach is already
planned by at least one producer, and is a good example of
in-process modification to reduce pollutant levels. A
modest reduction of fluoride of less than 50 percent is
presently achieved at only one plant with alum treatment
VIII-18
DRAFT
-------
DRATT
TABLE VIII-6.
COST-BENEFIT ANALYSIS FOR A REPRESENTATIVE PLANT
(ALL COSTS ARE CUMULATIVE)
SUBCATEGORY Feldspar, Wet Process
PLANT SIZE
90,900
PLANT AGE 10 YEARS
METRIC TONS PER YEAR OF Feldspar
PLANT LOCATION Eastern U.S.
INVESTED CAPITAL COSTS!
TOTAL
ANNUAL CAPITAL RECOVERY
OPERATING AND MAINTENANCE
COSTS:
ANNUAL 0 8 M (EXCLUDING
POWER AND ENERGY)
ANNUAL ENERGY AND POWER
TOTAL ANNUAL COSTS
COST/METRIC TON Feldspar
WASTE LOAD PARAMETERS
(kg /metric ton of ore )
Suspended Solids
Fluoride
pH
RAW
WASTE
LOAD
26ftn
0.22-
n.95
LEVEL
A
(MIN)
115,000
18,700
107,500
2,000
128,200
1.41
0.6
0.2
6-9
B
260,000
42,100
132,500
2,000
176,600
1.95
0.3
0.1
6-9
C
375,000
60,800
157,500
2,000
220,300
2.42
0.3
0.03
6-9
D
185,000
30,100
T18,500
4,000
152,600
1.68
0.3-3
0.2
6-9
E
415,000
70,800
156,500
6,000
233,300
2.56
0.1-0.3
0.03
6-9
LEVEL DESCRIPTION:
A — settling pond for suspended solids removal, no fluoride treatment.
B — larger settling ponds plus internal recycle of some fluoride-containing water plus
flocculation agents.
C — B plus segregation and separate lime treatment of Fluoride water.
D — present treatment by thickeners and filters plus lime treatment for fluoride.
E — D plus segregation and separate lime treatment of fluoride water plus improved
suspended solids treatment by clarifier installation.
VII1-19
DRAFT
-------
DRAFT
that has been installed for the purpose of flocculating
suspended solids.
3.5.1 cost Variance
The feldspar wet process subcategory consists of 6 plants
ranging in age from 3 to 26 years. Age is not a significant
cost variance factor.
Location
The feldspar wet processing operations are located in
southeastern and northeastern states in rural areas.
Location has not been found to be a significant cost
variance factor.
Size
The feldspar wet processing operations range in size from
45,700 to 154,000 kkg/yr (50,400-170,000 TPY). The
representative plant is 90,900 kkg/y (100,000 TPY). The
range of capital costs for treatment is $36,800 to $250,000,
and the range of operating costs is $18,400 to $165,000 as
reported by the feldspar wet process producers.
The variance of cost with size is estimated to be for
capital: exponent of 0.9 for treatments based on ponds,
exponent of 0.7 for treatments based on thickeners.
Operating costs other than taxes, insurance and capital
recovery are approximately proportional to size.
3.5.2 Cost Basis for Table VIII-6.
Capital Costs
Pond cost, dollars/hectare (dollars/acre): 30,600 (12,500)
Settling pond area, hectares (acres): 0.4-0.8 (1-2)
Thickeners, filters, clarifiers: 0-$50,000
Solids handling equipment: $40,000-50,000
Chemical metering equipment: 0-$50,000
Operating and Maintenance Costs
Other solid waste disposal costs: 0-$0.5/ton
Treatment chemicals: $10,000-25,000/yr
Energy unit cost: $0.01/kwh
Monitoring: 0-$15,000/yr
VIII-20
DRAFT
-------
DRAFT
3.6 Kvanite
Kyanite is produced at three locations. Two of the three
plants have complete recycle of process water after passing
through settling ponds. A summary of treatment technology
costs is given in Table VHI-7. Approximately two-thirds of
the cost comes from solid wastes removal from the settling
pond and land disposal. Depending on solid waste load,
costs could vary from approximately $1 to $4 per metric ton
of product.
3.6.1 Cost Variance
Age
The three plants of this subcategory range in age between 10
and 30 years. There is no significant treatment cost
variance due to this range.
Location
These plants are in two southeastern states in rural
locations, not a significant cost variance factor.
Size
The sizes range from 16,000 to 45,000 kkg/yr (18,000 to
50,000 TPY). The costs given are meant to be representative
over this size range on a unit production basis, that is,
costs are roughly proportional to size.
3.6A2 Cost Basis fpr Kvanite Category
Capital Costs
Pond cost, dollars/hectare (dollars/acre): 12,300 (5,000)
Settling pond area, hectares (acres):10 (25)
Pipes: $28,000
Pumps: $4,400
Operating and maintenance Costs
Pond dredging and solids waste hauling: $82,500/yr
Pond: $14,600/yr
Pipes: $3,300/yr
Energy unit cost: $0.01/kwh
Pumps: $1,200/yr
Labor: $3,000/yr
Maintenance: $16,900/yr
VIII-21
DRAFT
-------
DRAFT
TABLE VIII-7.
COST-BENEFIT ANALYSIS FOR A REPRESENTATIVE PLANT
(ALL COSTS ARE CUMULATIVE)'
SUBC ATEGORY Kyanite
PLANT SIZE 45,000
METRIC TONS PER YEAR OF Kyanite
PLANT AGE 15 YEARS PLANT LOCATION South eastern U.S.
INVESTED CAPITAL COSTS!
TOTAL
ANNUAL CAPITAL RECOVERY-
OPERATING AND MAINTENANCE
COSTS:
ANNUAL 0 a M (EXCLUDING
POWER AND ENERGY)
ANNUAL ENERGY AND POWER
TOTAL ANNUAL COSTS
COST/METRIC TON of Kyanite
WASTE LOAD PARAMETERS
(kg /metric ton of )
Tailings
TSS-
pH
RAW
WASTE
LOAD
5500
LEVEL
A
(MIN)
80,000
9,700
75,000
1,000
85,700
1.90
3
6-9
B
157,400
19,100
108,100
1,400
128,600
2.83
0
-
C
D
E
LEVEL DESCRIPTION:
A — pond settling
B — A plus recycle
Note: Most of the above cost at A level (65-70%) is the cost of removal and disposal
of solids from ponds.
VIII-22
DRAFT
-------
DRAFT
3.7 Naturally Occurring Magnesite
There is only one known U.S. plant that produces magnesia
from naturally occurring magnesite ore. This plant is
located in a dry western climate and has no discharge to
surface water by virtue of a combination
evaporation-percolation pond. Capital costs for this
treatment are $300,000 with operation/maintenance costs of
$15,000/yr. plus annual capital investment costs of $35,220.
Shale and Other Clay Minerals
The minerals included in this category are shale and aplite.
3.8.1 Shale
No water is used in either mining or processing of shale.
The only water involved is occasional mine drainage from
rain or ground water. In most cases runoff does not pick up
significant suspended solids. Any needed treatment costs
would be expected to fall in the range of $0.01 to $O.C5 per
ton of shale produced.
3.8. 1. 1 Cost Variance
Shale facilities range from 8 to 80 years in age. This is
not a significant variance factor for the costs to treat
mine water.
Location
Shale facilities having significant mine water are located
through the eastern half of the U.S. The volume of mine
water is the only significant cost factor influenced by
location.
Size
Shale facilities range from 700 to 250,000 kkg/yr (770 to
270,000 TPY). Size is not a cost variance factor, since the
mine pumpout is unrelated to production rate.
3.8.2 Aplite
Aplite is dry mined produced at two facilities in the U.S.
VIII-23
DRAFT
-------
DRAFT
One plant with a dry process uses wet scrubbers the
discharge from which is ponded to remove suspended solids
and then discharged. Wastewater treatment costs were
calculated to be $0.48 per metric ton of product.
The second processing plant uses a wet classification
process and a significantly higher water usage per ton of
product than the first plant. Except for a pond pumpout
every one to two years, this plant is on complete recycle.
The total treatment costs per metric ton of product is
$0.78.
The estimated costs to bring the "dry process" plant to a
condition of total recycle of its scrubber water are:
capital: $9,000
annual capital recovery:$1,470
annual operating and maintenance, excluding power and
energy: $630
annual power and energy: $1,300
total annual cost:$3,400
3.8.2.1 Cost Variance
Aplite is produced by two plants which are 17 and 41 years
old. Age has not been found to be a significant cost
variance factor.
Location
Both aplite plants are located in Virginia and, therefore,
location is not a significant cost variance factor.
Size
The aplite plants are 54,400 kkg/y (60,000 TPY) and
136,000 kkg/y (150,000 TPY). The costs per unit production
are applicable for only the plants specified.
3.8.2.2 Cost Basis for Aplite Category
Capital Costs
Pond cost, dollars/hectare (dollars/acre): 12,300-24,500
(5,000-10,000)
Settling pond area, hectares (acres): 5.5-32 (14-80)
Recycle equipment: $9,000
VIII-24
DRAFT
-------
DRAFT
Operating and Maintenance Costs
Treatment chemical costs: $3,500/yr
Energy unit cost: $0«01/kwh
Recycle O & M cost: $1,900/yr
Maintenance:$Hr500-16,500/yr
Minerals Group
Suspended solids are the only major pollutant involved in
the wastewater from this category. In some wet processing
operations pH control through addition of acid and alkalies
is practiced. Neutralization of the final wastewater may be
needed to bring the pH into the 6-9 range. Both mines and
processing plants may be either wet or dry. Dry operations
have no treatment costs.
Mine Water
Rain water and ground water seepage often make it necessary
to pumpout mine water. The only treatment normally needed
for this water is settling ponds for suspended solids.
Ponds are usually small, one acre or less. Costs for this
treatment are in the range of $0.01 to $0.05 per ton of talc
produced.
Wet Processes
Wet processes are conducted in both the eastern and western
U.S.
Eastern Operations
Wastewater from wet processes comes from process operations
and/or scrubber water. The usual method of treating the
effluent is to adjust pH by addition of lime, followed by
pond settling.
Treatment options, costs and resultant effluent quality are
summarized in Table VIII-8. Plants not requiring lime
treatment would have somewhat lower costs than those given.
VIII-25
DRAFT
-------
DRAFT
TABLE VI11-8.
COST-BENEFIT ANALYSIS FOR A REPRESENTATIVE PLANT
(ALL COSTS ARE CUMULATIVE)
SUBCATEGORY Talc Minerals, Ore Mining, Heavy Media and Flotation
PLANT SIZE 45,000
METRIC TONS PER YEAR OF talc minerals
PLANT AGE 25 YEARS PLANT LOCATION Eastern U.S.
INVESTED CAPITAL COSTS'.
TOTAL
•ANNUAL CAPITAL RECOVERY
OPERATING AND MAINTENANCE
COSTS:
ANNUAL 0 Q M (EXCLUDING
POWER AND ENERGY)
ANNUAL ENERGY AND POWER
TOTAL ANNUAL COSTS
COST/METRIC TON of products
WASTE LOAD PARAMETERS
(kg/metric ton of products )
TSS
PH
RAW
WASTE
LOAD
800 to
1800
LEVEL
A
(MIN)
100,000
11,700
27,000
2,000
40,700
0.89
0.3-1.3
6-9
B
150,000
17,600
34,000
3,000
54,600
1.09
0.3
6-9
C
D
E
LEVEL DESCRIPTION:
A — lime treatment and pond settling
B — A plus additional pond settling
VIII-26
DRAFT
-------
DRAFT
Western Qperationg
Wet process plants in the western part of the U.S. are
mostly located in arid regions and can be no discharge
facilities through evaporation* Costs for these evaporation
pond systems were estimated to be the same cost as Level B
of Table VIII- 8. The required evaporation pond size in this
case is similar to that needed for good settling pond
performance.
3.9. 1 £ost Variance
Age
Facilities in the talc minerals group range from 2 to 70
years of age. However, the heavy media separation and
flotation subcategory with a discharge consists of only
three plants of 10 to 30 years of age. This is not a
significant treatment cost variance factor.
Location
The heavy media separation and flotation subcategory
facilities are located in rural areas of the eastern U»S.
This location spread is a minor cost variance factor.
Talc minerals facilities range in size from 12,000 to
300,000 Jckg/yr (13,000 to 330ffOOO TPY) . The heavy media
separation and flotation subcategory facilities range from
12,000 to 236,000 kkg/yr 03*000 to 260,000 TPY) . The
representative plant size selected is 45,000 kkg/yr
(50,000 TPY) . Over this range of sizes capital costs
variance can be estimated by an exponent of 0.8 to size, and
operating costs other than capital recovery, taxes and
insurance are approximately proportional to size.
3.9.2 Cost Basis for Table VIII- 8.
Capital Costs
Land cost, dollars/hectare ^dollars/acre) ; 24^500 (10,000^
Mine pumpouta settling pond area, hectares (acres) :
up to 0.4 iup to 11
Process settling pond area, hectares (acres) : 2 _ (5_)_
Pumps and pipes: $15P000
Chemical treatment equipment; $35a,000
VIII-27
DRAFT
-------
DRAFT
Operating and Maintenance Costs
Treatment chemicals
Lime; $22/kkg ($20/tonl
Energy cost; $1,000-2,000/vr
Maintenance^ $^,000/vr
Labor; $3.000-10.000/vr
3.10 Abrasives
Garnet and tripoli are the major natural abrasives mined in
the U.S.
3.10.1 Garnet
There are three garnet producers in the U.S., two in Idaho
and one in New York State.
Two basic types of processing are used: (1) wet washing and
classifying of the ore, and (2) heavy media and froth
flotation.
Washing and classifying plants have already incurred
estimated wastewater treatment costs of $0.16 per metric ton
of garnet produced.
Heavy media and flotation process wastewater treatment
estimated costs already incurred are significantly higher,
$5 to $10 per metric ton of product.
The quantity and quality of discharge at the Idaho plants
are not known by the manufacturer. Sampling was precluded
by seasonal halting of operations. The hydraulic load per
ton of product at the Idaho operations is believed to be
higher than at the New York operation studied. The costs to
reduce the amount of suspended solids in these discharges to
that of the New York operation are estimated to be:
capital: $100,000
annual operating costs: $30,000
Further detailing of these estimated costs would be pure
speculation.
VIII-28
DRAFT
-------
DRAFT
$3.10.1.1 cost Variance
There are three garnet producers ranging in age from 40 to
50 years. Age has not been found to be a significant cost
variance factor.
Location
Two of the garnet producers are located in Idaho and one in
New York State. The regional deposits differ widely making
different ore processes necessary. Due to this difference
in processes, there is no representative plant in this
subcategory. Treatment costs must be calculated on an
individual basis.
Size
The garnet producers range in size from 5,100 kkg/y to an
estimated 86,200 kkg/y (5,600 TPY to an estimated
95,000 TPY). The differences in size are so great that
there is no representative plant for this subcategory. Due
to process and size differences, treatment costs must be
calculated on an individual basis.
3.10.2 Tripoli
There are several tripoli producers in the United States.
The production is dry both at the plants and the mines. One
small plant has installed a wet scrubber.
3.10.2.1 cost Variance
There is only one plant in this subcategory that has any
process wastewater. This is only from a special process
producing 10 percent of that plant's production. Therefore,
there are no cost variances due to age, location or size.
3.11 Diatomite Mining
Diatomite is mined and processed in the western U.S. Both
mining and processing are practically dry operations.
Evaporation ponds are used for waste disposal in all cases.
VIII-29
DRAFT
-------
DRAFT
3j.l_2 Graphite
There is only one producer of natural graphite in the United
States. For this mine and processing plant, mine drainage,
settling pond seepage and process water are treated for
suspended solids, iron removal and pH level. The pH level
and iron precipitation are controlled by lime addition. The
precipitated iron and other suspended solids are removed in
the settling pond and the treated wastewater discharged.
Present treatment costs are approximately $20-25 per ton of
graphite produced.
3.13 Miscellaneous Non-Metallic Minerals
The two minerals included in this category are jade and
novaculite.
3.13.1 Jade
The jade industry is very small and involves very little
wastewater. One plant represents 55 percent of the total
U.S. Production has only 190 liters/day (50 GPD) of
wastewater. Suspended solids are settled in a small tank
followed by discharge to the company lawn. Treatment costs
are considered negligible.
3.13.2 Novaculite
There is only one novaculite producer in the United States.
Processing is a dry operation resulting in no discharge. A
dust scrubber is utilized and the water is recycled after
passing through a settling tank. Both present treatment
costs and proposed recycle costs are negligible.
4.0 INDUSTRY STATISTICS
Below are summarized the estimated 1972 selling prices for
the individual minerals at this report. These values were
taken from minerals industry yearbooks and Bureau of Census
publications.
VIII-30
DRAFT
-------
DRAFT
Bentonite
Fire clav
Fuller '..a_ Earth
Kaolin
Ball Clav
Feldspar
Kyanite
Macmesite
Shale & Misc. Clav
Apli-te
Talc Minerals
Abrasives. Garnet
Abrasives. Tripoli
Diatomite
Graphite
($/short ton)
11.70 J 10. §01
9.00 f8.15>
25.50 (23,00)
28.40 (25.75)
17.65 (16.00)
22-28 (2U-31)
70T50 (64.00)
165 (150)
1«76 p. 60)
not knpwn
34 (31)
11** (103)
1
ttovaculite
72 (65)
withheld
22.000 (20-000)
after
66 (60)
VIII-31
DRAFT
-------
DRAFT
SECTION IX
EFFLUENT REDUCTION ATTAINABLE THROUGH THE
APPLICATION OF THE
BEST PRACTICABLE CONTROL TECHNOLOGY
CURRENTLY AVAILABLE
1.0 INTRODUCTION
The effluent limitations which must be achieved by July 1,
1977, are based on the degree of effluent reduction attain-
able through the application of the best practicable control
technology currently available. For the mining of clay,
ceramic, refractory, and miscellaneous materials, this level
of technology was based on the average of the best existing
performance by facilities of various sizes, ages, and
processes within each of the industry's subcategories. In
Section IV, this segment of the minerals mining and
processing industry was divided into thirteen major
categories based on similarities of process. Several of
these major categories have been further subcategorized and,
for reasons explained in Section IV, each subcategory will
be treated separately for the recommendation of effluent
limitations guidelines and standards of performance.
Best practicable control technology currently available
emphasizes treatment facilities at the end of a
manufacturing process but also includes the control
technology within the process itself when it is considered
to be normal practice within an industry. Examples of waste
management techniques which were considered normal practice
within these industries are:
IX-1
NOTICE: THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
a) manufacturing process controls;
b) recycle and alternative uses of water; and
c) recovery and/or reuse of some wastewater constituents.
Consideration was also given to:
a) the total cost of application of technology in relation
to the effluent reduction benefits to be achieved from
such application;
b) the size and age of equipment and facilities involved;
c) the process employed;
d) the engineering aspects of the application of various
types of control techniques;
e) process changes; and
f) non-water quality environmental impact (including energy
requirements) .
The following is a discussion of the best practicable
control technology currently available for each of the
chemical subcategories, and the proposed limitations on the
pollutants in their effluents.
2.0 GENERAL WATER GUIDELINES
2.j Process Water
Process water is defined as any water contacting the ore,
processing chemicals, intermediate products, by-products or
products of a process including contact cooling water. All
process water effluents are limited to the pH range of 6.0
to 9.0 unless otherwise specified.
IX-2
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL 'REVIEW BY EPA.
DRAFT
-------
DRAFT
2.2 Cooling Water
In the minerals mining and processing industryf cooling and
process waters are sometimes mixed prior to treatment and
discharge. In other situations, cooling water is discharged
separately. Based on the application of best practicable
technology currently available, the recommendations for the
discharge of such cooling water are as follows.
An allowed discharge of all non-contact cooling waters
provided that the following conditions are met:
a) Thermal pollution be in accordance with standards to be
set by EPA policies. Excessive thermal rise in once
through non-contact cooling water in the mineral mining
industry has not been a significant problem.
b) All non-contact cooling waters should be monitored to
detect leaks of pollutants from the process. Provisions
should be made for treatment to the standards
established for process wastewater discharges prior to
release in the event of such leaks.
c) No untreated process waters be added to the cooling
waters prior to discharge.
The above non-contact cooling water recommendations should
be considered as interim, since this type of water plus
blowdowns from water treatment, boilers and cooling towers
will be regulated by EPA at a later date as a separate
category.
2 .,3 Storm Water Runoff
Storm water runoff may present pollution control problems
for certain subcategories. This is true where large
stockpiles of process or waste materials are stored
uncovered or in processes generating large amounts of dust.
In these cases, a process water impoundment which is
designed, constructed and operated so as to contain the
IX-3
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
precipitation from the 10 year, 24 hour rainfall event as
established by the U.S. National Weather Service for the
area in which such impoundment is located, may discharge
that volume of process wastewater which is equivalent to the
volume of precipitation that falls within the impoundment in
excess of that attributable to the 10 year, 24 hour rainfall
event, when such event occurs.
2.4 Mine Water Discharge
A mine is defined as that area which is being or has been
disturbed during the process of mineral extraction. The
area ceases to be a mine when the criteria described below
are fulfilled. The desired reclamation goals of regulatory
agencies are usually universal: the restoration of affected
lands to a condition at least fully capable of supporting the
uses which it was capable of supporting prior to any mining,
and achievement of a stability which does not pose any threat
of water diminution or pollution. The point at which this
metamorphosis takes place between unreclaimed and reclaimed
surface mined land is difficult to determine, but must be
considered in establishing a surface mine operator's term of
responsibility for the quality of effluent from the. mined
area.
In order to accomplish the objectives of the desired
reclamation goals, it is mandatory that the surface mine
operator regrade and revegetate the disturbed area upon
completion of mining. The final regraded surface con-
figuration is dependent upon the ultimate land use of the
specific site, and control practices described in this report
can be incorporated into the regrading plan to minimize
erosion and sedimentation. A diverse and permanent
vegetative cover should be established and plant succession
at least equal in extent of cover to the natural vegetation
of the area. To assure compliance with these requirements
and permanence of vegetative cover, the operator should be
held responsible for successful revegetation and effluent
water quality for a period of five full years after the last
year of augmented seeding, fertilization, irrigation, or
effluent treatment. In areas of the country where the
annual average precipitation is twenty-six inches or less,
the operator's assumption of responsibility and liability
should extend for a period of ten full years after the last
year of augmented seeding, fertilization, irrigation or
effluent treatment.
IX-4
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
The quantity of the discharges resulting from pumpout of
water from mines, pits or quarries in those industries is
characteristically intermittent or has a high variability
of flow and is unrelated to the production rate at the mine.
Such mine water is generally the result of direct rainfall
into the mine, leakage from aquifers, or influx of surface
runoff. The latter should not be allowed since the construction
of simple dikes and ditches is usually sufficient to prevent
the flow of surface water into a mine or quarry. The other,
largely uncontrollable mine water must be disposed of by
pumping to allow proper operation of the mine. Where this
pumped water is not otherwise useful for process purposes
or disposable by total evaporation or percolation back
to the originating aquifer, it must be discharged.
Many of the individual mines studied in these industries
have no mine pumpout water at all, or have no point source
discharge of mine drainage. For the others, it was found
that the ubiquitous suspended solids and pll pollutant
problems could be readily brought under control by simple
pll adjustment and settling in ponds prior to discharge.
The exceptions to this are in the mines where materials
readily forming stable colloidal suspensions are mined, as
in montmorillonite mining. The other industry subcategory
where this situation could be found is in bentonite mining,
but no such mines with water needing pumpout were found.
The suspended solids picked up in montmorillonite mine
waters are generally not amenable to reduction to low
concentrations by simple settling.
IX-5
NOTICE! THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
For all mine pumpout discharges from the clay, ceramic,
refractory, and miscellaneous materials segment of the
minerals mining and processing industry except for the
montmorillonite and bentonite mining subcategories, any such
discharges not explicitly covered by the process water
discharge guideline limitation are to be limited to, based
on the information in Sections V through VIII:
Limitation
Pollutant Parameter Monthly Average Daily _Maximum
pH 6-9 6-9
TSS 20 mg/liter 100 mg/litei
The above limitations are based on whatever flow discharge
volume exists for the period under consideration. The
discharge of pollutant parameters other than the above
should not exceed in concentration those values established
for water quality standards,
3.0 PROCESS WASTE WATER GUIDELINES ANJD LIMITATIONS FOR THE
CLAY. CERAMIC. REFRACTORY. AND MISCELLANEOUS
MINERALS SEGMENT OF THE MINERAL MINING INDUSTRY
POINT SOURCE SUBCATEGORIES
3...1 Bentonite Production Subcategory
Based upon the information contained in Sections III through
VIII, a determination has been made that the degree of
effluent reduction attainable through the application of the
best practicable control technology currently available is
no discharge of pollutants in process wastewater.
Identification of BPCTCA
There is no control technology needed for the mining and
processing of bentonite, because no water is used in the
process.
IX-6
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
3,2 Fire Clay Productj-pn Subcategory
Based upon the information contained in Sections ill through
VIII, a determination has been made that the degree of
effluent reduction attainable through the application of the
best practicable control technology currently available is
no discharge of pollutants in process wastewater.
Mine water discharge for this subcategory is covered by the
general water guidelines earlier in this section,,
Identification of BPgTCA
There is no control technology needed for the mining and
processing of fire clay because no water is used in the
process.
3.3. 1 Fuller's Earth - Attapulgite Production Subcatecrory
Based upon the information contained in Sections III through
VIII, a determination has been made that the degree of
effluent reduction attainable through the application of the
best practicable control technology currently available is:
Effluent Limitation
kg /metric ton (\bs/ ton I of product
Ef f luent Characteristic MgjvthJ;^ Average Daily Maximum
TSS 0,017 ^0.034) 0.085 (0.17)
The above limitations were based on the average process
wastewater discharge of the two plants studied, 340 liters
per metric ton (80 gallons per ton} of product and,
estimated achievable concentration of 50 mg/liter of TSS.
Mine water discharge for this subcategory is covered by the
general water guidelines earlier in this section.
IX-7
NOTICE: THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
Identification of BPCTCA
Best practicable control technology currently available for
the mining and processing of Fuller's Earth (attapulgite) is
settling of suspended solids.
To implement this technology at plants not already using the
recommended control techniques would require the
installation of settling ponds.
Reason for Selection
At least two plants in this subcategory are presently using
this technology.
Total cost of Application
Based upon the information contained in Section VIII of this
report, the subcategory as a whole would have to invest up
to an estimated maximum of $50,000 to achieve limitations
prescribed herein.
It is concluded that the benefits of the reduction of the
discharge pollutants by the selected control technology
outweigh the costs. More than 60 percent of this industry
subcategory is presently achieving this level of pollutant
discharge.
Age and Size of Equipment and Facilities
The date obtained on this subcategory represents two plants
with ages over 50 years.
The best control technology currently available is
practicable regardless of the size or age of plants since
the use of existing technologies is not dependent on these
factors.
IX-8
NOTICE: THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
Process Employed
The general process employed in this production subcategory
involves mining, crushing, screening and drying of crude
ore.
The processes used by the establishments in this subcategory
are very similar in nature and their raw wastes are also
quite similar. These similarities will enhance the
application of the recommended treatment technologies.
Engineering Aspects
From an engineering standpoint8 the implementation of the
recommended best control technologies currently available is
practicable in this production subcategory because the use
of settling ponds in this industry is commonplace.
Process Changes
The recommended control technologies would not require any
process changes. These control technologies are presently
being used by plants in this production subcategory.
Non-Water Quality Environmental Impact
There appear to be no major non-water quality environmental
impact or major energy requirements for the implementation
of the recommended treatment technologies.
3.3.2 Fuller's Earth - Montmorillonite Production
~ Subcategorv
Based upon the information contained in Sections III through
VIII, a determination has been made that the degree of
effluent reduction attainable through the application of the
best practicable control technology currently available is
no discharge of pollutants in process wastewater.
IX-9
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
Pit pumpout in this subcategory contains non-settleable
suspended solids. However, an insufficient data base exists
for the establishment of meaningful effluent limitation
guidelines.
Identification of BPCTCA
Best practicable control technology currently available for
the mining and processing of Fuller's Earth-Montmorillonite
is recycle of all process scrubber water.
To implement this technology at plants not already using the
recommended control techniques would require the
installation of pumps and associated recycle equipment.
Reason for Selection
Two of the three plants studied presently use the
recommended technology.
Total Cost of Applicaton
Based upon £he information contained in Section VTII of this
report, the subcategory as a whole would have to invest up
to an estimated maximum of $30,000 to achieve limitations
prescribed herein. There is also an anticipated increase in
the operating cost of less than one percent of the 1971
selling price of this product.
It is concluded that the benefits of the total elimination
of the discharge pollutants by the selected control
technology outweigh the costs. Approximately 25 percent of
this industry subcategory is presently achieving this level
of pollutant discharge.
IX-10
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
Age and Si^e gf Equipment and
The data obtained on this subcategory represents plants with
ages ranging from 3 to 18 years and production capacities
ranging from 40 to 600 metric tons per day (HH to 660 tons
per day) .
The best control technology currently available is
practicable regardless of the size or age of plants since
the use of existing technologies is not dependent on these
factors.
Process Employed
The general process employed in this production subcategory
involves mining, crushing, drying, milling and screening of
the crude ore.
The processes used by the establishments din this subcategory
are very similar in nature and their raw wastes are also
quite similar. These similarities will enhance the
application of the recommended treatment technologies.
Engineering Aspects
From an engineering standpoint, the implementation of the
recommended best control technologies currently available is
practicable in this production subcategory because the
technology of total recycle exists at two facilities. A
third facility plans to implement the recommended technology
in the near future.
Process Changes
The recommended control technologies would not require major
process changes. These control technologies are presently
being used by plants in this production subcategory.
IX-11
NOTICE: THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
Non-Water Quality Environmental Impact
There appear to be no major non-water quality environmental
impact or major energy requirements for the implementation
of the recommended treatment technologies.
3.4.1.1 Kaolin Mining and' Drv Processing for General
Purpose Use Production Subcategorv
Based upon the information contained in Sections III through
VIII, a determination has been made that the degree of
effluent reduction attainable through the application of the
best practicable control technology currently available is
no discharge of pollutants in process wastewater.
Mine water discharge for this subcategory is covered by the
general water guidelines earlier in this section.
Identification of BPCTCA
There is no control technology necessary for the dry mining
and processing of kaolin for general purpose use.
3.4.1.2 Kaolin Mining and Wet Processing for High Grade
Pyc-duct Subcategorv
Based upon the information contained in Sections III through
VIII, a determination has been made that the degree of
effluent reduction attainable through the application of the
best practicable control technology currently available is:
Effluent Limitation
kg/metric ton (Ibs/ton). of product
Effluent Characteristic Monthly^Ayerage Daily Maximum
TSS 0.1 (0.2) 0.5 (1.0)
Zinc 0.001 (0.002) 0.002 (0.004)
IX-12
NOTICE! THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
The above limitations were based on the performance
attainable by the two exemplary plants (3024 and 3025), see
Section V.
Mine water discharge for this subcategory is covered by the
general water guidelines earlier in this section,,
Identification of BPCTCA
Best practicable control technology currently available for
the wet mining and processing of kaolin for high grade
product is lime treatment to precipitate zinc followed by
pond settling to reduce suspended solids.
To implement this technology at plants not already using the
recommended control techniques would require the
installation of lime treatment facilities and settling
ponds.
Reason for Selection
The recommended technologies are presently being used by at
least 2 exemplary plants accounting for two-thirds of the
total production in this subcategory„
Total Cost of Application
Based upon the information contained in Section VTII of this
report, the subcategory as a whole would have to invest up
to an estimated maximum of SHOO^OOQ to achieve limitations
prescribed herein. There is also an anticipated increase in
the operating cost of less than one percent of the total
product value.
It is concluded that the benefits of the reduction of the
discharge pollutants by the selected control technology
outweigh the costs. At least 66 percent of this industry
subcategory is presently achieving this level of pollutant
discharge.
IX-13
NOTICE: THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
Age and Size of Equipment and Facilities
The data obtained on this subcategory represents plants with
ages ranging from 28 to 37 years and production capacities
ranging from 850 to 1700 metric tons per day (940 to
1850 tons per day).
Process Employed
The general process employed in this production subcategory
involves mining, blunging and/or pug milling, degritting,
classification, bleaching and/or chemical treatment,
filtration and drying or bulk slurrying.
The processes used by the establishments in this subcategory
are very similar in nature and their raw wastes are also
quite similar. These similarities will enhance the
application of the recommended treatment technologies.
Engineering Aspects
From an engineering standpoint, the implementation of the
recommended best control technologies currently available is
practicable in this production subcategory because 2 plants
accounting for two-thirds of the total production in this
subcategory are presently using the recommended
technologies.
Process Changes
The recommended control technologies would not require major
process changes.
Non-Water Quality Environmental Ifflfiact
The single major impact on non-water quality factors of the
environment is the protential effect of land disposal of the
solids removed from the process wastewaters. These solids
may sometimes contain harmful constituents which could be
detrimental to the soil system in the area of disposal or
IX-14
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
possibly contaminate ground waters due to rainwater runoff
and percolation through the soil. There appear to be no
major energy requirements for the implementation of the
recommended treatment technologies,
3.4.2 Ball Clay Production Subcategory
Based upon the information contained in Sections III through
VIII, a determination has been made that the degree of
effluent reduction attainable through the application of the
best practicable control technology currently available is:
Effluent Charactgristj.c Mpn^h^v^yegage Daily Maximum
TSS 0.17 {0«3i») 0»85 (1.7)
The above limitations were based on the performance
demonstrated at the exemplary plant of those employing wet
scrubbers for dust collection. Other plants have no wet
scrubbers and hence no process wastewater.
Mine water discharge for this subcategory is covered by the
general water guidelines earlier in this section.
Identification of BPCTCA
Best practicable control technology currently available for
the mining and processing of ball clay is either the use of
dry bag collection techniques for dust control or, where wet
scrubbers are employed, the use of settling ponds to reduce
suspended solids in the effluent.
To implement this technology at plants not already using the
recommended control techniques would require either the
installation of dry bag collectors or settling ponds.
IX-15
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPAo
DRAFT
-------
DRAFT
Reason for Selection
All of the plants contacted use either one or the other of
the recommended technologies.
>tal Cost of Application
Based upon the information contained in Section VIII of this
report, the subcategory as a whole would have to invest up
to an estimated maximum of $10,000 to achieve limitations
prescribed herein. There is also an anticipated increase in
the operating cost equivalent to less than one percent of
the 1971 selling price of the product.
It is concluded that the benefits of the reduction of the
discharge pollutants by the selected control technology
outweigh the costs. Approximately 75 percent of this
industry subcategory is presently achieving this level of
pollutant discharge.
Age and Size of Equipment and Facilities
The data obtained on this subcategory represents plants with
ages ranging from 15 to 56 years and production capacities
ranging from 23,000 to 113,000 metric tons per year (25,000
to 125,000 tons per year).
The best control technology currently available is
practicable regardless of the size or age of plants since
the use of existing technologies is not dependent on these
factors.
Process Employed
The general process employed in this production subcategory
involves mining, shredding, milling or blunging,
classification and drying of the crude ore. The discharge
of process water in this subcategory is associated only with
plants using wet scrubbing to control dust.
IX-16
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
The processes used by the establishments in this subcategory
are very similar in nature and their raw wastes are also
quite similar. These similarities will enhance the
application of the recommended treatment technologies.
Engineering Aspects
From an engineering standpoint, the implementation of the
recommended best control technologies currently available is
practicable in this production subcategory because the
majority of facilities are presently using the recommended
technologies.
Process Changes
The recommended control technologies would not require major
process changes.
Non-Water Quality Environmental Impact
There appear to be no major non-water quality environmental
impact or major energy requirements for the implementation
of the recommended treatment technologies.
3^5.1 Feldspar Wet Processing Production Subcategory
Based upon the information contained in sections III through
VIII, a determination has been made that the degree of
effluent reduction attainable though the application of the
best practicable control technology currently available is:
Effluent Limitation
kg/metric ton (Ibs/ton) of ore processed
Iffj,uent Characteristic Monthly Average Daily Maximum
TSS 0.60 (1.2) 3.0 (6.0)
Fluoride 0.15 (0.3) 0.3 (0.6)
IX-17
NOTICE: THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
The above limitations were based on the performance achieved
by three exemplary plants for TSS and one of these three for
fluoride reduction.
Mine water discharge for this subcategory is covered by the
general water guidelines earlier in this section.
Identification of BPCTCA
Best practicable control technology currently available for
the mining and processing of feldspar by the wet process is
to recycle part of the process wastewater for washing
purposes, then neutralize and settle the remaining
wastewater to reduce the suspended solids. In addition,
fluoride reduction can be accomplished by chemical treatment
of wastewater from the flotation circuit and/or partial
recycle of the fluoride containing portion of the flotation
circuit.
To implement this technology at plants not already using the
recommended control techniques would require installation of
piping and pumps for recycle of water and installation of
neutralization, chemical treatment and settling equipment or
ponds.
Reason for Selection
The selected technology of partial recycle and chemical
treatment is is practiced at the exemplary facility. All
facilities are currently employing settling and neutra-
lization.
Total Cost of Application
Based upon the information contained in Section VI±1 of this
report, the subcategory as a whole would have to invest up
to an estimated maximum of $320,000 to achieve limitations
prescribed herein. There is also an anticipated increase in
the operating costs for the plants in this subcategory
IX-18
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
equivalent to approximately two percent of the total product
value.
It is concluded that the benefits of the reduction of the
discharge pollutants by the selected control technology
outweigh the costs. Approximately 8 percent of this
industry subcategory is presently achieving this level of
pollutant discharge.
Age and Size of Equipment and Facilities
The data obtained on this subcategory represents plants with
ages ranging from 15 to 26 years and production capacities
ranging from 46,000 to 154,000 metric tons per year (50,000
to 170,000 tons per year).
The best control technology currently available is
practicable regardless of the size or age of plants since
the use of existing technologies is not dependent on these
factors.
Process Employed
The general process employed in this production subcategory
involves mining and beneficiation by the flotation process
of crude feldspar.
The processes used by the establishments in this subcategory
are very similar in nature and their raw wastes are also
quite similar. These similarities will enhance the
application of the recommended treatment technologies.
Engineering Aspects
From an engineering standpoint, the implementation of the
recommended best control technologies currently available is
practicable in this production subcategory because recycle
and chemical treatment of process wastewater is currently
practiced at one facility and equipment is available for
wastewater settling and neutralization.
IX-19
NOTICE: THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
Process Changes
The recommended control technologies would not require major
process changes. These control technologies are presently
being used by plants in this production subcategory.
Non-Water Quality Environmental Impact
The single major impact on non-water quality factors of the
environment is the potential effect of land disposal of the
solids removed from the process wastewaters. These solids
may sometimes contain harmful constituents which could be
detrimental to the soil system in the area of disposal or
possibly contaminate ground waters due to rainwater runoff
and percolation through the soil. There appear to be no
major energy requirements for the implementation of the
recommended treatment technologies.
3 ..5.2 Feldspar Dry Processing Prpductign Subcategorv
Based upon the information contained in Sections III through
VIII* a determination has been made that the degree of
effluent reduction attainable through the application of the
best practicable control technology currently available is
no discharge of pollutants in process wastewater.
Mine water discharge for this subcategory is covered by the
general water guidelines earlier in this section.
Identification of BPCTCA
Best practicable control technology currently available for
the processing of feldspar by the dry process is natural
evaporation of dust control water used in the process. This
is the only water used in the process.
IX-20
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EEA.
DRAFT
-------
DRAFT
3,6 Kyanj,te Production Subcateaorv
Based upon the information contained in Sections III through
VIII, a determination has been made that the degree of
effluent reduction attainable through the application of the
best practicable control technology currently available is
no discharge of pollutants in process wastewater. There is
no mine water discharge occurring in this subcategory.
Identification of BPCTCA
Best practicable control technology currently available for
the mining and processing of kyanite by the standard process
is recycle of process water from settling ponds. To
implement this technology at plants not already using the
recommended control techniques would require installation of
suitable impoundments and recycle where required.
Reason for Selection
One of the three plants in this production subcategory is
currently employing the recommended technologies.
Total Cost of Application
Based upon the information contained in Section VIII of this
report, the subcategory as a whole would have to invest up
to an estimated maximum of $100,000 to achieve limitations
prescribed herein.. The anticipated increase in the
operating cost is approximately one percent of the 1971
selling price of this product.
It is concluded that the benefits of the total elimination
of the discharge pollutants by the selected control
technology outweigh the costs. Approximately 40 percent of
this industry subcategory is presently achieving this level
of pollutant discharge.
IX-21
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
Age and Size of Equipment and Facilities
The data obtained on this subcategory represents plants with
ages ranging from 10 to 30 years and production capacities
ranging from 18 to 90 metric tons per day (20 to 100 tons
per day).
The best control technology currently available is
practicable regardless of the size or age of plants since
the use of existing technologies is not dependent on these
factors.
Process Employed
The general process employed in this production subcategory
involves mining, classification, flotation and magnetic
separation of the crude ore.
The processes used by the establishments in this subcategory
are very similar in nature and their raw wastes are also
quite similar. These similarities will enhance the
application of the recommended treatment technologies.
Engineering Aspects
From an engineering standpoint, the implementation of the
recommended best control technologies currently available is
practicable in this production subcategory because these
technologies are in common usage.
Process changes
The recommended control technologies would not require major
process changes.
IX-22
NOTICE: THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
Non-Water Quality Environmental Impact
The single major impact on non-water quality factors of the
environment is the potential effect of land disposal of the
solids removed from the process wastewaters. There appear
to be no major energy requirements for the implementation of
the recommended treatment technologies.
3^.7 Naturally Occurring Magnesite Production Subcategory
Based upon the information contained in Sections III through
VIII, a determination has been made that the degree of
effluent reduction attainable through the application of the
best practicable control technology currently available is
no discharge of pollutants in process wastewater.
There is presently no mine water pumpout in this
subcategory.
Identification o£ BPCTCA
Best practicable control technology currently available for
the manufacture of magnesia (MgO) from naturally occurring
magnesite is either impoundment or recycle of process
wastewater.
Reason for Selection
There is one plant in the U.S. and this plant currently uses
the recommended technology.
Total Cost of Application
Based upon the information contained in Section VIII of this
report, the subcategory as a whole would have to invest no
money to achieve limitations prescribed herein. One hundred
percent of this industry subcategory is presently achieving
this level of pollutant discharge.
IX-23
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
Age and size of Equipment, and Facilities
Age and size in thare subcategory is irrelevant because
there is only one plant.
Process Employed
The general process employed in this production subcategory
involves mining, crushing, firing and beneficiation of
naturally occurring magnesite ore.
Engineering Aspects
From an engineering standpoint, the implementation of the
recommended best control technologies currently available is
practicable in this production subcategory because they are
presently employed in the only facility using this process.
Process Changes
The recommended control technologies would not require any
process changes.
Non-Water Quality Environmental Impact
The single major impact on non-water quality factors of the
environment is the potential effect of land disposal of the
solids removed from the process wastewaters. There appear
to be no major energy requirements for the implementation of
the recommended treatment technologies.
Shale Production Subcategory
Based upon the information contained in Sections III through
VIII, a determination has been made that the degree of
effluent reduction attainable through the application of the
best practicable control technology currently available is
no discharge of pollutants in process wastewater.
IX-24
NOTICE: THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
Mine water discharge for this subcategory is covered by the
general water guidelines earlier in this section.
Identification of BPCTCA
There is no control technology needed for the mining and
processing of shale.
3.8A2 Aplite Production Subcateggry
Based upon the information contained in Sections III through
VIIIr a determination has been made that the degree of
effluent reduction attainable through the application of the
best practicable control technology currently available is
no discharge of pollutants in process wastewater.
Identification of BPCTCA
Best practicable control technology currently available for
the mining and processing of aplite is ponding of process
wastewater to settle solids and recycle of water. To
implement this technology at plants not already using the
recommended control techniques would require installation of
water recycle equipment.
Reason for Selection
The one plant with an almost 100 percent recycle system can
be easily made 100 percent recycle by dredging out the
ponds, switching ponds or elevating the dikes rather than
periodically discharging the rising level of water.
Total Cost of Application
Based upon the information contained in Section VIII of this
report, the subcategory as a whole would have to invest up
to an estimated maximum of $9,000 to achieve limitations
prescribed herein. There is also an anticipated increase in
the operating cost equivalent to less than one percent of
the 1971 selling price of this product.
IX-2 5
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
It is concluded that the benefits of the total elimination
of the discharge pollutants by the selected control
technology outweigh the costs. Approximately 70 percent of
this industry subcategory is presently achieving this level
of pollutant discharge considering that one plant presently
discharges only once every two to three years.
Age and Size of Equipment and Facilities
The data obtained on this subcategory represents plants with
ages ranging from 17 to 41 years and production capacities
ranging from 150 to 400 metric tons per day (165 to 410 tons
per day).
The best control technology currently available is
practicable regardless of the size or age of plants since
the use of existing technologies is not dependent on these
factors.
Process Employed
The general process employed in this production subcategory
involves mining, crushing, drying, classifying and
separating the crude ore. The processes used by the
establishments in this subcategory are similar in nature and
their raw wastes are also similar. These similarities will
enhance the application of the recommended treatment
technologies.
Engineering Aspects
From an engineering standpoint, the implementation of the
recommended best control technologies currently available is
practicable in this production subcategory because the
recommended technologies are presently being employed at one
of the two U.S. facilities and can be installed at the other
using state-of-the-art and commercially available equipment.
IX-2 6
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
Process Changes
The recommended control technologies would not require major
process changes.
Non-Water Quality Environmental Impact
The single major impact on non-water quality factors of the
environment is the potential effect of land disposal of the
solids removed from the process wastewaters. There appear
to be no major energy requirements for the implementation of
the recommended treatment technologies.
3.9.1 Talc Minerals Group. Dry Process Production
Subcateaory
Based upon the information contained in Sections III through
VIII, a determination has been made that the degree of
effluent reduction attainable through the application of the
best practicable control technology currently available is
no discharge of pollutants in process wastewater.
Mine water discharge in this subcategory is covered by the
general water guidelines earlier in this section.
identification of BPCTCA
There is no control technology needed for the mining and
processing of talc minerals by the dry process, because no
water is used in the process.
3.9.2 Talc Minerals Group, Ore Mining and Washing
Production Subcategory
Based upon the information contained in Sections III through
VIII, a determination has been made that the degree of
effluent reduction attainable through the application of the
best practicable control technology currently available is
no discharge of pollutants in process wastewater.
IX-27
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
Mine water discharge for this subcategory is Covered by the
general water guidelines earlier in this section.
Identification of BPCTCA
Best practicable control technology currently available for
the mining of talc minerals by the ore mining and washing
processes is total impoundment or recycle of process
wastewater.
Reason for Selection
All plants in this production subcategory currently employ
the recommended control technology.
Total Cost of Application
Based upon the information contained in Section VIII of this
report, the subcategory as a whole would not have to invest
any money to achieve limitations prescribed herein. One
hundred percent of this industry subcategory is presently
achieving this level of pollutant discharge.
Age and Size of Equipment and Facilities
The data obtained on this subcategory represents only two
plants. Age and size were not disclosed.
The best control technology currently available is
practicable regardless of the size or age of plants since
the use of existing technologies is not dependent on these
factors.
Process Employed
The general process employed in this production subcategory
involves mining, crushing, washing, screening and milling of
the ore.
IX-28
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
The processes used by the establishments in this subcategory
are very similar in nature and their raw wastes are also
quite similar. These similarities will enhance the
application of the recommended treatment technologies.
Engineering Aspects
From an engineering standpoint, the implementation of the
recommended best control technologies currently available is
practicable in this production subcategory because the
recommended technologies are currently employed by all
facilities.
Process Changes
The recommended control technologies would not require any
changes in the manufacturing process. These control
technologies are presently being used by all plants in this
production subcategory.
Non-Water Quality Environmental Impact
There are no non-water quality environmental impacts or
energy requirements for the implementation of the
recommended treatment technologies.
3.9.3 Talc Minerals Group. Ore Mining. Heavy Media and
Flotation Production Subcategorv
Based upon the information contained in Sections III through
VIII, a determination has been made that the degree of
effluent reduction attainable through the application of the
best practicable control technology currently available is:
IX-29
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
Effluent Limitation
Kg/metric ton (Ibs/ton) of product
Effluent Characteristic Monthly Average Daily
TSS 0.5 (1.0) 2.5 (5.0)
The above limitations were based on the performance
achievable by the two exemplary plants and a third plant
having a special situation.
Mine water discharge for this subcategory is covered by the
general water guidelines earlier in this section.
Identification of BPCTCA
Best practicable control technology currently available for
the processing of talc minerals by heavy media process is pH
adjustment of the flotation tailings, gravity settling and
clarification. TO implement this technology at plants not
already using the recommended control techniques would
require the installation of pH monitoring and adjustment
equipment and the installation of settling and/or
clarification ponds.
Reason for Selection
Plants representing eighty-three percent, of the total
production in this subcategory are presently using the
recommended technologies .
Total Cost of Application
Based upon the information contained in Section VTII of this
report, the subcategory as a whole would have to invest up
to an estimated maximum of $50,000 to achieve limitations
prescribed herein. The anticipated increase in the
operating cost is negligible.
IX-30
NOTICE: THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
It is concluded that the benefits of the reduction of the
discharge pollutants by the selected control technology
outweigh the costs. Approximately eighty-three percent of
this industry subcategory is presently achieving this level
of pollutant discharge.
Aae and Size of Equipment and Facilities
The data obtained on this subcategory represents plants with
ages ranging from 10 to 38 years and production capacities
ranging from 30 to 130 metric tons per day (33 to 1UO tons
per day) .
The best control technology currently available is
practicable regardless of the size or age of plants since
the use of existing technologies is not dependent on these
factors.
Process Employed
The general process employed in this production subcategory
involves mining, crushing, flotation or heavy media
separation, thickening, filtering and drying of the crude
ore.
The processes used by the establishments in this subcategory
are very similar in nature and their raw wastes are also
quite similar. These similarities will enhance the
application of the recommended treatment technologies.
Engineering Aspects
From an engineering standpoint, the implementation of the
recommended best control technologies currently available is
practicable in this production subcategory because these
technologies are in common usage in this subcategory.
IX-31
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
Process Changes
The recommended control technologies would not require major
process changes.
Non-Water Quality Environmental Impact
The single major impact on non-water quality factors of the
environment is the potential effect of land disposal of the
solids removed from the process wastewaters. There appear
to be no major energy requirements for the implementation of
the recommended treatment technologies.
3.10.1 Natural Abrasives, Garnet Production Subcategorv
Based upon the information contained in Sections III through
VIII, a determination has been made that the degree of
effluent attainable through the application of the best
practicable control technology currently available is:
Effluent Limitation
kg/metric ton (Ibs/ton) of product
Effluent Characteristic Monthly Average Daily Maximum
TSS 0.4 (0.8) 2.0 (4.0)
The above limitations were based on an estimated average
process wastewater discharge of 12,500 liters per metric ton
(3,000 gallons per ton) of product and an estimated TSS
level of 30 mg/liter.
In the two plants studied, mine water is used as process
water.
Identification of BPCTCA
Best practicable control technology currently available for
the mining and processing of garnet is pH adjustment, where
necessary, and settling of suspended solids.
IX-3 2
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
To implement this technology at plants not already using the
recommended control techniques would require the
installation of pH adjustment equipment, where necessary,
and construction of settling ponds.
Reason for Selection
The two facilities accounting for over 80 percent of the
U.S. production are presently using the recommended
technologies.
Total Cost of Application
Based upon the information contained in Section VIII of this
report, the subcategory as a whole would have to invest up
to an estimated maximum of $100,000 to achieve limitations
prescribed herein. There is also an anticipated increase in
the annual operating cost of approximately $30,000.
It is concluded that the benefits of the reduction of the
discharge pollutants by the selected control technology
outweigh the costs. Approximately 80 percent of this
industry subcategory is presently achieving this level of
pollutant discharge.
Age and Size of Equipment and Facilities
The data obtained on this subcategory represents plants with
ages ranging from H3 to 50 years and production capacities
for the two plants studied vary by a factor of 2.
The best control technology currently available is
practicable regardless of the size or age of plants since
the use of existing technologies is not dependent on these
factors.
The best control technology currently available is
practicable regardless of the size or age of plants since
the use of existing technologies is not dependent on these
factors.
IX-3 3
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
Process Employed
The general processes employed in this production
subcategory involve mining and beneficiation of the crude
ore.
The processes used by the establishments in this subcategory
are sufficiently similar to enhance the application of the
recommended treatment technologies.
Engineering Aspects
From an engineering standpoint, the implementation of the
recommended best control technologies currently available is
practicable in this production subcategory because the
technologies of pH adjustment and suspended solids settling
are widely used in this industry.
Process Changes
The recommended control technologies would not require major
process changes. These control technologies are presently
being used by plants in this production subcategory.
Non-Water Quality Environmenta1 Impact
There appear to be no major non-water quality environmental
impact or major energy requirements for the implementation
of the recommended treatment technologies.
3.10.2 Natural Abrasives. Tripoli Production Subcategory
Based upon the information contained in Sections III through
VIII, a determination has been made that the degree of
effluent reduction attainable through the application of the
best practicable control technology currently available is
no discharge of pollutants in process wastewater.
Mine water discharge for this subcategory is covered by the
general water guidelines earlier in this section.
IX-3 4
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
Identification of BPCTCA
There is no control technology needed for the mining and
processing of tripoli.
3 ..11 Diatomite Mining Production Subcateaorv
Based upon the information contained in Sections III through
VIII, a determination has been made that the degree of
effluent reduction attainable through the application of the
best practicable control technology currently available is
no discharge of pollutants in process wastewater.
There is no mine water discharge for this subcategory.
Identification of BPCTCA
Best practicable control technology currently available for
the mining and processing of diatomite by the standard
process is use of evaporation ponds and/or recycle of
process water.
To implement this technology at plants not already using the
recommended control techniques would require the
construction of impoundments and/or recycling equipment.
Reason for Selection
Three plants of this subcategory representing approximately
half the U.S. production utilize this recommended
technology.
Total Cost of Application
Based upon the information contained in Section VIII of this
report, the subcategory as a whole would not have to invest
any money to achieve limitations prescribed herein. We
estimate 100 percent of this industry subcaterogy is
presently achieving this level of pollutant discharge.
IX-35
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
and size of Equipment and Facilities
The data obtained on this subcategory represents plants with
ages ranging from 27 to 80 years and production capacities
ranging from 27 to UOO metric tons per day (30 to 450 tons
per day).
The best control technology currently available is
practicable regardless of the size or age of plants since
the use of existing technologies is not dependent on these
factors.
Process Employed
The general process employed in this production subcategory
involves the mining, crushing, drying, milling and
classifying of crude diatomite.
The processes used by the establishments in this subcategory
are very similar in nature and their raw wastes are also
quite similar. These similarities will enhance the
application of the recommended treatment technologies.
Engineering Aspects
From an engineering standpoint, the implementation of the
recommended best control technologies currently available is
practicable in this production subcategory because, the
establishments mining crude diatomite are located in
geographic areas where land is available for impoundments.
Process water recycle is practiced in several plants in this
subcategory and is technically feasible in the remainder, if
necessary.
Process Changes
The recommended control technologies would not require major
process changes. These control technologies are presently
being used by plants in this production subcategory.
IX-36
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
Non-Water Quality Environmental Impact
The single major impact on non-water quality factors of the
environment is the potential effect of land disposal of the
solids removed from the process wastewaters. These solids
may sometimes contain harmful constituents which could be
detrimental to the soil system in the area of disposal or
possibly contaminate ground waters due to rainwater runoff
and percolation through the soil. There appear to be no
major energy requirements for the implementation of the
recommended treatment technologies.
3.12 Graphite Production Subcategory
Based upon the information contained in Sections III through
VIII, a determination has been made that the degree of
effluent reduction attainable through the application of the
best practicable control technology currently available is:
Effluent Limitation
kg/metric ton (Ibs/ton) of product
Effluent Characteristic Monthly Average Daily Maximum
TSS 1.6 (3.2) 8.0 (16.0)
Manganese 0.03 (0.06) 0.25 (0.50)
Iron 0.16 (0.32) 1.3 (2.6)
BODS 1.6 (3.2) 6.3 (12.6)
COD 2.3 (4.6) 7.5 (15)
The above average limitations were based on the exemplary
performance achievable by the single plant in this
subcategory.
Mine water discharge for this subcategory is included in the
above limitations.
Identification of BPCTCA
IX-37
NOTICE: THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
Best practicable control technology currently available for
the mining and processing of graphite is neutralization and
pond settling.
Reason for Selection
There is only one plant in the U.S. and this plant currently
uses the recommended technology.
Total Cost of Application
Based upon the information contained in Section VIII of this
report, the subcategory as a whole would have to invest no
money to achieve limitations prescribed herein. One hundred
percent of this industry subcategory is presently achieving
this level of pollutant discharge.
Age and Size of Equipment and Facilities
Age and size in this subcategory are irrelevant because
there is only one plant.
Process Employed
The general process employed in this production subcategory
involves mining, crushing, sizing, flotation separation,
filtering and drying of graphite ore.
Engineering Aspects
From an engineering standpoint, the implementation of the
recommended best control technologies currently available is
practicable in this production subcategory because they are
presently employed in the only facility using this process.
Process Changes
The recommended control technologies would not require any
process changes.
IX-38
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
Eton-Water Quality Environmental Impact
The single major impact on non-water quality factors of the
environment is the potential effect of land disposal of the
solids removed from the process wastewaters. There appear
to be no major energy requirements for the implementation of
the recommended treatment technologies.
3.13.1 Jade Production Subcatecrorv
Based upon the information contained in Sections III through
VIII, a determination has been made that the degree of
effluent reduction attainable through the application of the
best practicable control technology currently available is
no discharge of pollutants in process wastewater.
There is no mine water discharge in this subcategory.
Identification of BPCTCA
Best practicable control technology currently available for
the mining and processing of jade is settling and
evaporation of the small volume of wastewater. To implement
this technology at plants not already using the recommended
control techniques would require installation of a settling
tank and appropriate evaporation facilities.
Reason for Selection
The only major U.S. jade production facility presently
employs these techniques.
Total cost of Application
The remainder of this industry is so small and highly
fragmented as to be economically insignificant. Therefore,
there is no economic impact. Approximately 55 percent of
this industry subcategory is presently achieving this level
of pollutant discharge.
IX-3 9
NOTICE: THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
and size of Equipment and Facilities
Age and size of equipment are irrelevant in this subcategory
because there is only one plant.
Process Employed
The general process employed in this production subcategory
involves mining, sawing, sanding, and polishing operations.
Engineering Aspects
There are no engineering aspects associated with the
implementation of this technology.
Process Changes
The recommended control technologies would not require any
process changes.
Non-Water Quality Environmental Impact
There appear to be no major non-water quality environmental
impact or major energy requirements for the implementation
of the recommended treatment technologies.
3.13.2 Novaculite Production Subcategorv
Based upon the information contained in Sections III through
VIII, a determination has been made that the degree of
effluent reduction attainable through the application of the
best practicable control technology currently available is
no discharge of pollutants in process wastewater.
There is no mine water discharge for this subcategory.
IX-40
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
Identification of BPCTCA
Best practicable control technology currently available for
the mining and processing of novaculite by the quarrying
process is total recycle of process scrubber water.
Reason for Selection
There is only one facility in the U.S. It is presently
using this technology.
Total Cost of Application
Based upon the information contained in Section VIII of this
report, the subcategory as a whole would have to invest no
money to achieve limitations prescribed herein. One
hundred percent of this industry subcategory is presently
achieving this level of pollutant discharge.
Age and Size of Equipment and Facilities
Age and size in this subcategory are irrelevant because
there is only one plant.
Process Employed
The general process employed in this production subcategory
involves surface mining of novaculite, followed by grinding
and packaging.
Engineering Aspects
From an engineering standpoint, the implementation of the
recommended best control technologies currently available is
practicable in this production subcategory because the sole
plant in this subcategory already practices the recommended
technology.
IX-41
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
Process Changes
The recommended control technologies would not require any
process changes.
Non-Water Quality Environmental Impact
There appear to be no major non-water quality environmental
impact or major energy requirements for the implementation
of the recommended treatment technologies.
IX-42
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS 'BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
SECTION X
EFFLUENT REDUCTION ATTAINABLE THROUGH THE
APPLICATION OF THE BEST AVAILABLE
TECHNOLOGY ECONOMICALLY ACHIEVABLE
1.0 INTRODUCTION
The effluent limitations which must be achieved by July 1,
1983 are based on the degree of effluent reduction attain-
able through the application of the best available
technology economically achievable. For the mining clay,
ceramic, refractory and miscellaneous minerals industry,
this level of technology was based on the very best control
and treatment technology employed by a specific point source
within each of the industry's subcategories, or where it is
readily transferable from one industry process to another.
In Section IV, this segment of the mineral mining and
processing industry was divided into thirteen major
categories based on similarities of process. Several of
those major categories have been further subcategorized and,
for reasons explained in Section IV, each subcategory will
be treated separately for the recommendation of effluent
limitations guidelines and standards of performance.
The following factors were taken into consideration in
determining the best available technology economically
achievable:
(1) the age of equipment and facilities involved;
(2) the process employed;
(3) the engineering aspects of the application of various
types of control techniques;
(4) process changes;
(5) cost of achieving the effluent reduction resulting from
application of BATEA; and
X-1
NOTICE: THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
(6) non-water quality environmental impact (including energy
requirements).
In contrast to the best practicable technology currently
available, best available technology economically achievable
assesses the availability in all cases of in-process
controls as well as control or additional treatment
techniques employed at the end of a production process.
In-process control options available which were considered
in establishing these control and treatment technologies
include the following:
(1) alternative water uses
(2) water conservation
(3) waste stream segregation
(4) water reuse
(5) cascading water uses
(6) by-product recovery
(7) reuse of wastewater constituents
(8) waste treatment
(9) good housekeeping
(10) preventive maintenance
(11) quality control (raw material, product, effluent)
(12) monitoring and alarm systems.
Those plant processes and control technologies which at the
pilot plant, semi-works, or other level, have demonstrated
both technological performances and economic viability at a
level sufficient to reasonably justify investing in such
facilities were also considered in assessing the best avail-
able technology economically achievable. Although economic
factors are considered in this development, the costs for
this level of control are intended to be for the top-of-the-
line of current technology subject to limitations imposed by
economic and engineering feasibility. However, this
technology may necessitate some industrially sponsored
development work prior to its application.
X-2
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
Based upon the information contained in Sections III through
IX of this report, the following determinations were made on
the degree of effluent reduction attainable with the appli-
cation of the best available control technology economically
achievable in the various subcategories of the inorganic
chemical industry.
2.0 GENERAL WATER GUIDELINES
2.1 Process Water
Process water is defined as any water contacting the ore,
processing chemicals, intermediate products, by-products or
products of a process including contact cooling water. All
process water effluents are limited to the pH range of 6.0
to 9.0 unless otherwise specified.
2.2 CooJ.inq Water
In the mineral mining and processing industry, cooling and
process waters are sometimes mixed prior to treatment and
discharge. In other situations, cooling water is discharged
separately. Based on the application of best available
technology economically achievable, the recommendations for
the discharge of such cooling water are as follows.
An allowed discharge of all non-contact cooling waters
provided that the following conditions are met:
X-3
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
a) Thermal pollution be in accordance with standards to be
set by EPA policies. Excessive thermal rise in once
through non-contact cooling water in the mineral mining
and processing industry has not been a significant
problem.
b) All non-contact cooling waters should be monitored to
detect leaks of pollutants from the process. Provisions
should be made for treatment to the standards
established for the process wastewater discharges prior
to release in the event of such leaks.
c) No untreated process waters be added to the cooling
waters prior to discharge.
The above non-contact cooling water recommendations should
be considered as interim, since this type of water plus
blowdowns for water treatment, boilers and cooling towers
will be regulated by EPA at a later date as a separate
category.
2.3 Storm Water Runoff
Storm water runoff may present pollution control problems
for certain subcategories. This is true where large
stockpiles of process or waste materials are stored
uncovered or in processes generating large amounts of dust.
In these cases, a process water impoundment which is
designed, constructed and operated so as to contain the
precipitation from the 25 year, 24 hour rainfall event as
established by the U.S. National Weather Service for the
area in which such impoundment is located may discharge that
volume of process wastewater which is equivalent to the
volume of precipitation that falls within the impoundment in
excess of that attributable to the 25 year, 24 hour rainfall
event, when such event occurs.
X-U
NOTICE: THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
2.4 Mine Water Pumpout
The quantity of the discharges resulting from pumpout of
water from mines, pits and quarries in these industries is
characteristically intermittent or has a high variability of
flow and is unrelated to the production rate of the mine.
such mine water is generally the result of direct rainfall
into the mine, leakage from aquifers, or influx of surface
runoff. The latter should not be allowed since the
construction of simple dikes and ditches is usually
sufficient to prevent the flow of surface water into a mine
or quarry. The other, largely uncontrollable mine water
must be disposed of by pumping to allow proper operation of
the mine. Where this pumped water is not otherwise useful
for process purposes or disposable by total evaporation or
percolation back to the originating aquifer, it must be
discharged.
Many of the individual mines studied in these industries
have no mine pumpout water at all, or have no point source
discharge of mine drainage. For the others it was found
that the ubiquitous suspended solids and pH pollutant
problems could be readily brought under control by simple pH
adjustment and settling in ponds prior to discharge. The
exceptions to this are in the mines where materials readily
forming stable colloidal suspensions are mined, as in mont-
morillonite mining. The other industry subcategory where
this situation could be found is in bentonite mining, but no
such mines with water needing pumpout were found. The
suspended solids picked up in montmorillonite mine waters
are generally not amenable to reduction to low
concentrations by simple settling.
For all mine pumpout discharges from the clay, ceramic,
refractory, and miscellaneous materials segment of the
mineral mining and processing industry except for the
montmorillonite and bentonite mining subcategories, any such
discharges not explicitly covered by the process water
discharge guideline limitation are to be limited to, based
on the information in Sections V through VIII:
X-5
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
Limitation
Pollutant Parameter Monthly Average Daily Maximum
pH 6-9 6-9
TSS 20 mg/liter 100 ing/liter
The above limitations are based on whatever flow discharge
volume exists for the period under consideration. The
discharge of pollutant parameters other than the above
should not exceed in concentration those values established
for water quality standards.
3.0 PROCESS WASTEWATER GUIDELINES AND LIMITATIONS FOR THE
CLAY. CERAMIC. REFRACTORY. AND MISCELLANEOUS
MINERALS SEGMENT OF THE MINERAL MINING INDUSTRY
POINT SOURCE SUBCATEGORY
The following industry subcategories were required to
achieve no discharge of process wastewater pollutants to
navigable waters based on best practicable control
technology currently available:
bentonite, fire clay, fuller1s earth (montmorillonite) ,
kaolin (general purpose grade), feldspar (dry process),
kyanite, magnesite, shale, aplite, talc group (dry
process), talc group (ore mining and washing process),
tripoli, diatomite, jade and novaculite.
The same limitations guidelines are recommended based on
best available technology economically achievable.
3.1 Fuller's Earth - Attapulqite Production Subcateoory
Based upon the information contained in Sections III through
IX, a determination has been made that the degree of
effluent reduction attainable through the application of the
best available technology economically achievable is no
discharge of pollutants in process wastewater.
X-6
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
Mine water discharge in this subcategory is covered by
general water guidelines earlier in this section.
Identification of BATEA
Best available technology economically achievable for the
mining and processing of Fuller^ Earth-Attapulgite is the
use of settling ponds, flocculants where required, and
recycle of all process wastewater.
To implement this technology at plants not already using the
recommended control techniques would require the
installation of settling ponds, facilities to add
flocculants where necessary, and recycle piping and
equipment.
Reason for Selection
The recommended level of discharge can be readily attained
by using the recommended technology.
Total Cost of Application
Based upon the information contained in Section VIII of this
report, the subcategory as a whole would have to invest up
to an estimated maximum of $60,000 to achieve limitations
prescribed herein. There is also an anticipated increase in
the operating cost of less than one percent of the selling
price of this product.
It is concluded that the benefits of the total elimination
of the discharge pollutants by the selected control
technology outweigh the costs. None of this industry
subcategory is presently achieving this level of pollutant
discharge.
X-7
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
Agg and Sj.ze of Equipment and Facilities
The data obtained on this subcategory represent two plants
with ages over 50 years.
The best available technology economically achievable is
practicable regardless of the size of age of plants since
the use of existing technologies is not dependent on these
factors.
Process Employed
The general process employed in this production subcategory
involves mining, crushing, screening and drying of crude
ore.
The processes used by the establishments in this subcategory
are very similar in nature and their raw wastes are also
quite similar. These similarities will enhance the
application of the recommended treatment technologies.
Engineering Aspects
From an engineering standpoint, the implementation of the
recommended best available technologies economically
achievable is practicable in this production subcategory
because the use of settling ponds recycle and flocculants in
this industry is commonplace.
Process Changes
The recommended control technologies would require process
changes. These control technologies are presently being
used by other plants in this industry segment.
Non-Water Quality Environmental Impact
There appear to be no major non-water quality environmental
impacts or major energy requirements for the implementation
of the recommended treatment technologies.
X-8
NOTICE: THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
312 Wet Kaplan Mining and Processing fog High Grade Product
Production Subcategory
Based upon the information contained in Sections III through
IX, a determination has been made that the degree of
effluent reduction attainable through the application of the
best available technology economically achievable is:
Effluent Limitation
Effluent kg/metric ton libs/ton of product
Characteristic Monthly Average Daily Maximum
TSS 0.06 (0.12) 0.30 (0.60)
The above limitations were based on exemplary plant
performance.
Mine water discharge for this subcategory is covered by the
general water guidelines earlier in this section.
Identification of BATEA
Best available technology economically achievable for the
wet mining and processing of kaolin for high grade product
is the elimination of zinc from the process raw waste by
substituting sodium hydrosulfite as the bleaching agent and
pond settling of suspended solids.
To implement this technology at plants not already using the
recommended control techniques would require substitution of
bleaching agent.
Reason for Selection
The two plants studied are considering the future bleaching
agent substitution to eliminate zinc from their effluents.
Recycle of process water in this subcategory is not possible
because the build-up of dissolved solids interferes wxth the
process.
X-9
NOTICE- THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
Cost of Application
Based upon the information contained in Section VIII of this
report, the subcategory as a whole would not have to invest
any money to achieve limitations prescribed herein. There
is no anticipated increase in the operating cost.
It is concluded that the benefits of the reduction of the
discharge pollutants by the selected control technology
outweigh the costs. None of this industry subcategory is
presently achieving this level of pollutant discharge.
Age and size of Egu4pment and Facilities
The data obtained on this subcategory represents plants with
ages ranging from 28 to 37 years and production capacities
ranging from 850 to 1700 metric tons per day (940 to
1850 tons per day).
The best control technology currently available is
practicable regardless of the size or age of plants since
the use of existing technologies is not dependent on these
factors.
Process Employed
The general process employed in this production subcategory
involves mining, blunging and/or pug milling, degritting,
classification, bleaching and/or chemical treatment,
filtration and drying or bulk slurrying.
The processes used by the establishments in this subcategory
are very similar in nature and their raw wastes are also
quite similar. These similarities will enhance the
application of the recommended treatment technologies.
X-10
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
Engineering Aspects
From an engineering standpoint, the implementation of the
recommended best available technologies economically
achievable is practicable in this production subcategory
because this relatively simple in-process change would
eliminate zinc from the process effluent.
Process Changes
The recommended control technologies would not require major
process changes.
Non-Water Quality Environmental Impact
There appear to be no major non-water quality environmental
impacts or major energy requirements for the implementation
of the recommended treatment technologies.
3.3 Ball Clay Production Subcateaorv
Based upon the information contained in Sections III through
IX, a determination has been made that the degree of
effluent reduction attainable through the application of the
best available technology economically achievable is no
discharge of pollutants in process wastewater.
Mine water discharge for this subcategory is covered by the
general water guidelines earlier in this section.
Identification of BATEA
Best available technology economically achievable for the
mining and processing of ball clay is the use of dry bag
collectors where possible or recycle of wet scrubber where
wet scrubbers are used.
To implement this technology at plants not already using the
recommended control techniques would require the
installation of settling ponds or equipment and flocculation
X-11
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
plus piping and pumps for recycle of scrubber water where
used.
Reason for Selection
Settling of suspended solids and recycle of scrubber water
is currently practiced in other portions of this industry.
Total Cost of Application
Based upon the information contained in Section VIII of this
report, the subcategory as a whole would have to invest up
to an estimated maximum of $25,000 to achieve limitations
prescribed herein. There is also an anticipated increase in
the operating cost of less than one percent of the selling
price of this product.
It is concluded that the benefits of the total elimination
of the discharge pollutants by the selected control
technology outweigh the costs. Approximately 75 percent of
this industry subcategory is presently achieving this level
of pollutant discharge.
Age and Size of Equipment and Facilitj.es
The data obtained on this subcategory represents plants with
ages ranging from 15 to 56 years and production rates
ranging from 23,000 to 113,000 metric tons per year (25,000
to 125,000 tons per year).
The best available technology economically achievable is
practicable regardless of the size or age of plants since
the use of existing technologies is not dependent on these
factors.
Process Employed
The general process employed in this production subcategory
involves mining, shredding, milling or blunging,
classification and drying of the crude ore.
X-12
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
The processes used by the establishments in this subcategory
are very similar in nature and their raw wastes are also
quite similar. These similarities will enhance the
application of the recommended treatment technologies.
Engineering Aspects
From an engineering standpoint, the implementation of the
recommended best available technologies economically
achievable is practicable in this production subcategory
because the technology and equipment are currently employed
in other portions of the clay mining category.
Process Changes
The recommended control technologies would not require major
process changes. These control technologies are presently
being used by plants in this production subcategory.
Non-Water Quality Environmental Impact
There appear to be no major non-water quality environmental
impacts or major energy requirements for the implementation
of the recommended treatment technologies.
3.4 Feldspar (Wet Processing) Production Subcategorv
Based upon the information contained in Sections III through
IX, a determination has been made that the degree of
effluent reduction attainable through the application of the
best available technology economically achievable is:
Effluent Limitation
Effluent kg/metric ton fibs/ton) of ore processed
Characteristic Monthly Average Daily Maximum
TSS 0.6 (1.2) 3.0 (6.0)
Fluoride 0.1 (0.2) fj.2 (O.4)
X-13
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
The above limitations were based on an improvement in
exemplary plant performance by deliberate chemical treatment
to reduce fluorides.
Mine water discharge for this subcategory is covered by the
general water guidelines earlier in this section.
Identification of BATEA
Best available technology economically achievable for the
mining and processing of feldspar by the wet process is to
recycle part of the process wastewater for washing purposes,
neutralization to pH 9 with lime to reduce soluble fluoride
and settling to remove suspended solids.
To implement this technology at plants not already using the
recommended control techniques would require installation of
piping and pumps for recycle of water, lime feeding and
neutralization equipment and settling equipment or ponds.
Reason for Selection
The selected technology of partial recycle is currently
practiced at two facilities. Three plants are currently
using lime treatment to adjust pH and can readily adopt this
technology to reduce soluble fluoride. All plants are using
settling equipment or ponds.
Total Cost of Application
Based upon the information contained in Section VIII of this
report, the subcategory as a whole would have to invest up
to an estimated maximum of $400,000 to achieve limitations
prescribed herein. There is also an anticipated increase in
the operating cost for the plants in this subcategory
equivalent to approximately four percent of the total
product value.
X-14
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
It is concluded that the benefits of the reduction of the
discharge pollutants by the selected control technology
outweigh the costs. None of this industry subcategory is
presently achieving this level of pollutant discharge.
Age and Size of Equipment and Facilities
The data obtained on this subcategory represents plants with
ages ranging from 15 to 26 years and production rates
ranging from 46,000 to 154,000 metric tons per year (50,400
to 170,000 tons per year).
The best available technology economically achievable is
practicable regardless of the size or age of plants since
the use of existing technologies is not dependent on these
factors.
Process Employed
The general process employed in this production subcategory
involves the mining and beneficiation by the flotation
process of crude feldspar.
The processes used by the establishments in this subcategory
are very similar in nature and their raw wastes are also
quite similar. These similarities will enhance the
application of the recommended treatment technologies.
Engineering Aspects
From an engineering standpoint, the implementation of the
recommended best available technologies economically
achievable is practicable in this production subcategory
because a portion of these technologies are currently
practiced by plants in this subcategory and the remaining
portion is available technology practiced by plants in the
chemical industry and readily transferable. The equipment
and operating technology is available at the present time.
X-15
NOTICE: THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
Process
The recommended control technologies would require major
process changes. These control technologies are presently
being partially used by plants in this production
subcategory.
Non-Water Quality Environment a 1 Impact
The single major impact on non-water quality factors of the
environment is the potential effect of land disposal of the
solids removed from the process wastewaters. These solids
may sometimes contain harmful constituents which could be
detrimental to the soil system in the area of disposal or
possibly contaminate ground waters due to rainwater runoff
and percolation through the soil. There appear to be no
major energy requirements for the implementation of the
recommended treatment technologies.
3.5 Talc Minerals Group. Or,e Mining. Heavy Media and
Flotation Production Subcategorv
Based upon the information contained in Sections III through
IX, a determination has been made that the degree of
effluent reduction attainable through the application of the
best available technology economically achievable is:
Effluent Limitation
Effluent kg/metric ton (Ibs/tonl of product
Characteri stic Monthly Average Daj.lv Maximum
TSS 0.3 (0.6) 1.5 (3.0)
The above limitations were based on performance Of one
exemplary plant plus one plant having a special situation.
Mine water discharge for this subcategory is covered by the
general water guidelines earlier in this section.
X-16
NOTICE: THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
Identification of BATEA
Best available technology economically achievable for the
mining and processing of talc minerals by the ore mining,
heavy media and/or flotation process is the same as for
BPCTCA plus additional settling or in one case, conversion
from wet scrubbing to a dry collection method to control air
pollution.
To implement this technology at plants not already using the
recommended control techniques would require installation of
additional ponds or installation of dry dust collectors.
Reason for Selection
Two of the four plants in this subcategory are presently
achieving this level of effluent reduction using the
recommended treatment technologies.
Total Cost of Application
Based upon the information contained in Section VIII of this
report, the subcategory as a whole would have to invest up
to an estimated maximum of $100,000 to achieve limitations
prescribed herein. There is also an anticipated increase in
the operating cost equivalent to less than one percent of
the selling price of this product.
It is concluded that the benefits of the reduction of the
discharge pollutants by the selected control technology
outweigh the costs. Approximately 55 percent of this
industry subcategory is presently achieving this level of
pollutant discharge.
Age and size of Equipment and Facilities
The data obtained on this subcategory represent plants with
ages ranging from 10 to 38 years and production rates
ranging from 30 to 120 metric tons per day (33 to 130 tons
per day) .
X-17
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
The best available technology economically achievable is
practicable regardless of the size or age of plants since
the use of existing technologies is not dependent on these
factors.
Process Employed
The general process employed in this production subcategory
involves mining, crushing, flotation or heavy media
separation, thickening, filtering and drying of the crude
ore.
The processes used by the establishments in this subcategory
are very similar in nature and their raw wastes are also
quite similar. These similarities will enhance the
application of the recommended treatment technologies.
Engineering Aspects
From an engineering standpoint, the implementation of the
recommended best available technologies economically
achievable is practicable in this production subcategory
because these technologies are in common usage in this
subcategory.
Process Changes
The recommended control technologies would not require major
process changes.
Non-Water Quality Environmental Impact
The single major impact on non-water quality factors of the
environment is the potential effect of land disposal of the
solids removed from the process wastewaters. There appear
to be no major energy requirements for the implementation of
the recommended treatment technologies.
X-18
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
3^6 Garnet Production Subcategory
Based upon the information contained in Sections III through
IX, a determination has been made that the degree of
effluent reduction attainable through the application of the
best available technology economically achievable is:
Effluent Limitation
Effluent ka/metric ton i^bs/ton) of product
Cha^acteri stic Monthly Average Daily Maximum
TSS 0.25 (0.5) 1.25 (2.5)
The above limitations were based on an estimated average
process wastewater discharge of 12,500 liters per metric ton
(3,000 gallons per ton) of product and an estimated TSS
level of 20 mg/liter.
Mine water discharge for this subcategory is covered by the
general water guidelines earlier in this section.
Identification of BATEA
Best available technology economically achievable for the
mining and processing of garnet is pH adjustment to achieve
pH 6 to 9, settling of suspended solids, and sand bed
filtration where necessary.
To implement this technology at plants not already using the
recommended control techniques would require the
installation of pH neutralization equipment, settling ponds,
and sand bed filter equipment.
Reason for selection
Two facilities accounting for over 80 percent of the U.S.
production presently use a portion of the recommended
technologies and technology exists for further removal of
suspended solids.
X-19
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
Total Cost pf ftpplj.catjj.on
Based upon the information contained in Section VIII of this
report, the subcategory as a whole would have to invest up
to an estimated maximum of $150,000 to achieve limitations
prescribed herein. There is also an anticipated increase in
the annual operating cost of approximately $50,000.
It is concluded that the benefits of the reduction of the
discharge pollutants by the selected control technology
outweigh the costs. None of this industry subcategory is
presently achieving this level of pollutant discharge.
Age and Size of Equipment and Facilities
The data obtained on this subcategory represents plants with
ages ranging from 43 to 50 years and production capacities,
for the two plants studied, varied by a factor of two.
The best available technology economically achievable is
practicable regardless of the size or age of plants since
the use of existing technologies is not dependent on these
factors.
Process Employed
The general process employed in this production subcategory
involves the mining and beneficiation of the crude ore.
The processes used by the establishments in this subcategory
are sufficiently similar to enhance the application of the
recommended treatment technologies.
Engineering Aspects
From an engineering standpoint, the implementation of the
recommended best available technologies economically
achievable is practicable in this production subcategory
because the technologies of pH adjustment and reduction of
suspended solids are widely used in this industry.
X-20
NOTICE: THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
Procegs Changes
The recommended control technologies would not require major
process changes. These control technologies are presently
being used by plants in this production subcategory.
Non-Water Quality Environmental Impact
There appear to be no major non-water quality environmental
impacts or major energy requirements for the implementation
of the recommended treatment technologies.
3T7 Graphite Production Subcategorv
Based upon the information contained in Sections III through
IX, a determination has been made that the degree of
effluent reduction attainable through the application of the
best available technology economically achievable is the
same as that recommended for BPCTCA because no proven
technology option exists to reduce the pollutants further
without interfering with the process employed.
X-21
NOTICE: THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
DRAFT
-------
DRAFT
SECTION XI
NEW SOURCE PERFORMANCE STANDARDS
AND PRETREATMENT STANDARDS
INTRODUCTION
This level of technology is to be achieved by new sources.
The term "new source" is defined in the Act to mean "any
source, the construction of which is commenced after the
publication of proposed regulations prescribing a standard
of performance". This technology is evaluated by adding to
the consideration underlying the identification of best
available technology economically achievable, a
determination of what higher levels of pollution control are
available through the use of improved production processes
and/or treatment techniques. Thus, in addition to
considering the best in-plant and end-of-process control
technology, new source performance standards are how the
level of effluent may be reduced by changing the production
process itself. Alternative processes, operating methods or
other alternatives were considered. However, the end result
of the analysis identifies effluent standards which reflect
levels of control achievable through the use of improved
production processes (as well as control technology), rather
than prescribing a particular type of process or technology
which must be employed.
The following factors were considered with respect to
production processes which were analyzed in assessing the
best demonstrated control technology currently available for
new sources:
a) the type of process employed and process changes;
b) operating methods;
c) batch as opposed to continuous operations;
d) use of alternative raw materials and mixes of raw
materials;
e) use of dry rather than wet processes (including
substitution of recoverable solvents from water); and
f) recovery of pollutants as by-products.
XI-1
DRAFT
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
-------
DRAFT
In addition to the effluent limitations covering discharges
directly into waterways, the constituents of the effluent
discharge from a plant within the industrial category which
would interfere with, pass through, or otherwise be
incompatible with a well designed and operated publicly
owned activated sludge or trickling filter wastewater
treatment plant were identified. A determination was made
of whether the introduction of such pollutants into the
treatment plant should be completely prohibited.
2.0 GENERAL WATER GUIDELINES
The process water, cool ing/wa€4irwaSifrbfc^S8wn 'guidelines for
new sources are identical to those based on best available
technology economically achievable. In addition, a process
water impoundment should be designed, constructed and
operated so as to contain the precipitation from the
25-year, 24-hour rainfall event as established by the U.S.
National Weather Service for the area in which such
impoundment is located. It may discharge that volume of
process wastewater which is equivalent to the volume of
precipitation that falls within the impoundment in excess of
that attributable to the 25-year, 24-hour rainfall event,
when such event occurs.
3.0 EFFLUENT REDUCTION ATTAINABLE BY. THE APPLICATION OF THE
BEST AVAILABLE DEMONSTRATED CONTROL TECHNOLOGIES.
PROCESSES. OPERATING METHODS OR OTHER ALTERNATIVES
Based upon the information contained in Sections III through
X of this report, the following determinations were made on
the degree of effluent reduction attainable with the
application of new source standards for the various
subcategories of the clay, ceramic, refractory, and
miscellaneous minerals segment of the mineral mining and
processing industry.
The following industry subcategories were required to
achieve no discharge of process wastewater pollutants to
navigable waters based on best available technology
economically achievable:
bentonite, fire clay, fuller's earth (montmorillonite),
kaolin (general purpose grade), ball clay, feldspar (dry
process), kyanite, magnesite, shale, aplite, talc group
XI-2
DRAFT
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
-------
DRAFT
(dry process), talc group (ore mining and washing
process), tripoli, diatomite, jade and novaculite.
The same limitations guidelines are recommended as new
source performance standards.
The following industry subcategories are required to achieve
specific effluent limitations as given in the following
paragraphs.
3.1 Fuller's Earth (Attapulgite)
Same as BATEA
3.2 Wet Kaolin (High Grade Product)
Same as BATEA
3.3 Feldspar (Wet Process)
For new plants, based upon the information contained in
Sections III through X, a determination has been made that
the degree of effluent reduction attainable as a new source
performance standard for the mining and processing of
feldspar by the wet process is:
Effluent Limitation
Effluent kg/metric ton (Ibs/ton) of ore processed
Characteristic Monthly Average Daily Maximum
TSS 0.4 (0.8) 2.0 (4.0)
fluoride 0.05 (0.1) 0.1 (0.2)
This limitation would be achieved in a newly constructed
plant by segregating the fluoride-containing process
wastewater (estimated to be 20 percent of the total volume
discharged), treating with lime to precipitate the fluoride,
recombining supernatant with other process wastewater and
further settling with the aid of flocculants, if necessary,
to reduce suspended solids before discharge of effluent.
The difference in utilizing the above technology in a newly
constructed plant over the technology recommended as BATEA
XI-3
DRAFT
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
-------
DRAFT
is estimated to be less than one percent of the estimated
total construction cost.
3.4 Talc Group fHeavv Media and Flotation Process)
Same as BATEA
3r5 Garnet
Same as BATEA
3.6 Graphite
Same as BATEA
4.0 PRETREATMENT STANDARDS
Recommended pretreatment guidelines for discharge of plant
wastewater into public treatment works conform in general
with EPA Pretreatment Standards for Municipal Sewer Works as
published in the July 19, 1973 Federal Register and
"Title 40 - Protection of the Environment, chapter 1 -
Environmental Protection Agency, Subchapter D - Water
Programs - Part 128 - Pretreatment Standards" a subsequent
EPA publication. The following definitions conform to these
publications:
a. compatible Pollutant
The term "compatible pollutant" means biochemical oxygen
demand, suspended solids, pH and fecal coliform bacteria,
plus additional pollutants identified in the NPDES permit if
the publicly owned treatment works was designed to treat
such pollutants, and, in fact, does remove such pollutants
to a substantial degree. Examples of such additional
pollutants may include:
chemical oxygen demand
total organic carbon
phosphorus and phosphorus compounds
nitrogen and nitrogen compounds
fats, oils, and greases of animal or vegetable
origin except as defined below in 4.1
Prohibited Wastes.
XI-4
DRAFT
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UP01I COMMENTS RECEIVED AMD FURTHER INTERNAL REVIEW BY EPA.
-------
DRAFT
b.. Incompatible Pollutant
The term "incompatible pollutant" means any pollutant which
is not a compatible pollutant as defined above.
c« Joint Treatment Works
Publicly owned treatment works for both non-industrial and
industrial wastewater.
df Major Contributing industry
A major contributing industry is an industrial user of the
publicly owned treatment works that: has a flow of 50,000
gallons or more per average work day; has a flow greater
than five percent of the flow carried by the municipal
system receiving the waste; has in its waste, a toxic
pollutant in toxic amounts as defined in standards issued
under Section 307 (a) of the Act; or is found by the permit
issuance authority, in connection with the issuance of an
NPDES permit to the publicly owned treatment works receiving
the waste, to have significant impact, either singly or in
combination with other contributing industries, on that
treatment works or upon the quality of effluent from that
treatment works.
e. Pretreatment
Treatment of wastewaters from sources before introduction
into the joint treatment works.
4.1 Prohibited Wastes
No waste introduced into a publicly owned treatment works
shall interfere with the operation or performance of the
works. Specifically, the following wastes shall not be
introduced into the publicly owned treatment works:
a. Wastes which create a fire or explosion hazard in the
publicly owned treatment works;
XI-5
DRAFT
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
-------
DRAFT
b. Wastes which will cause corrosive structural damage to
treatment works, but in no case wastes with a pH lower
than 5.0, unless the works are designed to accommodate
such wastes;
c. Solid or viscous wastes in amounts which would cause
obstruction to the flow in sewers, or other interference
with the proper operation of the publicly owned
treatment works, and
d. Wastes at a flow rate and/or pollutant discharge rate
which is excessive over relatively short time periods so
that there is a treatment process upset and subsequent
loss of treatment efficiency.
4.2 Pretreatment for Incompatible Pollutants
In addition to the above, the pretreatment standard for
incompatible pollutants introduced into a publicly owned
treatment works by a major contributing industry shall be
best practicable control technology currently available;
provided that, if the publicly owned treatment works which
receives the pollutants is committed, in its NPDES permit,
to remove a specified percentage of any incompatible
pollutant, the pretreatment standard applicable to users of
such treatment works shall be correspondingly reduced for
that pollutant; and provided further that the definition of
best practicable control technology currently available for
industry categories may be segmented for application to
pretreatment if the Administrator determines that the
definition for direct discharge to navigable waters is not
appropriate for industrial users of joint treatment works.
483 Recommended Pretreatment Guidelines
In accordance with the preceding Pretreatment Standards for
Municipal Sewer Works, the following are recommended for
Pretreatment Guidelines for the wastewater effluents:
a. No pretreatment required for removal of compatible
pollutants - biochemical oxygen demand, suspended solids
(unless hazardous) pH and fecal coliform bacteria;
XI-6
DRAFT
NOTICE; THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGS BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
-------
DRAFT
b. Suspended solids containing hazardous pollutants such as
heavy metals, cyanides and chromates should conform to
be restricted to those quantities recommended in
Section IX Guidelines for Best Practical Treatment and
Control Currently Achievable;
c. Pollutants such as chemical oxygen demand, total organic
carbon, phosphorus and phosphorus compounds, nitrogen
and nitrogen compounds and fats, oils and greases need
not be removed provided the publicly owned treatment
works was designed to treat such pollutants and will
accept them. Otherwise levels should be at or below
BPCTCA Guideline Recommendations;
d. Innocuous dissolved solids such as sodium chloride,
sodium sulfate, calcium chloride and calcium sulfate
should be permitted provided that the industrial plant
is not a "major contributing industry".
e. Plants covered under the "major contributing industry"
definition should not be permitted to discharge large
quantities of dissolved solids into a public sewer even
though they might be at the BPCTCA Guideline
Recommendations of this report. Each of these cases
would have to be considered individually by the sewer
authorities, and,
f. Discharge of all other incompatible hazardous or toxic
pollutants from the mining and processing plants of this
study to municipal sewers should conform to BPCTCA
guidelines levels for discharge to surface water.
XI-7
DRAFT
NOTICE: THESE ARE TENTATIVE RECOMMENDATIONS BASED UPON
INFORMATION IN THIS REPORT AND ARE SUBJECT TO CHANGE BASED
UPON COMMENTS RECEIVED AND FURTHER INTERNAL REVIEW BY EPA.
-------
DRAFT
SECTION XII
ACKNOWLEDGEMENTS
The preparation of this report was accomplished through the
efforts of the staff of General Technologies Division,
Versar, Inc., Springfield, Virginia, under the overall
direction of Dr. Robert G. Shaver, Vice President. Mr.
Robert C. Smith, Jr., Chief Engineer, Project Office,
directed the day-to-day work on the program.
Mr. Michael W. Kosakowski, Project Officer, Effluent
Guidelines Division, through his assistance, leadership, and
advice has made an invaluable contribution to the
preparation of this report. Mr. Kosakowski provided a
careful review of the draft report and suggested
organizational, technical, and editorial changes. He was
also most helpful in making arrangements for the drafting,
presenting, and distribution of the completed report.
Mr. Allen Cywin, Director, Effluent Guidelines Division, Mr.
Ernst P. Hall, Jr., Assistant Director, Effluent Guidelines
Division, and Mr. Harold B. Coughlin, Branch Chief, Effluent
Guidelines Division, offered many helpful suggestions during
the program.
Acknowledgement and appreciation is also given to the
secretarial staffs of both the Effluent Guidelines Division
and General Technologies Division of Versar, Inc., for their
efforts in the typing of drafts, necessary revisions, and
final preparation of the effluent guidelines document.
Appreciation is extended to the following trade associations
and state and federal agencies for assistance and
cooperation rendered to us in this program:
American Mining Congress
Asbestos Information Association, Washington, D.C.
Barre Granite Association
Brick Institute of America
Building Stone Institute
Fertilizer Institute
XII-1
DRAFT
-------
DRAFT
Florida Limerock Institute, Inc.
Florida Phosphate Council
Georgia Association of Mineral Processing Industries
Gypsum Association
Indiana Limestone Institute
Louisiana Fish and Wildlife Commission
Louisiana Water Pollution Control Board
Marble Institute of America
National Clay Pipe Institute
National Crushed Stone Association
National Industrial Sand Association
National Limestone Institute
National Sand and Gravel Association
New York State Department of Environmental Conservation
North Carolina Minerals Association
North Carolina Sand, Gravel and Crushed Stone Association
Portland Cement Association
Refractories Institute
Salt Institute
State of Indiana Geological Survey
Texas Water Quality Board
U.S. Bureau of Mines
U.S. Fish and Wildlife Service, Lacrosse, Wisconsin
Vermont Department of Water Resources
Appreciation is also extended to the many mineral mining and
producing companies who gave us invaluable assistance and
cooperation in this program.
Also, our appreciation is extended to the individuals of the
staff of General Technologies Division of Versar, Inc., for
their assistance during this program. Specifically, our
thanks to:
Dr. R. L. Durfee, Senior Chemical Engineer
Mr. D. H. Sargent, Senior Chemical Engineer
Mr. E. F. Abrams, Chief Engineer
Mr. L. c. McCandless, Senior Chemical Engineer
Dr. L. C. Parker, Senior Chemical Engineer
Mr. E. F. Rissman, Environmental Scientist
Mr. J. C. Walker, Chemical Engineer
Mrs. G. Contos, Chemical Engineer
Mr. M. W. slimak. Environmental Scientist
Dr. I. Frankel, Chemical Engineer
Mr. M. DeFries, Chemical Engineer
XII-2
DRAFT
-------
DRAFT
Ms. C. V. Fong, Chemist
Mrs. D. K. Guinan, Chemist
Mr. J. G. Casana, Environmental Engineer
Mr. R. C. Green, Environmental Scientist
Mr. R. S. Wetzel, Environmental Engineer
Ms. M.A. Connole, Biological Scientist
Ms. M. Smith, Analytical Chemist
Mr. M. C. Calhoun, Field Engineer
Mr. D. McNeese, Field Engineer
Mr. E. Hoban, Field Engineer
Mr. P. Nowacek, Field Engineer
Mr. B. Ryan, Field Engineer
Mr. R. Freed, Field Engineer
Mr. N. O. Johnson, Consultant
Mr. F. Shay, Consultant
Dr. L. W. Ross, Chemical Engineer
XII-3
DRAFT
-------
DRAFT
SECTION XIII
REFERENCES
1. Agnellor L., "Kaolin", Industrial and Engineering
Chemistry. Vol. 52, No. 5, May 1960, pp. 370-376.
2. "American Ceramic Society Bulletin," Vol. 53, No. 1,
January 1974, Columbus, Ohio.
3. Bates, R. L., Geology of the Industrial Rocks and
Minerals. Dover Publications, Inc., New York, 1969.
4. Boruff, C.S., "Removal of Fluorides from Drinking
Waters," Industrial and Engineering Chemistry, Vol. 26,
No. 1, January 1934, pp. 69-71.
5. Brown, W.E., U.S. Patent 2,761,835, September 1956.
6. Brown, W.E., and Gracobine, C.R., U.S. Patent 2,761,841,
September 1956.
7. "Census of Minerals Industries", 1972, Bureau of the
Census, U.S. Department of Commerce, U.S. Government
Printing Office, Washington, D.C. MIC72(P)-14A-1
through MIC72(P)-14E-4.
8. "Commodity Data Summaries, 1974, Appendix I To Mining
and Minerals Policy," Bureau of Mines, U.S., Department
of the Interior, U.S. Government Printing Office,
Washington, D.C.
9. "Dictionary of Mining, Mineral, and Related Terms,"
Bureau of Mines, U.S. Department of the Interior, U.S.
Government Printing Office, Washington, D.C., 1968.
10. "Engineering and Mining Journal," McGraw-Hill, October
1974. 1974.
11. Haden, W., Jr., and Schwint, I., "Attapulgite, Its
Properties and Applications," Industrial and Engineering
Chemistry. Vol. 59, No. 9, September 1967, pp. 57-69.
XIII-1
DRAFT
-------
DRAFT
12. Maier, F.J., "Defluoridation of Municipal Water
Supplies," Journal AWWA, August 1953, pp. 879-888.
13. McNeal, W., and Nielsen, G., "International Directory of
Mining and Mineral Processing Operations," E/MJ,
McGraw-Hill, 1973-1974.
14. "Minerals yearbook. Metals, Minerals, and Fuels,
Vol. 1," U.S. Department of the Interior, U.S.
Government Printing Office, Washington, D.G., 1971,
1972.
15. "Mining Engineering, Publication of the Society of
Mining Engineers of AIME, Annual Review for 1973;"
Vol. 25, No. 1, January 1973; Vol. 26, No. 3, March 1974
through Vol. 26, No. 8, August 1974.
16. "Modern Mineral Processing Flowsheets," Denver Equipment
Company, 2nd Ed., Denver, Colorado
17. Patton, T.C., "Silica, Microcrystalline," Pigment
Handbook Vol. 1, J. Wiley and Sons, Inc., 1973,
pp. 157-159.
18. Popper, H., Modern Engineering Cost Techniques»
McGraw-Hill, New York, 1970.
19. "Product Directory of the Refractories Industry in the
U.S.," The Refractories Institute, Pittsburgh, Pa. 1972.
20. Slabaugh, W.H., and Culbertsen, J.L., J^ Phys. Chem.,
55, 744, 1951.
21. State Directories of the Mineral Mining Industry from 36
of 50 States.
22. Trauffer, W.E., "New Vermont Talc Plant Makes High-Grade
Flotation Product for Special Uses," Pit and Quatry,
December 1964, pp. 72-74, 101.
23. Williams, F.J., Nezmayko, M., and Weintsitt, D.J., $J.
Phys. Chem.x 57, 8^. 1953.
XIII-2
DRAFT
-------
DRAFT
SECTION XIV
GLOSSARY
1.0 MINING TERMS
Aquifer - an underground stratum that yields water.
Bench - a ledge, which, in open pit mines and quarries,
forms a single level of operation above which mineral or
waste materials are excavated from a contiguous bank or
bench face.
Berm - a horizontal shelf built for the purpose of
strengthening and increasing the stability of a slope or
to catch or arrest slope slough material; berm is
sometimes used as a synonym for bench.
Blunge - to mix thoroughly.
Burden - valueless material overlying the ore.
Dragline - a type of excavating equipment which employs a
rope-hung bucket to dig up and collect the material.
Dredge, bucket - a two-pontooned dredge from which are
suspended buckets which excavate material at the bottom
of the pond and deposit it in concentrating devices on
the dredge decks.
Dredge, suction - a centrifugal pump mounted on a barge.
Drill, churn - a drilling rig utilizing a blunt-edged chisel
bit suspended from a cable for putting down vertical
holes in exploration and quarry blasting.
Drill, diamond - a drilling machine with a rotating, hollow,
diamond-studded bit that cuts a circular channel around
a core which when recovered provides a columnar sample
of the rock penetrated.
XIV - 1
DRAFT
-------
DRAFT
Drill, rotary - various types of drill machines that rotate
a rigid, tubular string of rods to which is attached a
bit for cutting rock to produce boreholes.
Hydraulic Mining - mining by washing sand and dirt away with
water which leaves the desired mineral.
Jumbo - a drill carriage on which several drills are
mounted.
Outcrop - the part of a rock formation that appears at the
surface of the ground or deposits that are so near to
the surface as to be found easily by digging.
Overburden - material of any nature, consolidated or
unconsolidated, that overlies a deposit of useful
materials, ores, etc.
Permeability - capacity for transmitting a fluid.
Raise - an inclined opening driven upward from a level to
connect with the level above or to explore the ground
for a limited distance above one level.
Reserve - known ore bodies that may be worked at some future
time.
Ripper - a tractor accessory used to loosen compacted soils
and soft rocks for scraper loading.
Room and Pillar - a system of mining'in which the
distinguishing feature is the winning of 50 percent or
more of the ore in the first working. The ore is mined
in rooms separated by narrow ribs (pillars); the ore in
the pillars is won by subsequent working in which the
roof is caved in successive blocks.
Scraper - a tractor-driven surface vehicle the bottom of
which is fitted with a cutting blade which when lowered
is dragged through the soil.
Shuttle-car - a vehicle which transports raw materials from
loading machines in trackless areas of a mine to the
main transportation system.
XIV - 2
DRAFT
-------
DRAFT
Skip - a guided steel hoppit used in vertical or inclined
shafts for hoisting mineral.
Stacker - a conveyor adapted to piling or stacking bulk
materials or objects.
Stope - an excavation from which ore has been excavated in a
series of steps.
Stripping ratio - the unit amount of spoil that must be
removed to gain access to a similar unit amount of ore
or mineral material.
Sump - any excavation in a mine for the collection of water
for pumping.
Waste - the barren rock in a mine or the part of the ore
deposit that is too low in grade to be of economic value
at the time.
XIV - 3
DRAFT
-------
DRAFT
2.0 MINERAL PROCESSING
Aeration - the introduction of air into the pulp in a
flotation cell in order to form air bubbles.
Baghouse - chamber in which exit gases are filtered through
membranes (bags) which arrest solids.
Cell, cleaner - secondary cells for the retreatment of the
concentrate from primary cells.
Cell, rougher - flotation cells in which the bulk of the
gangue is removed from the ore.
Clarifier - a centrifuge, settling tank, or other device,
for separating suspended solid matter from a liquid.
Classifier, air - an appliance for approximately sizing
crushed minerals or ores employing currents of air.
Classifier, rake - a mechanical classifier utilizing
reciprocal rakes on an inclined plane to separate coarse
from fine material contained in a water pulp.
Classifier, spiral - a classifier for separating fine-size
solids from coarser solids in a wet pulp consisting of
an interrupted-flight screw conveyor, operating in an
inclined trough.
Collector - a heteropolar compound chosen for its ability to
adsorb selectively in froth flotation and render the
adsorbing surface relatively hydrophobic.
Conditioner - an apparatus in which the surfaces of the
mineral species present in a pulp are treated with
appropriate chemicals to influence their reaction during
aeration.
Crusher, cone - a machine for reducing the size of materials
by means of a truncated cone revolving on its vertical
axis within an outer chamber, the anular space between
the outer chamber and cone being tapered.
XIV - U
DRAFT
-------
DRAFT
Crusher, gyratory - a primary crusher consisting of a
vertical spindle, the foot of which is mounted in an
eccentric bearing within a conical shell. The top
carries a conical crushing head revolving eccentrically
in a conical maw.
Crusher, jaw - a primary crusher designed to reduce the size
of materials by impact or crushing between a fixed plate
and an oscillating plate or between two oscillating
plates, forming a tapered jaw.
Crusher, roll - a reduction crusher consisting of a heavy
frame on which two rolls are mounted; the rolls are
driven so that they rotate toward one another. Rock is
fed in from above and nipped between the moving rolls,
crushed, and discharged below.
Depressant - a chemical which causes substances to sink
through a froth, in froth flotation.
Dispersant - a substance (as a polyphosphate) for promoting
the formation and stabilization of a dispersion of one
substance in another.
Dryer, flash - an appliance in which the moist material is
fed into a column of upward-flowing hot gases with
moisture removal being virtually instantaneous.
Dryer, fluidized bed - a cool dryer which depends on a mass
of particles being fluidized by passing a stream of hot
air through it. As a result of the fluidization,
intense turbulence is created in the mass including a
rapid drying action.
Dryer, rotary - a dryer in the shape of an inclined rotating
tube used to dry loose material as it rolls through.
Electrostatic separator - a vessel fitted with positively
and negatively charged conductors used for extracting
dust from flue gas or for separating mineral dust from
gangues.
Filter, pressure - a machine utilizing pressure to increase
the removal rate of solids from tailings.
XIV - 5
DRAFT
-------
DRAFT
Filter, vacuum - a filter in which the air beneath the
filtering material is exhausted to hasten the process.
Flocculant - an agent that induces or promotes gathering of
suspended particles into aggregations.
Flotation - the method of mineral separation in which a
froth created in water by a variety of reagents floats
some finely crushed minerals, whereas other minerals
sink.
Frother - substances used in flotation to make air bubbles
sufficiently permanent, principally by reducing surface
tension.
Grizzly - a device for the coarse screening or scalping of
bulk materials.
Hydrocyclone - a cyclone separator in which a spray of water
is used.
Hydroclassifier - a machine which uses an upward current of
water to remove fine particles from coarser material.
Humphrey spiral - a concentrating device which exploits
differential densities of mixed sands by a combination
of sluicing and centrifugal action. The ore pulp
gravitates down through a stationary spiral trough with
five turns. Heavy particles stay on the inside and the
lightest ones climb to the outside.
Kiln, rotary - a kiln in the form of a long cylinder,
usually inclined, and slowly rotated about its axis; the
kiln is fired by a burner set axially at its lower end.
Kiln, tunnel - a long tunnel-shaped furnace through which
ware is generally moved on cars, passing progressively
through zones in which the temperature is maintained for
preheating, firing and cooling.
Launder - a chute or trough for conveying powdered ore, or
for carrying water to or from the crushing apparatus.
XIV - 6
DRAFT
-------
DRAFT
Log washer - a slightly slanting trough in which revolves a
thick shaft or log, earring blades obliquely set to the
axis. Ore is fed in at the lower end, water at the
upper. The blades slowly convey the lumps of ore upward
against the current, while any adhering clay is
gradually disintegrated and floated out the lower end.
Magnetic separator - a device used to separate magnetic from
less magnetic or nonmagnetic materials.
Mill, ball - a rotating horizontal cylinder in which
non-metallic materials are ground using various types of
grinding media such as quartz pebbles, porcelain balls,
etc.
Mill, buhr - a stone disk mill, with an upper horizontal
disk rotating above a fixed lower one.
Mill, chaser - a cylindrical steel tank lined with wooden
rollers revolving 15-30 times a minute.
Mill, hammer - an impact mill consisting of a rotor, fitted
with movable hammers, that is revolved rapidly in a
vertical plane within a closely fitting steel casing.
Mill, pebble - horizontally mounted cylindrical mill,
charged with flints or selected lumps of ore or rock.
Mill, rod - a mill for fine grinding, somewhat similar to a
ball mill, but employing long steel rods instead of
balls to effect the grinding.
Mill, roller - a fine grinding mill having vertical rollers
running in a circular enclosure with a stone or iron
base.
Neutralization - making neutral or inert, as by the addition
of an alkali or an acid solution.
Scrubber, dust - special apparatus used to remove dust from
air by washing.
Scrubber, ore - device in which coarse and sticky ore is
washed free of adherent material, or mildly
di sintegrated.
XIV - 7
DRAFT
-------
DRAFT
Sink-float - processes that separate particles of different
sizes or composition on the basis of specific gravity.
Slimes - extremely fine particles derived from ore,
associated rock, clay or altered rock.
Sluice - to cause water to flow at high velocities for
wastage, for purposes of excavation, ejecting debris,
etc.
Slurry - pulp not thick enough to consolidate as a sludge
but sufficiently dewatered to flow viscously.
Table, air - a vibrating, porous table using air currents to
effect gravity concentration of sands.
Table, wet - a concentration process whereby a separation of
minerals is effected by flowing a pulp across a riffled
plane surface inclined slightly from the horizontal,
differentially shaken in the direction of the long axis
and washed with an even flow of water at right angles to
the direction of motion.
Thickener - an apparatus for reducing the proportion of
water in a pulp.
Weir - an obstruction placed across a stream for the purpose
of channeling the water through a notch or an opening in
the weir itself.
Wire saw - a saw consisting of one- and three-strand wire
cables, running over pulleys as a belt. When fed by a
slurry of sand and water and held against rock by
tension, it cuts a narrow channel by abrasion.
XIV - 8
DRAFT
-------
TABLE XIV-1
METRIC UNITS
11
•n
Multiply (English Units)
ENGLISH UNIT ABBREVIATION
CONVERSION TABLE
by To obtain (Metric units)
CONVERSION ABBREVIATION METRIC UNIT
acre
acre - feet
British Thermal Unit
ac
ac ft
BTU
0.405
1233.5
0.252
ha
cu m
kg cal
hectares
cubic meters
kilogram - calories
British Thermal Unit/
pound BTU/lb
cubic feet/minute cfm
cubic feet/second cfs
cubic feet cu ft
cubic feet cu ft
cubic inches cu in
degree Fahrenheit F°
feet ft
gallon gal
gallon/minute gpm
horsepower hp
inches in
inches of mercury in Hg
pounds Ib
million gallons/day mgd
mile mi
pound/square inch
(gauge) psig
square feet sq ft
square inches sq in
tons (short) t
yard y
0.555
0.028
1.7
0.028
28.32
16.39
0.555 (°F-32)*
0.3048
3.785
0.0631
0.7457
2.54
0.03342
0.454
3,785
1.609
(0.06805 psig+1)*
0.0929
6.452
0.907
0.9144
kg cal/kg
cu m/mln
cu m/min
cu m
I
cu cm
°C
m
I
I/sec
kw
cm
atm
kg
cu m/day
km
atm
sq m
sq cm
kkg
m
kilogram calories/kilogram
cubic meters/minute
cubic meters/minute
cubic meters
liters
cubic centimeters
degree Centigrade
meters
liters
liters/second
killowatts
centimeters
atmospheres
kilograms
cubic meters/day
kilometer
atmospheres (absolute)
square meters
square centimeters
metric tons (1000 kilograms)
meters
------- |